US20130333346A1 - Synthetic Rope Formed of Blend Fibers - Google Patents
Synthetic Rope Formed of Blend Fibers Download PDFInfo
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- US20130333346A1 US20130333346A1 US13/970,396 US201313970396A US2013333346A1 US 20130333346 A1 US20130333346 A1 US 20130333346A1 US 201313970396 A US201313970396 A US 201313970396A US 2013333346 A1 US2013333346 A1 US 2013333346A1
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/02—Ropes built-up from fibrous or filamentary material, e.g. of vegetable origin, of animal origin, regenerated cellulose, plastics
- D07B1/025—Ropes built-up from fibrous or filamentary material, e.g. of vegetable origin, of animal origin, regenerated cellulose, plastics comprising high modulus, or high tenacity, polymer filaments or fibres, e.g. liquid-crystal polymers
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B1/00—Constructional features of ropes or cables
- D07B1/02—Ropes built-up from fibrous or filamentary material, e.g. of vegetable origin, of animal origin, regenerated cellulose, plastics
-
- D—TEXTILES; PAPER
- D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
- D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
- D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
- D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
- D02G3/04—Blended or other yarns or threads containing components made from different materials
- D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B5/00—Making ropes or cables from special materials or of particular form
- D07B5/06—Making ropes or cables from special materials or of particular form from natural or artificial staple fibres
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2201/00—Ropes or cables
- D07B2201/10—Rope or cable structures
- D07B2201/1028—Rope or cable structures characterised by the number of strands
- D07B2201/1036—Rope or cable structures characterised by the number of strands nine or more strands respectively forming multiple layers
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2201/00—Ropes or cables
- D07B2201/20—Rope or cable components
- D07B2201/2015—Strands
- D07B2201/2035—Strands false twisted
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2201/00—Ropes or cables
- D07B2201/20—Rope or cable components
- D07B2201/2015—Strands
- D07B2201/2036—Strands characterised by the use of different wires or filaments
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2201/00—Ropes or cables
- D07B2201/20—Rope or cable components
- D07B2201/2015—Strands
- D07B2201/2041—Strands characterised by the materials used
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2205/00—Rope or cable materials
- D07B2205/20—Organic high polymers
- D07B2205/201—Polyolefins
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2205/00—Rope or cable materials
- D07B2205/20—Organic high polymers
- D07B2205/201—Polyolefins
- D07B2205/2014—High performance polyolefins, e.g. Dyneema or Spectra
-
- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2205/00—Rope or cable materials
- D07B2205/20—Organic high polymers
- D07B2205/2046—Polyamides, e.g. nylons
- D07B2205/205—Aramides
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2205/00—Rope or cable materials
- D07B2205/20—Organic high polymers
- D07B2205/2096—Poly-p-phenylenebenzo-bisoxazole [PBO]
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- D—TEXTILES; PAPER
- D07—ROPES; CABLES OTHER THAN ELECTRIC
- D07B—ROPES OR CABLES IN GENERAL
- D07B2401/00—Aspects related to the problem to be solved or advantage
- D07B2401/20—Aspects related to the problem to be solved or advantage related to ropes or cables
- D07B2401/2005—Elongation or elasticity
Definitions
- the present invention relates to rope structures, systems, and methods and, more particularly, to combinations of fibers to obtain rope structures, systems, and methods providing improved performance.
- the basic element of a typical rope structure is a fiber.
- the fibers are typically combined into a rope subcomponent referred to as a yarn.
- the yarns may further be combined to form rope subcomponents such as bundles or strands.
- the rope subcomponents are then combined using techniques such as braiding, twisting, and weaving to form the rope structure.
- Different types of fibers typically exhibit different characteristics such as tensile strength, density, flexibility, and abrasion resistance. Additionally, for a variety of reasons, the costs of different types of fibers can vary significantly.
- a rope structure designed for a particular application may comprise different types of fibers.
- U.S. Pat. Nos. 7,134,267 and 7,367,176 assigned to the assignee of the present application describe rope subcomponents comprising fibers combined to provide desirable strength and surface characteristics to the rope structure.
- the first yarns are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO, have a breaking elongation of approximately 2%-5%, and have a tenacity of approximately 25-45 gpd.
- the second yarns are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two, have a breaking elongation of approximately 2%-12%, and have a tenacity of approximately 6-22 gpd.
- the first and second yarns are combined to form rope sub-components.
- the rope sub-components comprise approximately 20-80% by weight of the first yarns.
- the present invention may also be embodied as a method of forming a rope structure comprising the following steps.
- a plurality of first yarns is provided.
- the first yarns are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO, have a breaking elongation of approximately 2%-5%, and have a tenacity of approximately 25-45 gpd.
- a plurality of second yarns is provided.
- the second yarns are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two, have a breaking elongation of approximately 2%-12%, and have a tenacity of approximately 6-22 gpd.
- the plurality of first yarns and the plurality of second yarns are combined to form a plurality of rope sub-components.
- the rope sub-components comprise approximately 40-60% by weight of the first yarns.
- the plurality of rope subcomponents is combined to form the rope structure.
- the present invention may also be embodied as a rope structure comprising a plurality of first yarns and a plurality of second yarns.
- the first yarns are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO, have a breaking elongation of approximately 2%-5%, and have a tenacity of approximately 25-45 gpd.
- the second yarns are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two, have a breaking elongation of approximately 2%-12%, and have a tenacity of approximately 6-22 gpd.
- the first and second yarns are combined to form bundles, and the bundles comprise approximately 20-80% by weight of the second yarns.
- FIG. 1 is a highly schematic view depicting a first example rope system of the present invention and a method of fabricating the first example rope system;
- FIG. 2 is a highly schematic view depicting a second example rope system of the present invention and a method of fabricating the second example rope system;
- FIG. 3 is a highly schematic view depicting a third example rope system of the present invention and a method of fabricating the third example rope system;
- FIG. 4 is a highly schematic view depicting a fourth example rope system of the present invention and a method of fabricating the fourth example rope system;
- FIG. 5 is a highly schematic view depicting a fifth example rope system of the present invention and a method of fabricating the fifth example rope system
- FIG. 6 is a highly schematic view depicting a sixth example rope system of the present invention and a method of fabricating the sixth example rope system.
- the present invention relates to rope structures comprising blended fibers and methods of making rope structures comprising blended fibers.
- a first, more general example will be described in Section I with reference to FIG. 1
- second and third more specific examples will be described in Section II-VI with reference to FIGS. 2-6 , respectively.
- One of the example rope subcomponent forming methods is described in further detail in Section VII below.
- the example rope structure 20 comprises a plurality of first yarns 30 and second yarns 32 .
- the first yarns 30 and second yarns 32 are combined to form bundles 40 .
- the example bundles 40 each comprise a center portion 42 comprising the second yarns 32 .
- the first yarns 30 are arranged to define a cover portion 44 of the example bundles 40 .
- the example bundles 40 are further processed to obtain a plurality of rope subcomponents 50 .
- the rope subcomponents 50 are combined to form the rope structure 20 .
- the first yarns 30 are arranged to define the cover portion 44 of the bundles 40 and the second yarns are arranged to define the center portion 42 .
- the first yarn could form the center portion and the second yarn could form the cover portion of the bundle.
- the first and second yarns could be evenly distributed throughout the bundles 40 and thus the substantially evenly throughout the rope subcomponents 50 and the rope structure 20 .
- the rope structure could be formed by a combination of the various forms of yarns described herein.
- the example first yarns 30 are formed of a material such as High Modulus PolyEthylene (HMPE).
- HMPE High Modulus PolyEthylene
- the first yarns 30 may be formed by any high modulus (i.e., high tenacity with low elongation) fiber such as LCP, Aramids, and PBO.
- the example first yarns 30 have a tenacity of approximately 40 gpd and a breaking elongation of approximately 3.5%.
- the tenacity of the first yarns 30 should be within a first range of approximately 30-40 gpd and in any event should be within a second range of approximately 25-45 gpd.
- the breaking elongation of the first yarns 30 should be in a first range of approximately 3.0-4.0% and in any event should be within a second range of approximately 2%-5%.
- the example second yarns 32 are formed of a material such as high modulus polypropylene (HMPP).
- HMPP high modulus polypropylene
- the second yarns 32 may be formed of high modulus polyolefin fiber such as high modulus fibers made from resins such as polyethylene, polypropylene, blends, or copolymers of the two.
- HMPP High Modulus Polypropylene
- Alternative materials include any material having characteristics similar to High Modulus PolyproPylene (HMPP) or PEN. Examples of commercially available materials (identified by tradenames) that may be used to form the second yarns include Ultra Blue, Innegra, and Tsunooga.
- the fibers forming the example second yarns 32 have a tenacity of approximately 10 gpd and a breaking elongation of approximately 8%.
- the tenacity of the fibers forming the second yarns 32 should be within a first range of approximately 9-12 gpd and in any event should be within a second range of approximately 7.0-20.0 gpd.
- the breaking elongation of the fibers forming the example second yarns 32 should be in a first range of approximately 5.0-10.0% and in any event should be within a second range of approximately 3.5%-12.0%.
- the fibers forming the example second yarns 32 have a tenacity of approximately 8.5 gpd and a breaking elongation of approximately 7%.
- the tenacity of the fibers forming the first yarns 30 should be within a first range of approximately 7-12 gpd and in any event should be within a second range of approximately 6.0-22.0 gpd.
- the breaking elongation of the fibers forming the example second yarns 32 should be in a first range of approximately 5.0%-10.0% and in any event should be within a second range of approximately 2.0%-12.0%.
- the example bundles 40 comprise approximately 35-45% by weight of the first yarns 30 .
- the percent by weight of the example first yarns 30 should be within a first range of approximately 40-60% by weight and, in any event, should be within a second range of approximately 20-80% by weight.
- the balance of the bundles 40 may be formed by the second yarns 32 or a combination of the second yarns 32 and other materials.
- the example rope structure 20 comprises a plurality of the bundles 40 , so the example rope structure 20 comprises the same percentages by weight of the first and second yarns 30 and 32 as the bundles 40 .
- the exact number of strands in the first yarns 30 and the second yarns 32 is based on the yarn size (i.e., diameter) and is pre-determined with the ratio of the first and second yarns.
- first and second steps represented by brackets 60 and 62 are performed.
- the first yarns 30 are provided; in the second step 62 , the second yarns 32 are provided.
- the first yarns 30 and the second yarns 32 are twisted into the bundle 40 such that the second yarns 32 form the center portion 42 and the first yarns 30 form the cover portion 44 of the bundle 40 .
- the bundles 40 are twisted to form the rope subcomponents 50 .
- the example rope subcomponent 50 is thus a twisted blend fiber bundle.
- a plurality of the bundles 40 may be twisted in second, third, or more twisting steps to form a larger rope subcomponent 50 as required by the dimensions and operating conditions of the rope structure 20 .
- the example fifth step 68 is a braiding or twisting step, and the resulting rope structure 20 is thus a braided or twisted blend fiber rope.
- the rope structure 20 may be coated with water based polyurethane or other chemistry or blends to provide enhanced performance under certain operating conditions.
- appropriate coatings include one or more materials such as polyurethane (e.g., Permuthane, Sancure, Witcobond, Eternitex, Icothane), wax (e.g., Recco, MA-series emulsions), and lubricants (e.g., E22 Silicone, XPT260, PTFE 30).
- the example rope structure 120 comprises four first yarns 130 and three second yarns 132 .
- the first yarns 130 and second yarns 132 are combined to form a bundle 140 .
- the bundle 140 comprises a center portion 142 comprising the second yarns 132 .
- the first yarns 130 are arranged to define a cover portion 144 of the bundle 140 .
- the bundle 140 is further processed to obtain twelve rope strands 150 .
- the twelve rope strands 150 are combined to form the rope structure 120 .
- the example first yarns 130 are formed of HMPE and have a size of approximately 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%.
- the example second yarns 132 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 or 10.0 gpd, a modulus of approximately 190 gpd or 225 gpd, and a breaking elongation of approximately 7.0% or 8.0%.
- the following tables A and B describe first and second ranges of fiber characteristics for the first and second yarns 130 and 132 , respectively:
- the example rope structure 120 comprises approximately 43% of HMPE by weight and had an average breaking strength of approximately 4656 lbs. In comparison, a rope structure comprising twelve strands of HMPE fibers (100% HMPE by weight) has an average breaking strength of approximately 8600 lbs. The example rope structure 120 thus comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers.
- the rope structure 120 has a calculated tenacity of greater than approximately 17 gpd (before accounting for strength loss due to manufacturing processes) (medium tenacity) and a specific gravity of less than 1 and thus floats in water.
- a calculated tenacity of greater than approximately 17 gpd (before accounting for strength loss due to manufacturing processes) (medium tenacity) and a specific gravity of less than 1 and thus floats in water.
- medium tenacity a calculated tenacity of greater than approximately 17 gpd (before accounting for strength loss due to manufacturing processes) (medium tenacity) and a specific gravity of less than 1 and thus floats in water.
- the actual rope strength is only about 50% of the initial fiber strength when expressed as tenacity in gpd.
- a rope structure comprising 12 strands of HMPE fiber (100% HMPE by weight) has an average breaking strength of 8600 lbs which equates to 22.5 gpd, or 56% of the original fiber tenacity of 40 gpd.
- the blended rope comprising 43% HMPE and 57% HMPP has a tenacity of 12.0 gpd (based on fiber tenacity and the same 56% strength efficiency).
- the rope structure 120 can thus be used as a floating rope having a medium level tenacity (12.0 gpd rope tenacity) and relatively low cost in comparison to a rope comprising only HMPE fibers (22.5 gpd rope tenacity).
- first and second steps represented by brackets 160 and 162 are performed.
- first step 160 four ends of the first yarns 130 are provided; in the second step 162 , the three ends of the second yarns 132 are provided.
- bracket 164 the first yarns 130 and the second yarns 132 are blended into the bundle 140 such that the second yarns 132 form the center portion 142 and the first yarns 130 form the cover portion 144 of the bundle 140 .
- the bundle 140 is twisted to form the strands 150 .
- the example rope strand 150 is thus a twisted blend fiber bundle.
- a plurality of the bundles 140 may be twisted in second, third, or more twisting steps to form a larger strand as required by the dimensions and operating conditions of the rope structure 120 .
- the example fifth step 168 is a braiding step, and the resulting rope structure 120 is thus a 1 ⁇ 4′′ diameter braided blend fiber rope.
- the rope structure 120 may be coated with water based polyurethane or other chemistry or blends to provide enhanced performance under certain operating conditions.
- the example rope structure 220 comprises five first yarns 230 and four second yarns 232 .
- the first yarns 230 and second yarns 232 are combined to form a bundle 240 .
- the bundle 240 comprises a center portion 242 comprising the second yarns 232 .
- the first yarns 230 are arranged to define a cover portion 244 of the bundle 240 .
- the bundle 240 is further processed to obtain sub-strands 250 . Seven of the sub-strands 250 are combined to form large strands 260 . Twelve of the large strands 260 are combined to form the rope structure 220 .
- the example first yarns 230 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%.
- the example second yarns 232 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd or 10.0 gpd, a modulus of approximately 190 gpd or 225 gpd, and a breaking elongation of approximately 7.0% or 8.0%.
- the following tables C and D describe first and second ranges of fiber characteristics for the first and second yarns 230 and 232 , respectively:
- the example rope structure 220 comprises approximately 42% of HMPE by weight and had an average breaking strength of approximately 37,000 lbs.
- a similar rope structure comprising HMPE fibers (100% HMPE by weight) has an average breaking strength of approximately 64,400 lbs.
- the example rope structure 220 thus comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers.
- the rope structure 220 has a calculated tenacity of greater than approximately 27 gpd (before accounting for strength loss due to manufacturing processes) (medium tenacity) and a specific gravity of less than 1 and thus floats in water. In the manufacturing process, there is an efficiency loss due to twisting, braiding and processing of the fibers. In a typical rope manufacturing operation, the actual rope strength is only about 50% of the initial fiber strength when expressed as tenacity in gpd.
- a rope structure comprising 12 strands of HMPE fiber (100% HMPE by weight) has an average breaking strength of 64400 lbs which equates to 20.0 gpd, or 50% of the original fiber tenacity of 40 gpd.
- the blended rope comprising 42% HMPE and 58% HMPP has a tenacity of 10.8 gpd (based on fiber tenacity and the same 50% strength efficiency).
- the rope structure 220 can thus be used as a floating rope having a medium level tenacity (10.8 gpd rope tenacity) and relatively low cost in comparison to a rope comprising only HMPE fibers (20.0 gpd rope tenacity).
- first and second steps represented by brackets 270 and 272 are performed.
- first step 270 four ends of the first yarns 230 are provided; in the second step 272 , the three ends of the second yarns 232 are provided.
- bracket 274 the first yarns 230 and the second yarns 232 are twisted into the bundle 240 such that the second yarns 232 form the center portion 242 and the first yarns 230 form the cover portion 244 of the bundle 240 .
- a fourth step represented by bracket 276 the bundles 240 are twisted to form the strands 250 .
- the example rope strand 250 is thus a twisted blend fiber bundle.
- seven of the strands 250 may be twisted together to form the larger strand 260 .
- the example fifth step 280 is a braiding step, and the resulting rope structure 220 is thus a 3 ⁇ 4′′ diameter braided blend fiber rope.
- the rope structure 220 may be coated with water based polyurethane or other chemistry or blends to provide enhanced performance under certain operating conditions.
- the example rope structure 320 comprises a plurality of first yarns 330 , a plurality of second yarns 332 , a plurality of third yarns 334 , and a plurality of fourth yarns 336 .
- the first yarns 330 and second yarns 332 are combined to form a plurality of first bundles 340 .
- the first bundles 340 comprise a center portion 340 a comprising the second yarns 332 .
- the first yarns 330 are arranged to define a cover portion 340 b of the first bundles 340 .
- the third yarns 334 and fourth yarns 336 are combined, preferably using a false-twisting process, to form a plurality of second bundles 342 .
- the second bundles 342 comprise a center portion 342 a comprising the third yarns 334 .
- the fourth yarns 336 are arranged to define a cover portion 342 b of the second bundles 342 .
- the first bundles 340 are further processed to obtain sub-strands 350 .
- the second bundles 342 are processed to obtain sub-strands 352 .
- the first and second subcomponents or strands 350 and 352 are combined to form the rope structure 320 .
- the example first yarns 330 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%.
- the example second yarns 332 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd, a modulus of approximately 190 gpd, and a breaking elongation of approximately 7.0%.
- the example third yarns 334 are also formed of HMPE and have a size of approximately 1600 denier, a tenacity of approximately 40.0 gpd, and a breaking elongation of approximately 3.5%.
- the first and third yarns 330 and 334 may be different.
- the example fourth yarns 336 are formed of Polyester sliver and have a size of approximately 52 grain.
- the fourth yarn may be of one or more of the following materials: polyester, nylon, Aramid, LCP, and HMPE fibers.
- the example rope structure 320 comprises approximately 42% of HMPE by weight and 6% Polyester Sliver by weight and had an average breaking strength of approximately 302,000 lbs.
- a similar rope structure comprising HMPE fibers (94% HMPE by weight) and Polyester Sliver (6% Polyester by weight) has an average breaking strength of approximately 550,000 lbs.
- the example rope structure 320 thus comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of HMPE and Polyester sliver fibers.
- the rope structure 320 has a specific gravity of less than 1 and thus floats in water.
- the rope structure 320 can thus be used as a floating rope having a medium level of strength and tenacity and relatively low cost in comparison to a rope comprising only HMPE fibers.
- first, second, third, and fourth yarns 330 , 332 , 334 , and 336 are provided at steps 360 , 362 , 364 , and 366 .
- the first yarns 330 and the second yarns 332 are twisted into the bundles 340 such that the second yarns 332 form a center portion 340 a and the first yarns 330 form a cover portion 340 b of the bundle 340 .
- the bundles 340 are twisted to form the strands 350 .
- the example rope strands 350 are thus twisted blend fiber bundles.
- the third yarns 334 and the fourth yarns 336 are false twisted into the bundles 342 such that the third yarns 334 form a center portion 342 a and the fourth yarns 336 form a cover portion 342 b of the bundle 342 .
- the bundles 342 are false-twisted together to form the strands 352 .
- the example rope strand 352 is thus a false-twisted blend fiber bundle.
- the first and second strands 350 and 352 are combined by any appropriate method such as twisting or braiding to form the rope structure 320 .
- the rope structure 320 may be coated as generally described above.
- the example rope structure 420 comprises a plurality of first yarns 430 , a plurality of second yarns 432 , and a plurality of third yarns 434 .
- the first yarns 430 and second yarns 432 are combined to form a plurality of first bundles 440 .
- the first bundles 440 comprise a center portion 440 a comprising the second yarns 432 .
- the first yarns 430 are arranged to define a cover portion 440 b of the first bundles 440 .
- the third yarns 434 are combined, preferably using a false-twisting process, with the first bundles 440 to form rope subcomponents or strands 450 .
- the first and second yarns 430 and 432 are arranged to define a core portion of the strands 450 .
- the third yarns 434 are arranged to define at least a portion of the cover portion of the strands 450 .
- the example first yarns 430 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%.
- the example second yarns 432 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd, a modulus of approximately 190 gpd, and a breaking elongation of approximately 7.0%.
- the example third yarns 434 are formed of Polyester sliver and have a size of approximately 52 grain.
- the example rope structure 420 comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers.
- the rope structure 420 has a specific gravity of less than 1 and thus floats in water.
- the rope structure 420 can thus be used as a floating rope having a medium level of strength and tenacity and relatively low cost in comparison to a rope comprising only HMPE fibers.
- the first yarns 430 are provided; at a step 462 , the second yarns 432 are provided.
- the first yarns 430 and the second yarns 432 are combined into the bundles 440 such that the second yarns 432 form the center portion 440 a and the first yarns 430 form the cover portion 440 b of the bundle 440 .
- the third yarns 434 are provided.
- the third yarns 434 are false twisted with the bundles 440 to form the strands 450 such that the third yarns 434 form the cover portion of the bundle 450 .
- the strands 450 are combined by any appropriate method, such as twisting or braiding, to form the rope structure 420 .
- the rope structure 420 may be coated as generally described above.
- the example rope structure 520 comprises a plurality of first yarns 530 arranged in bundles, a plurality of second yarns 532 , and a plurality of third yarns 534 .
- the second yarns 532 and third yarns 534 are combined, preferably using a false-twisting process, to form a plurality of second bundles 540 .
- the second bundles 540 comprise a center portion 540 a comprising the second yarns 532 .
- the third yarns 534 are arranged to define a cover portion 540 b of the second bundles 540 .
- the bundles of first yarns 530 are combined with the second bundles 540 to form rope subcomponents or strands 550 .
- the second and third yarns 532 and 534 are arranged to define a core portion of the strands 550 .
- the bundles of first yarns 530 are arranged to define at least a portion of a cover portion of the strands 550 .
- the example first yarns 530 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%.
- the example second yarns 532 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd, a modulus of approximately 190 gpd, and a breaking elongation of approximately 7.0%.
- the example third yarns 534 are formed of Polyester sliver and have a size of approximately 52 grain.
- the example rope structure 520 comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers. Additionally, the rope structure 520 has a a specific gravity of less than 1 and thus floats in water. The rope structure 520 can thus be used as a floating rope having a medium level of strength and tenacity and relatively low cost in comparison to a rope comprising only HMPE fibers.
- the first yarns 530 are provided, typically in the form of bundles.
- the second yarns 532 and third yarns 534 are provided.
- the second yarns 532 and the third yarns 534 are combined, preferably using a false-twisting process, into the bundles 540 such that the second yarns 532 form the center portion 540 a and the third yarns 534 form the cover portion 540 b of the bundle 540 .
- bracket 576 the first yarns 530 (or bundles formed therefrom) are twisted with the bundles 540 to form the strands 550 .
- bracket 580 the strands 550 are combined by any appropriate method, such as twisting or braiding, to form the rope structure 520 .
- the rope structure 520 may be coated as generally described above.
- a bundle of first fibers may be combined with a bundle of second fibers (e.g., yarns) using a false twisting process to form rope subcomponents which are in turn combined to form other rope subcomponents and/or rope structures.
- the false twisting process is described, for example, in U.S. Pat. Nos. 7,134,267 and 7,367,176, the specifications of which are incorporated herein by reference.
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Abstract
A rope structure of the present invention comprises a plurality of first yarns and a plurality of second yarns. The first yarns are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO, have a breaking elongation of approximately 2%-5%, and have a tenacity of approximately 25-45 gpd. The second yarns are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two, have a breaking elongation of approximately 2%-12%, and have a tenacity of approximately 6-22 gpd. The first and second yarns are combined to form rope sub-components. The rope sub-components comprise approximately 20-80% by weight of the first yarns.
Description
- This application (Attorney's Ref. No. P217607) is a continuation of U.S. patent application Ser. No. 13/367,215 filed Feb. 6, 2012.
- U.S. patent application Ser. No. 13/367,215 filed Feb. 6, 2012, is a continuation of U.S. patent application Ser. No. 12/463,284 filed May 8, 2009, now U.S. Pat. No. 8,109,072, which issued on Feb. 7, 2012.
- U.S. patent application Ser. No. 12/463,284 claims benefit of U.S. Provisional Patent Application Ser. No. 61/130,986 filed Jun. 4, 2008.
- The contents of all related applications identified above are incorporated herein by reference.
- The present invention relates to rope structures, systems, and methods and, more particularly, to combinations of fibers to obtain rope structures, systems, and methods providing improved performance.
- The basic element of a typical rope structure is a fiber. The fibers are typically combined into a rope subcomponent referred to as a yarn. The yarns may further be combined to form rope subcomponents such as bundles or strands. The rope subcomponents are then combined using techniques such as braiding, twisting, and weaving to form the rope structure.
- Different types of fibers typically exhibit different characteristics such as tensile strength, density, flexibility, and abrasion resistance. Additionally, for a variety of reasons, the costs of different types of fibers can vary significantly.
- A rope structure designed for a particular application may comprise different types of fibers. For example, U.S. Pat. Nos. 7,134,267 and 7,367,176 assigned to the assignee of the present application describe rope subcomponents comprising fibers combined to provide desirable strength and surface characteristics to the rope structure.
- The need exists for rope structures that optimize a given operating characteristic or set of characteristics of a rope structure while also minimizing the cost of materials used to form the rope structure.
- The present invention may be embodied as a rope structure of the present invention comprises a plurality of first yarns and a plurality of second yarns. The first yarns are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO, have a breaking elongation of approximately 2%-5%, and have a tenacity of approximately 25-45 gpd. The second yarns are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two, have a breaking elongation of approximately 2%-12%, and have a tenacity of approximately 6-22 gpd. The first and second yarns are combined to form rope sub-components. The rope sub-components comprise approximately 20-80% by weight of the first yarns.
- The present invention may also be embodied as a method of forming a rope structure comprising the following steps. A plurality of first yarns is provided. The first yarns are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO, have a breaking elongation of approximately 2%-5%, and have a tenacity of approximately 25-45 gpd. A plurality of second yarns is provided. The second yarns are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two, have a breaking elongation of approximately 2%-12%, and have a tenacity of approximately 6-22 gpd. The plurality of first yarns and the plurality of second yarns are combined to form a plurality of rope sub-components. The rope sub-components comprise approximately 40-60% by weight of the first yarns. The plurality of rope subcomponents is combined to form the rope structure.
- The present invention may also be embodied as a rope structure comprising a plurality of first yarns and a plurality of second yarns. The first yarns are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO, have a breaking elongation of approximately 2%-5%, and have a tenacity of approximately 25-45 gpd. The second yarns are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two, have a breaking elongation of approximately 2%-12%, and have a tenacity of approximately 6-22 gpd. The first and second yarns are combined to form bundles, and the bundles comprise approximately 20-80% by weight of the second yarns.
-
FIG. 1 is a highly schematic view depicting a first example rope system of the present invention and a method of fabricating the first example rope system; -
FIG. 2 is a highly schematic view depicting a second example rope system of the present invention and a method of fabricating the second example rope system; -
FIG. 3 is a highly schematic view depicting a third example rope system of the present invention and a method of fabricating the third example rope system; -
FIG. 4 is a highly schematic view depicting a fourth example rope system of the present invention and a method of fabricating the fourth example rope system; -
FIG. 5 is a highly schematic view depicting a fifth example rope system of the present invention and a method of fabricating the fifth example rope system; and -
FIG. 6 is a highly schematic view depicting a sixth example rope system of the present invention and a method of fabricating the sixth example rope system. - The present invention relates to rope structures comprising blended fibers and methods of making rope structures comprising blended fibers. In the following discussion, a first, more general example will be described in Section I with reference to
FIG. 1 , and second and third more specific examples will be described in Section II-VI with reference toFIGS. 2-6 , respectively. One of the example rope subcomponent forming methods is described in further detail in Section VII below. - Referring initially to
FIG. 1 of the drawing, depicted therein is a firstexample rope structure 20 constructed in accordance with, and embodying, the principles of the present invention. Theexample rope structure 20 comprises a plurality offirst yarns 30 andsecond yarns 32. Thefirst yarns 30 andsecond yarns 32 are combined to formbundles 40. Theexample bundles 40 each comprise acenter portion 42 comprising thesecond yarns 32. Thefirst yarns 30 are arranged to define acover portion 44 of theexample bundles 40. Theexample bundles 40 are further processed to obtain a plurality ofrope subcomponents 50. Therope subcomponents 50 are combined to form therope structure 20. - In the
example rope structure 20, thefirst yarns 30 are arranged to define thecover portion 44 of thebundles 40 and the second yarns are arranged to define thecenter portion 42. Alternatively, the first yarn could form the center portion and the second yarn could form the cover portion of the bundle. In yet another example, the first and second yarns could be evenly distributed throughout thebundles 40 and thus the substantially evenly throughout therope subcomponents 50 and therope structure 20. As still another example, the rope structure could be formed by a combination of the various forms of yarns described herein. - The example
first yarns 30 are formed of a material such as High Modulus PolyEthylene (HMPE). Alternatively, thefirst yarns 30 may be formed by any high modulus (i.e., high tenacity with low elongation) fiber such as LCP, Aramids, and PBO. The examplefirst yarns 30 have a tenacity of approximately 40 gpd and a breaking elongation of approximately 3.5%. The tenacity of thefirst yarns 30 should be within a first range of approximately 30-40 gpd and in any event should be within a second range of approximately 25-45 gpd. The breaking elongation of thefirst yarns 30 should be in a first range of approximately 3.0-4.0% and in any event should be within a second range of approximately 2%-5%. - The example
second yarns 32 are formed of a material such as high modulus polypropylene (HMPP). As one example, thesecond yarns 32 may be formed of high modulus polyolefin fiber such as high modulus fibers made from resins such as polyethylene, polypropylene, blends, or copolymers of the two. Typically, such fibers are fabricated using the melt-spinning process, but thesecond yarns 32 may be fabricated using processes instead of or in addition to melt-spinning process. Alternative materials include any material having characteristics similar to High Modulus PolyproPylene (HMPP) or PEN. Examples of commercially available materials (identified by tradenames) that may be used to form the second yarns include Ultra Blue, Innegra, and Tsunooga. - In a first example, the fibers forming the example
second yarns 32 have a tenacity of approximately 10 gpd and a breaking elongation of approximately 8%. In this first example, the tenacity of the fibers forming thesecond yarns 32 should be within a first range of approximately 9-12 gpd and in any event should be within a second range of approximately 7.0-20.0 gpd. The breaking elongation of the fibers forming the examplesecond yarns 32 should be in a first range of approximately 5.0-10.0% and in any event should be within a second range of approximately 3.5%-12.0%. - In a second example, the fibers forming the example
second yarns 32 have a tenacity of approximately 8.5 gpd and a breaking elongation of approximately 7%. In this second example, the tenacity of the fibers forming thefirst yarns 30 should be within a first range of approximately 7-12 gpd and in any event should be within a second range of approximately 6.0-22.0 gpd. The breaking elongation of the fibers forming the examplesecond yarns 32 should be in a first range of approximately 5.0%-10.0% and in any event should be within a second range of approximately 2.0%-12.0%. - The example bundles 40 comprise approximately 35-45% by weight of the
first yarns 30. The percent by weight of the examplefirst yarns 30 should be within a first range of approximately 40-60% by weight and, in any event, should be within a second range of approximately 20-80% by weight. In any of the situations described above, the balance of thebundles 40 may be formed by thesecond yarns 32 or a combination of thesecond yarns 32 and other materials. - The
example rope structure 20 comprises a plurality of thebundles 40, so theexample rope structure 20 comprises the same percentages by weight of the first andsecond yarns bundles 40. - The exact number of strands in the
first yarns 30 and thesecond yarns 32 is based on the yarn size (i.e., diameter) and is pre-determined with the ratio of the first and second yarns. - Referring now for a moment back to
FIG. 1 of the drawing, a first example method of manufacturing theexample rope structure 20 will now be described. Initially, first and second steps represented bybrackets first step 60, thefirst yarns 30 are provided; in thesecond step 62, thesecond yarns 32 are provided. In a third step represented bybracket 64, thefirst yarns 30 and thesecond yarns 32 are twisted into thebundle 40 such that thesecond yarns 32 form thecenter portion 42 and thefirst yarns 30 form thecover portion 44 of thebundle 40. - In an optional fourth step represented by
bracket 66, thebundles 40 are twisted to form therope subcomponents 50. Theexample rope subcomponent 50 is thus a twisted blend fiber bundle. Alternatively, a plurality of thebundles 40 may be twisted in second, third, or more twisting steps to form alarger rope subcomponent 50 as required by the dimensions and operating conditions of therope structure 20. - One or more of the
rope subcomponents 50 are then combined in a fifth step represented bybracket 68 to form therope structure 20. The examplefifth step 68 is a braiding or twisting step, and the resultingrope structure 20 is thus a braided or twisted blend fiber rope. - Optionally, after the
fifth step 68, therope structure 20 may be coated with water based polyurethane or other chemistry or blends to provide enhanced performance under certain operating conditions. Examples of appropriate coatings include one or more materials such as polyurethane (e.g., Permuthane, Sancure, Witcobond, Eternitex, Icothane), wax (e.g., Recco, MA-series emulsions), and lubricants (e.g., E22 Silicone, XPT260, PTFE 30). - Referring now to
FIG. 2 of the drawing, depicted therein is a secondexample rope structure 120 constructed in accordance with, and embodying, the principles of the present invention. Theexample rope structure 120 comprises fourfirst yarns 130 and threesecond yarns 132. Thefirst yarns 130 andsecond yarns 132 are combined to form abundle 140. Thebundle 140 comprises acenter portion 142 comprising thesecond yarns 132. Thefirst yarns 130 are arranged to define acover portion 144 of thebundle 140. Thebundle 140 is further processed to obtain twelverope strands 150. The twelverope strands 150 are combined to form therope structure 120. - The example
first yarns 130 are formed of HMPE and have a size of approximately 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%. The examplesecond yarns 132 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 or 10.0 gpd, a modulus of approximately 190 gpd or 225 gpd, and a breaking elongation of approximately 7.0% or 8.0%. The following tables A and B describe first and second ranges of fiber characteristics for the first andsecond yarns -
-
Characteristic First Range Second Range tenacity (gpd) 30-40 25-45 modulus (gpd) 900-1500 475-3500 breaking elongation (%) 3-4 2-5 -
-
Characteristic First Range Second Range tenacity (gpd) 7-12 6-22 modulus (gpd) 100-300 50-500 breaking elongation (%) 5-10 2-12 - The
example rope structure 120 comprises approximately 43% of HMPE by weight and had an average breaking strength of approximately 4656 lbs. In comparison, a rope structure comprising twelve strands of HMPE fibers (100% HMPE by weight) has an average breaking strength of approximately 8600 lbs. Theexample rope structure 120 thus comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers. - Additionally, the
rope structure 120 has a calculated tenacity of greater than approximately 17 gpd (before accounting for strength loss due to manufacturing processes) (medium tenacity) and a specific gravity of less than 1 and thus floats in water. In the manufacturing process, there is an efficiency loss due to twisting, braiding and processing of the fibers. The more a fiber is twisted or distorted from being parallel, the higher the efficiency loss will be. In a typical rope manufacturing operation, the actual rope strength is only about 50% of the initial fiber strength when expressed as tenacity in gpd. - Accordingly, a rope structure comprising 12 strands of HMPE fiber (100% HMPE by weight) has an average breaking strength of 8600 lbs which equates to 22.5 gpd, or 56% of the original fiber tenacity of 40 gpd. The blended rope comprising 43% HMPE and 57% HMPP has a tenacity of 12.0 gpd (based on fiber tenacity and the same 56% strength efficiency). The
rope structure 120 can thus be used as a floating rope having a medium level tenacity (12.0 gpd rope tenacity) and relatively low cost in comparison to a rope comprising only HMPE fibers (22.5 gpd rope tenacity). - Referring now for a moment back to
FIG. 2 of the drawing, a first example method of manufacturing theexample rope structure 120 will now be described. Initially, first and second steps represented bybrackets first step 160, four ends of thefirst yarns 130 are provided; in thesecond step 162, the three ends of thesecond yarns 132 are provided. In a third step represented bybracket 164, thefirst yarns 130 and thesecond yarns 132 are blended into thebundle 140 such that thesecond yarns 132 form thecenter portion 142 and thefirst yarns 130 form thecover portion 144 of thebundle 140. - In a fourth step represented by
bracket 166, thebundle 140 is twisted to form thestrands 150. Theexample rope strand 150 is thus a twisted blend fiber bundle. As discussed above, a plurality of thebundles 140 may be twisted in second, third, or more twisting steps to form a larger strand as required by the dimensions and operating conditions of therope structure 120. - Twelve of the
yarns 150 formed from thebundles 140 are then combined in a fifth step represented bybracket 168 to form therope structure 120. The examplefifth step 168 is a braiding step, and the resultingrope structure 120 is thus a ¼″ diameter braided blend fiber rope. Optionally, after the fifth step, therope structure 120 may be coated with water based polyurethane or other chemistry or blends to provide enhanced performance under certain operating conditions. - Referring now to
FIG. 3 of the drawing, depicted therein is a thirdexample rope structure 220 constructed in accordance with, and embodying, the principles of the present invention. Theexample rope structure 220 comprises fivefirst yarns 230 and foursecond yarns 232. Thefirst yarns 230 andsecond yarns 232 are combined to form abundle 240. Thebundle 240 comprises acenter portion 242 comprising thesecond yarns 232. Thefirst yarns 230 are arranged to define acover portion 244 of thebundle 240. Thebundle 240 is further processed to obtain sub-strands 250. Seven of the sub-strands 250 are combined to formlarge strands 260. Twelve of thelarge strands 260 are combined to form therope structure 220. - The example
first yarns 230 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%. The examplesecond yarns 232 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd or 10.0 gpd, a modulus of approximately 190 gpd or 225 gpd, and a breaking elongation of approximately 7.0% or 8.0%. The following tables C and D describe first and second ranges of fiber characteristics for the first andsecond yarns -
-
Characteristic First Range Second Range tenacity (gpd) 30-40 25-45 modulus (gpd) 900-1500 475-3500 breaking elongation (%) 3-4 2-5 -
-
Characteristic First Range Second Range tenacity (gpd) 7-12 6-22 modulus (gpd) 100-300 50-500 breaking elongation (%) 5-10 2-12 - The
example rope structure 220 comprises approximately 42% of HMPE by weight and had an average breaking strength of approximately 37,000 lbs. In comparison, a similar rope structure comprising HMPE fibers (100% HMPE by weight) has an average breaking strength of approximately 64,400 lbs. Theexample rope structure 220 thus comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers. - Additionally, the
rope structure 220 has a calculated tenacity of greater than approximately 27 gpd (before accounting for strength loss due to manufacturing processes) (medium tenacity) and a specific gravity of less than 1 and thus floats in water. In the manufacturing process, there is an efficiency loss due to twisting, braiding and processing of the fibers. In a typical rope manufacturing operation, the actual rope strength is only about 50% of the initial fiber strength when expressed as tenacity in gpd. A rope structure comprising 12 strands of HMPE fiber (100% HMPE by weight) has an average breaking strength of 64400 lbs which equates to 20.0 gpd, or 50% of the original fiber tenacity of 40 gpd. The blended rope comprising 42% HMPE and 58% HMPP has a tenacity of 10.8 gpd (based on fiber tenacity and the same 50% strength efficiency). Therope structure 220 can thus be used as a floating rope having a medium level tenacity (10.8 gpd rope tenacity) and relatively low cost in comparison to a rope comprising only HMPE fibers (20.0 gpd rope tenacity). - Referring now for a moment back to
FIG. 2 of the drawing, a first example method of manufacturing theexample rope structure 220 will now be described. Initially, first and second steps represented bybrackets first step 270, four ends of thefirst yarns 230 are provided; in thesecond step 272, the three ends of thesecond yarns 232 are provided. In a third step represented bybracket 274, thefirst yarns 230 and thesecond yarns 232 are twisted into thebundle 240 such that thesecond yarns 232 form thecenter portion 242 and thefirst yarns 230 form thecover portion 244 of thebundle 240. - In a fourth step represented by
bracket 276, thebundles 240 are twisted to form thestrands 250. Theexample rope strand 250 is thus a twisted blend fiber bundle. In afifth step 278, seven of thestrands 250 may be twisted together to form thelarger strand 260. - Twelve of the
larger strands 260 are then combined in a fifth step represented bybracket 280 to form therope structure 220. The examplefifth step 280 is a braiding step, and the resultingrope structure 220 is thus a ¾″ diameter braided blend fiber rope. Optionally, after the fifth step, therope structure 220 may be coated with water based polyurethane or other chemistry or blends to provide enhanced performance under certain operating conditions. - Referring now to
FIG. 4 of the drawing, depicted therein is a fourthexample rope structure 320 constructed in accordance with, and embodying, the principles of the present invention. Theexample rope structure 320 comprises a plurality offirst yarns 330, a plurality ofsecond yarns 332, a plurality ofthird yarns 334, and a plurality offourth yarns 336. Thefirst yarns 330 andsecond yarns 332 are combined to form a plurality offirst bundles 340. Thefirst bundles 340 comprise acenter portion 340 a comprising thesecond yarns 332. Thefirst yarns 330 are arranged to define acover portion 340 b of the first bundles 340. Thethird yarns 334 andfourth yarns 336 are combined, preferably using a false-twisting process, to form a plurality ofsecond bundles 342. The second bundles 342 comprise acenter portion 342 a comprising thethird yarns 334. Thefourth yarns 336 are arranged to define acover portion 342 b of the second bundles 342. - The
first bundles 340 are further processed to obtain sub-strands 350. The second bundles 342 are processed to obtain sub-strands 352. The first and second subcomponents orstrands rope structure 320. - The example
first yarns 330 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%. The examplesecond yarns 332 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd, a modulus of approximately 190 gpd, and a breaking elongation of approximately 7.0%. Like thefirst yarns 330, the examplethird yarns 334 are also formed of HMPE and have a size of approximately 1600 denier, a tenacity of approximately 40.0 gpd, and a breaking elongation of approximately 3.5%. However, the first andthird yarns fourth yarns 336 are formed of Polyester sliver and have a size of approximately 52 grain. However the fourth yarn may be of one or more of the following materials: polyester, nylon, Aramid, LCP, and HMPE fibers. - The following tables E, F, G, and H describe first and second ranges of fiber characteristics for the first, second, and
third yarns -
-
Characteristic First Range Second Range tenacity (gpd) 30-40 25-45 modulus (gpd) 900-1500 475-3500 breaking elongation (%) 3-4 2-5 -
-
Characteristic First Range Second Range tenacity (gpd) 7-12 6-22 modulus (gpd) 100-300 50-500 breaking elongation (%) 5-10 2-12 -
-
Characteristic First Range Second Range tenacity (gpd) 30-40 25-45 breaking elongation (%) 3-4 2-5 - The
example rope structure 320 comprises approximately 42% of HMPE by weight and 6% Polyester Sliver by weight and had an average breaking strength of approximately 302,000 lbs. In comparison, a similar rope structure comprising HMPE fibers (94% HMPE by weight) and Polyester Sliver (6% Polyester by weight) has an average breaking strength of approximately 550,000 lbs. Theexample rope structure 320 thus comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of HMPE and Polyester sliver fibers. - Additionally, the
rope structure 320 has a specific gravity of less than 1 and thus floats in water. Therope structure 320 can thus be used as a floating rope having a medium level of strength and tenacity and relatively low cost in comparison to a rope comprising only HMPE fibers. - Referring now for a moment back to
FIG. 4 of the drawing, a first example method of manufacturing theexample rope structure 320 will now be described. Initially, the first, second, third, andfourth yarns steps - In a step represented by
bracket 370, thefirst yarns 330 and thesecond yarns 332 are twisted into thebundles 340 such that thesecond yarns 332 form acenter portion 340 a and thefirst yarns 330 form acover portion 340 b of thebundle 340. In a step represented bybracket 372, thebundles 340 are twisted to form thestrands 350. Theexample rope strands 350 are thus twisted blend fiber bundles. - In a step represented by
bracket 374, thethird yarns 334 and thefourth yarns 336 are false twisted into thebundles 342 such that thethird yarns 334 form acenter portion 342 a and thefourth yarns 336 form acover portion 342 b of thebundle 342. In step represented bybracket 376, thebundles 342 are false-twisted together to form thestrands 352. Theexample rope strand 352 is thus a false-twisted blend fiber bundle. - At a final step represented by
bracket 380, the first andsecond strands rope structure 320. As an additional optional step, therope structure 320 may be coated as generally described above. - Referring now to
FIG. 5 of the drawing, depicted therein is a fifthexample rope structure 420 constructed in accordance with, and embodying, the principles of the present invention. Theexample rope structure 420 comprises a plurality offirst yarns 430, a plurality ofsecond yarns 432, and a plurality ofthird yarns 434. Thefirst yarns 430 andsecond yarns 432 are combined to form a plurality offirst bundles 440. Thefirst bundles 440 comprise acenter portion 440 a comprising thesecond yarns 432. Thefirst yarns 430 are arranged to define acover portion 440 b of the first bundles 440. - The
third yarns 434 are combined, preferably using a false-twisting process, with thefirst bundles 440 to form rope subcomponents orstrands 450. The first andsecond yarns strands 450. Thethird yarns 434 are arranged to define at least a portion of the cover portion of thestrands 450. - The example
first yarns 430 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%. The examplesecond yarns 432 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd, a modulus of approximately 190 gpd, and a breaking elongation of approximately 7.0%. The examplethird yarns 434 are formed of Polyester sliver and have a size of approximately 52 grain. - The following tables H and I describe first and second ranges of fiber characteristics for the first and second,
yarns -
-
Characteristic First Range Second Range tenacity (gpd) 30-40 25-45 modulus (gpd) 900-1500 475-3500 breaking elongation (%) 3-4 2-5 -
-
Characteristic First Range Second Range tenacity (gpd) 7-12 6-22 modulus (gpd) 100-300 50-500 breaking elongation (%) 5-10 2-12 - The
example rope structure 420 comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers. - Additionally, the
rope structure 420 has a specific gravity of less than 1 and thus floats in water. Therope structure 420 can thus be used as a floating rope having a medium level of strength and tenacity and relatively low cost in comparison to a rope comprising only HMPE fibers. - Referring now for a moment back to
FIG. 5 of the drawing, a first example method of manufacturing theexample rope structure 420 will now be described. Initially, at astep 460, thefirst yarns 430 are provided; at astep 462, thesecond yarns 432 are provided. In a step represented bybracket 464, thefirst yarns 430 and thesecond yarns 432 are combined into thebundles 440 such that thesecond yarns 432 form thecenter portion 440 a and thefirst yarns 430 form thecover portion 440 b of thebundle 440. - In a
step 470, thethird yarns 434 are provided. In a step represented bybracket 472, thethird yarns 434 are false twisted with thebundles 440 to form thestrands 450 such that thethird yarns 434 form the cover portion of thebundle 450. At a final step represented bybracket 480, thestrands 450 are combined by any appropriate method, such as twisting or braiding, to form therope structure 420. - As an additional optional step, the
rope structure 420 may be coated as generally described above. - Referring now to
FIG. 6 of the drawing, depicted therein is a sixthexample rope structure 520 constructed in accordance with, and embodying, the principles of the present invention. Theexample rope structure 520 comprises a plurality offirst yarns 530 arranged in bundles, a plurality ofsecond yarns 532, and a plurality ofthird yarns 534. Thesecond yarns 532 andthird yarns 534 are combined, preferably using a false-twisting process, to form a plurality ofsecond bundles 540. The second bundles 540 comprise acenter portion 540 a comprising thesecond yarns 532. Thethird yarns 534 are arranged to define acover portion 540 b of the second bundles 540. - The bundles of
first yarns 530 are combined with thesecond bundles 540 to form rope subcomponents orstrands 550. The second andthird yarns strands 550. The bundles offirst yarns 530 are arranged to define at least a portion of a cover portion of thestrands 550. - The example
first yarns 530 are formed of HMPE and have a size of 1600 denier, a tenacity of approximately 40 gpd, a modulus of approximately 1280 gpd, and a breaking elongation of approximately 3.5%. The examplesecond yarns 532 are formed of HMPP and have a size of approximately 2800 denier, a tenacity of approximately 8.5 gpd, a modulus of approximately 190 gpd, and a breaking elongation of approximately 7.0%. The examplethird yarns 534 are formed of Polyester sliver and have a size of approximately 52 grain. - The following tables J and K describe first and second ranges of fiber characteristics for the first and
second yarns -
-
Characteristic First Range Second Range tenacity (gpd) 30-40 25-45 modulus (gpd) 900-1500 475-3500 breaking elongation (%) 3-4 2-5 -
-
Characteristic First Range Second Range tenacity (gpd) 7-12 6-22 modulus (gpd) 100-300 50-500 breaking elongation (%) 5-10 2-12 - The
example rope structure 520 comprises less than half of HMPE fibers but has a breaking strength of more than half of that of a rope structure of pure HMPE fibers. Additionally, therope structure 520 has a a specific gravity of less than 1 and thus floats in water. Therope structure 520 can thus be used as a floating rope having a medium level of strength and tenacity and relatively low cost in comparison to a rope comprising only HMPE fibers. - Referring now for a moment back to
FIG. 5 of the drawing, a first example method of manufacturing theexample rope structure 520 will now be described. Initially, at astep 560, thefirst yarns 530 are provided, typically in the form of bundles. Atsteps second yarns 532 andthird yarns 534 are provided. In a step represented bybracket 574, thesecond yarns 532 and thethird yarns 534 are combined, preferably using a false-twisting process, into thebundles 540 such that thesecond yarns 532 form thecenter portion 540 a and thethird yarns 534 form thecover portion 540 b of thebundle 540. - In a step represented by
bracket 576, the first yarns 530 (or bundles formed therefrom) are twisted with thebundles 540 to form thestrands 550. At a final step represented bybracket 580, thestrands 550 are combined by any appropriate method, such as twisting or braiding, to form therope structure 520. - As an additional optional step, the
rope structure 520 may be coated as generally described above. - As described above, a bundle of first fibers (e.g., yarns) may be combined with a bundle of second fibers (e.g., yarns) using a false twisting process to form rope subcomponents which are in turn combined to form other rope subcomponents and/or rope structures. The false twisting process is described, for example, in U.S. Pat. Nos. 7,134,267 and 7,367,176, the specifications of which are incorporated herein by reference.
Claims (10)
1. A rope structure comprising:
a plurality of first yarns, where the first yarns
are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO,
have a breaking elongation of approximately 2%-5%, and
have a tenacity of approximately 25-45 gpd; and
a plurality of second yarns, where the second yarns
are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two,
have a breaking elongation of approximately 2%-12%, and
have a tenacity of approximately 6-22 gpd; wherein
the first and second yarns are combined to form rope sub-components; and
the rope sub-components comprise approximately 20-80% by weight of the first yarns.
2. A rope structure as recited in claim 1 , in which the rope sub-components comprise approximately 20-80% by weight of the second yarns.
3. A rope structure as recited in claim 2 , in which the rope sub-components comprise approximately 20-80% by weight of the second yarns and other materials.
4. A method of forming a rope structure comprising the steps of:
providing a plurality of first yarns, where the first yarns
are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO,
have a breaking elongation of approximately 2%-5%, and
have a tenacity of approximately 25-45 gpd;
providing a plurality of second yarns, where the second yarns
are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two,
have a breaking elongation of approximately 2%-12%, and
have a tenacity of approximately 6-22 gpd;
combining the plurality of first yarns and the plurality of second yarns to form a plurality of rope sub-components, where the rope sub-components comprise approximately 40-60% by weight of the first yarns; and
combining the plurality of rope subcomponents to form the rope structure.
5. A method as recited in claim 4 , in which the rope sub-components comprise approximately 35-45% by weight of the first yarns.
6. A method as recited in claim 4 , in which the step of combining the plurality of first yarns and the plurality of second yarns to form a plurality of rope sub-components comprises the step of forming the rope sub-components such that the rope sub-components comprise approximately 40-60% by weight of the first yarns.
7. A method as recited in claim 4 , in which the step of combining the plurality of first yarns and the plurality of second yarns to form a plurality of rope sub-components comprises the step of forming the rope sub-components such that the rope sub-components comprise approximately 35-45% by weight of the first yarns.
8. A rope structure comprising:
a plurality of first yarns, where the first yarns
are formed of at least one material selected from the group of materials comprising HMPE, LCP, Aramids, and PBO,
have a breaking elongation of approximately 2%-5%, and
have a tenacity of approximately 25-45 gpd; and
a plurality of second yarns, where the second yarns
are formed of at least one material selected from the group of materials comprising polyolefin, polyethylene, polypropylene, and blends or copolymers of the two,
have a breaking elongation of approximately 2%-12%, and
have a tenacity of approximately 6-22 gpd; wherein
the first and second yarns are combined to form bundles; and
the bundles comprise approximately 20-80% by weight of the second yarns.
9. A rope structure as recited in claim 8 , in which the bundles comprise approximately 20-80% by weight of the first yarns.
10. A rope structure as recited in claim 8 , in which the bundles comprise approximately 20-80% by weight of the second yarns and other materials.
Priority Applications (1)
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US13/970,396 US20130333346A1 (en) | 2008-06-04 | 2013-08-19 | Synthetic Rope Formed of Blend Fibers |
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US13098608P | 2008-06-04 | 2008-06-04 | |
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US13/367,215 US8511053B2 (en) | 2008-06-04 | 2012-02-06 | Synthetic rope formed of blend fibers |
US13/970,396 US20130333346A1 (en) | 2008-06-04 | 2013-08-19 | Synthetic Rope Formed of Blend Fibers |
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-
2009
- 2009-05-08 US US12/463,284 patent/US8109072B2/en active Active
- 2009-05-21 KR KR1020090044381A patent/KR20090127058A/en not_active Application Discontinuation
- 2009-06-04 JP JP2009151548A patent/JP2009293181A/en not_active Withdrawn
- 2009-06-04 EP EP09251484A patent/EP2130969A3/en not_active Withdrawn
- 2009-06-04 DE DE09251484T patent/DE09251484T1/en active Pending
-
2012
- 2012-02-06 US US13/367,215 patent/US8511053B2/en not_active Expired - Fee Related
-
2013
- 2013-08-19 US US13/970,396 patent/US20130333346A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
EP2130969A3 (en) | 2010-03-10 |
EP2130969A2 (en) | 2009-12-09 |
DE09251484T1 (en) | 2010-08-26 |
KR20090127058A (en) | 2009-12-09 |
JP2009293181A (en) | 2009-12-17 |
US8511053B2 (en) | 2013-08-20 |
US20090301052A1 (en) | 2009-12-10 |
US8109072B2 (en) | 2012-02-07 |
US20120131895A1 (en) | 2012-05-31 |
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