WO2008129116A1

WO2008129116A1 - Rope of a hoisting appliance, method for manufacturing the rope of a hoisting appliance, and an elevator

Info

Publication number: WO2008129116A1
Application number: PCT/FI2008/000043
Authority: WO
Inventors: Raimo Pelto-Huikko
Original assignee: Kone Corporation
Priority date: 2007-04-19
Filing date: 2008-03-19
Publication date: 2008-10-30
Also published as: FI20070304A; FI20070304A0; FI125355B

Abstract

Rope of a hoisting appliance and method for manufacturing rope of a hoisting appliance (1), which rope of a hoisting appliance comprises a core wire (2) or similar and a plurality of outer wire layers, each of which comprises a plurality of wires (3). The rope (1) comprises at least one such wire layer, essentially all the wires (3) of which are at essentially the same distance from the core wire (2) and contain composite material and of which at least a part are essentially wedge-shaped in the shape of their cross-section. The hoisting appliance rope (1) can comprise at least one such wire layer that comprises wire bundles essentially at the same distance from the longitudinal axis of the rope and which wire bundles comprise wires (3) comprised of composite, and at least a part of which wire bundles are essentially wedge-shaped in the shape of their cross-section. In the method a plurality of wires (3) are directed into at least one outer layer (L) as a part of the rope (1) such that at least a part of the wires (3) forming the rope (1) are composite and in the method at least a part of the composite wires (3) intended to be a part of the rope (1) are coated with polymer and the wires (3) are directed into the proximity of each other as a part of the rope (1).

Description

ROPE OF A HOISTING APPLIANCE, METHOD FOR MANUFACTURING THE ROPE OF A HOISTING APPLIANCE, AND AN ELEVATOR

FIELD OF THE INVENTION

The object of the present invention is the rope of a hoisting appliance as defined in the preamble of claim 1, the rope of a hoisting appliance as defined in the preamble of claim 11, a method for manufacturing the rope of a hoisting appliance as defined in the preamble of claim 12, a method for manufacturing the rope of a hoisting appliance as defined in the preamble of claim 19 and an elevator as defined in the preamble of claim 22.

BACKGROUND OF THE INVENTION

Ropes braided of metal wires or strands, among others are known prior art. The problems of wire ropes are often a high weight and thickness in relation to tensile strength owing to the material properties of metal . Conventional ropes braided from metal strands are also not round in their cross-section and smooth. Owing to this, one problem with them is noise and vibration when they meet the surface of the rope pulley. In addition, the stranding reduces the contact surface between the rope and traction sheaves, in which case the contact pressures that occur are great. Metal ropes possessing a round cross-section are also prior art. This kind of rope is presented in publication US2004/0026178A1, among others, in which the rope comprises braids of metal wires, which are arranged into a rim and which are surrounded by a polymer layer. Prior art also includes synthetic ropes, which comprise wires composed of fibers. In wires and strands laid from separate fibers all the fibers move with respect to each other, wear and might break also inside the wire and the strand. Thus only tough textile-type fibers, such as e.g. aramid fibers, can be used in these structures. In addition ropes comprising composites are also prior art. The structure of these ropes is not generally multilayer and they comprise wires that are generally round in their cross-section, so that the cross-sectional area of the rope is not utilized effectively and also the behavior of the rope when subjected to bending is disadvantageous. In prior-art ropes the problems are thus a high weight and thickness in relation to tensile strength and tensile stiffness. In addition, utilization of the cross-sectional area is often weak and in the rope there are air gaps in the structure. Also the structure of the rope does not allow a very abrupt deflection radius nor advantageous movement of the wires with respect to each other. For these reasons the behavior of the rope when subjected to bending is often disadvantageous, the rope is not the optimal in terms of its properties and/or the service life of the rope is poor.

PURPOSE OF THE INVENTION

The purpose of the invention is to eliminate the drawbacks of prior-art ropes and to produce a rope

of good properties. According to the invention at least one of the following advantages, among others, is achieved. The rope according to the invention is light and of high tensile strength with respect to its self-weight. It is thin compared to prior-art ropes possessing the same tensile strength and rigidity, which for its part enables a small deflection radius, i.e. the bending radius to which the rope can be bent without breaking. The rope according to the invention is even on its surface, which keeps the noise nuisances and vibration produced by the rope moderate. The structure of the rope according to the invention is symmetrical and utilizes the surface area of the cross-section of the rope effectively. In addition the rope behaves well when subjected to bending because the wires of the rope according to the invention are able to move well in relation to each other. Further, the rope according to the invention possesses characteristics that promote the achievement of a long service life. Among other things, it withstands the lateral force exerted from the rope pulleys because the surface pressure between the wires remains small.

In elevator systems the elevator car, the counterweight, or both, can be moved with the rope according to the invention. It can also be used in connection with other hoisting appliances, e.g. as a rope of cranes. The lightness of the rope is useful, especially in accelerating situations, because the energy required by changes in the speed of the rope depends on its mass. Lightness is also useful in rope systems in which separate compensation ropes are needed. In addition, lightness makes handling of the ropes easier. The rope according to the invention is also well suited to high tensile ratios, in which normally the rope masses are great. The deflection radius and weight of the rope according to the invention remain reasonable even in these kinds of situations. By varying the material and the structure of the rope according to the invention it is possible to achieve a rope that is optimal for specific cases in demanding conditions in terms of its longitudinal rigidity, weight and tensile strength. The structure of the rope according to the invention combined especially with the advantages of composite material produce the aforementioned benefits. The individual fibers inside a composite wire do not move with respect to each other but instead the wire is a fixed substance that bends elastically. In a composite wire the brittleness or wear resistance of an individual fiber is not of as great importance as in wires comprising separate fibers.

The purpose of the method according to the invention is to enable the manufacturing of high-quality rope. With the method a rope is achieved that effectively utilizes .the surface area of the cross-section of the rope and which behaves well when subjected to bending and which meets high quality requirements in terms of its longitudinal rigidity, weight and tensile strength. The method also makes possible the manufacture of a rope that has a long service life. With the method the rope can easily be formed into a shape that accurately fills the cross-section of the rope. This kind of rope withstands the lateral force exerted from pulleys well because the surface pressure between wires remains small. With the method the rope can easily be formed to be round and of a smooth outer surface, in which case the contact pressure between the rope and the pulley remains small. In this case the contact noise and vibration are a lot smaller than e.g. with steel wire ropes.

SUMMARY OF THE INVENTION

The rope of a hoisting appliance according to the invention is characterized by what is disclosed in the characterization parts of claims 1 and 11. The method according to the invention is characterized by what is disclosed in the characterization parts of claims 12 and 19. The elevator according to the invention is ^•characterized by what¹- i*s^tj disclosed in the characterization part of claim 22. Other embodiments of the invention are characterized by what is disclosed in the other claims. Some inventive embodiments are also discussed in the descriptive section and in the drawings of the present application. The inventive content of the application can also be defined differently than in the claims presented below. The inventive content may also consist of several separate inventions, especially if the invention is considered in the light of expressions or implicit sub- tasks or from the point of view of advantages or categories of advantages achieved. In this case, some of the attributes contained in the claims below may be superfluous from the point of view of separate inventive concepts . The features of the various embodiments can be applied within the scope of the basic inventive concept in conjunction with other embodiments.

The hoisting appliance rope according to the invention comprises a core wire or similar and a plurality of outer wire layers, of which wire layers each comprises a plurality of wires. The rope comprises at least one such wire layer, essentially all the wires of which are at essentially the same distance from the core wire and contain composite material and of which at least a part are essentially wedge-shaped in the shape of their cross- section. The aforementioned composite material comprises fibers in a polymer matrix. Utilizing composite material as a material of the rope according to our invention is especially advantageous because by utilizing composites a light structure, but strong in terms of its tensile strength, is achieved. The good formability of composite also enables the forming of the composite wires used in the rope into a certain preferred shape. This also enables effective utilization of the surface area of the cross- section.

In one embodiment of the invention the rope comprises at least two such wire layers, essentially all the wires of which are at essentially the same distance from the core wire or similar and contain composite material and of which at least a part are essentially wedge-shaped in the shape of their cross-section.

In one embodiment of the invention at least one of the outer wire layers comprises composite wires in a helical formation with respect to the longitudinal direction of the rope. The helical shape gives the wire layer and thus also the whole rope flexibility and in dimensioning the roping the rigidity of the rope can be selected to be that desired by changing the helical angles. One advantage of the helical-shaped layer structure is that the helical shape has a reducing effect on the deflection angle of the rope because the helical layer is able to adapt to the changing position of the rope at the deflection point.

In one embodiment of the invention the composite wires in the helical formation of at least one outer wire layer are of different handedness than the wires in the helical formation of the outer wire layer surrounding it. Preferably the handedness of the wire layers that are in helical formation changes only once as viewed in the direction of the radius of the rope.

In one embodiment of the invention a layer comprising essentially just polymer is between the outer surface of at least one outer wire layer and the inner surface of the next outer wire layer. It binds the wires of the wire layers that are against it to the rope and prevents the fraying of any broken wires from the rope. This layer is in one embodiment of the invention elastomer, in which case it allows reciprocal movement between the layers outside it and inside it, thus acting as a sort of bearing.

In one embodiment of the invention the angle between the side surfaces of the wires of at least one outer wire layer is smaller ^"than the angle between the side surfaces of the wires of the wire layer inside it in the direction of the radius of the rope.

In one embodiment of the invention the wires (3) of two outer wire layers are of different handedness in the helical formation and between the aforementioned two different-handed wire layers is an elastomer layer.

In one embodiment of the present invention the aforementioned composite material contains carbon fiber, glass fiber or aramid fiber.

In one embodiment of the invention the wires of the wire layer next outermost to the polymer layer are metal. Most preferably a layer comprising metal wires is the outermost, in which case the metal layer protects the inner layers from wear . In one embodiment of the invention the inside sides and the outside sides of all the wires of at least one outer wire layer are curved.

In one embodiment of the invention at least a part of the individual wires (3) of at least one outer wire layer comprises a thin polymer layer around a composite material, which isolates the parts that comprise composite of adjacent wires from each other. It is most preferred that the polymer is selected to be such that it still essentially retains the properties of its surface that are dependent on temperature at the temperature when the wire inside it can be formed into its final permanent shape with heat and compression. A thin layer surrounding a wire enables movement of the wire with respect to other wires and wire layers also when the rope is manufactured with compression utilizing heat. Polymer films prevent the wires inside them from attaching to each other in the manufacturing phase of the rope, although the composite material of the wires is in a malleable state. The films are placed in the finished rope against each other but do not cling to each other, in which case their relative movement is possible.

According to another embodiment of the invention the hoisting appliance rope comprises a core wire or similar and at least one outer layer comprising wires, which layer comprises a plurality of wire bundles. More precisely, the rope comprises at least one such wire layer that comprises wire bundles essentially at the same distance from the longitudinal axis of the rope and which wire bundles comprise wires comprising composite, and of which wire bundles at least a part are essentially wedge-shaped in the shape of their cross-section.

According to the method that is the object of the invention the hoisting appliance rope is manufactured by directing a plurality of wires into at least one outer layer as a part of the rope, in which case at least a part of the wires forming the rope are composite and the method comprises a phase a, in which at least a part of the composite wires intended to be a part of the rope are coated with polymer and a phase b, in which the wires are directed into the proximity of each other as a part of the rope.

In one embodiment of the method according to the invention the method also comprises a phase in which the partly unfinished rope is compressed in order to shape the wires and to achieve a tight rope structure. The wires are shaped in this way to be preferably wedge-shaped.

In one embodiment of the method according to the invention the wires are heated in connection with compressing the wires .

In one embodiment of the method according to the invention in phase a the polymer matrix of the composite wire is still in an unhardened state and between phases a and b the composite wires are cooled in order to slow down the hardening of the composite wire.

In one embodiment of the method according to the invention in phase a the wires are coated by wrapping a polymer film around them.

In one embodiment of the method according to the invention the wires contain resin that hardens in heat and in connection with compression the wires are heated in order to speed up the hardening of the resin of the wires.

In one embodiment of the method according to the invention the composite wires are heated to a temperature between the softening point of their polymer matrix and the softening point of the polymer film. According to a second method that is the object of the invention the hoisting appliance rope is manufactured by- directing a plurality of wire bundles into at least one outer wire bundle layer as a part of the rope and at least a part of the wires of which the wire bundles are comprised are composite and the method comprises a phase a, in which at least a part of the wire bundles intended to be a part of the rope are coated with polymer and a phase b, in which the wire bundles are directed into the proximity of each other as a part of the rope being manufactured.

In one embodiment of the second method of the invention the method also comprises a phase in which the partly unfinished rope is compressed in order to shape the wire bundles and to achieve a dense rope structure. The wire bundles are shaped in this way to be preferably wedge- shaped. In another embodiment of the method according to the invention the wire bundles are heated in connection with compressing the wire bundles.

The elevator according to the invention comprises an elevator car, or similar, roping for moving the elevator car and a power source for moving the roping. The roping comprises one of the ropes described above. In this way the advantages listed earlier are achieved. Thus, for example, the mass of the elevator to be moved is smaller than before.

LIST OF FIGURES

In the following, the invention will be described in detail by the aid of some embodiments with reference to the attached drawings, wherein

Fig. 1 diagrammatically presents one embodiment of the rope according to the invention

Fig. 2 diagrammatically presents the layer structure of the rope of Fig. 1 as a three-dimensional cross-sectional view Fig. 3 diagrammaticalIy presents a second embodiment of the rope according to the invention

Fig. 4 diagrammatically presents the layer structure of the rope of Fig. 3 as a three-dimensional cross-sectional view

Fig. 5 diagrammatically presents a third embodiment of the rope according to the invention

Fig. 6 diagrammatically presents the layer structure of the rope of Fig. 5 as a three-dimensional cross-sectional view

Fig. 7 diagrammatically presents a phase incorporated in one embodiment of method according to the invention

Fig. 8a diagrammatically presents the rope in one embodiment of the method according to the invention before compression

Fig. 8b diagrammatically presents a cross-sectional side view of the nozzle used in one embodiment of the method according to the invention

Fig. 8c diagrammatically presents the nozzle used in one embodiment of the method according to the invention and a cross-section of the rope as viewed towards direction of travel of the rope

Fig. 9a diagrammatically presents a cross-section of the rope in one embodiment of the method according to the invention, in which the outermost layer is not yet compressed into its shape

Fig. 9b diagrammatically presents a cross-section of the rope of Fig. 9a in the phase in which the outermost is compressed into its shape. Fig. 10a diagrammaticalIy presents one cross-section of the rope according to the invention in one embodiment of the method according to the invention, in which the outermost layer of the rope is not yet compressed into its shape

Fig. 10b diagrammaticalIy presents a cross-section of the rope of Fig. 10a in the phase in which the outermost is compressed into its shape.

DETAILED DESCRIPTION OF THE INVENTION

Fig. 1 diagrammaticalIy presents the cross-section of a rope according to one embodiment of the invention and Fig. 2 a three-dimensional cross-sectional view of it. The rope

(1) comprises a core wire (2), around which are outer wire layers (L), which comprise wires (3). An outer wire layer refers to a wire layer that is situated between the core wire of the rope and the surface of the rope. In the embodiment illustrated in Figs. 1 and 2 the wires ,(3) o,f, the three next outermost wire layers (L) from the core wire are in a helical formation of the same direction and against the outermost of these layers is an elastomer layer

(e) . The outermost wire layer (L) surrounds the elastomer layer (e) , the wires of which are in a helical formation of a different handedness than the wires (3) of the wire layers that are in a helical formation inside it. The elastomer layer (e) flexibly binds the wires of the wire layers that are against it to the rope and prevents any broken wires of the rope fraying from the rope. At the same time it allows reciprocal movement between the layers on the outside of it and on the inside of it, thus acting as a sort of bearing, when the layers (L) of a rope (1) subjected to bending or other load move in relation to each other. Essentially all the wires (3) are, in the embodiment of Figs. 1 and 2, composite, preferably carbon composite or glass fiber composite, the polymer matrix of which is epoxy or e.g. polyurethane. The wires (3) of each wire layer (L) are essentially at the same distance from the core wire (2) . The wires (3) are wedge-shaped in terms of the shape of their cross-section and placed in the rope (1) to form sectors. The term wedge-shaped means that the wires are on average tapered in terms of the dimensions of their cross- section. The advantage of a wedge-shaped form is effective utilization of the surface area of the cross-section of the rope. The wires also support each other and retain their position well when loaded and bending. Preferably the inner surfaces and the outer surfaces of the wires (3) are curved and the juxtaposed surfaces of adjacent wires (3) are preferably counterpart pairs. The side surfaces of the wires are preferably aligned in the direction of the radius of the cross-section of the rope. The presence of a polymer layer is not essential from the viewpoint of the operation of the invention. Also the number of layers can be fitted to be optimal for the specific case.

Fig. 3 diagrammatically presents the cross-section of a rope (4) according to a second embodiment of the invention and Fig. 4 a three-dimensional cross-sectional view of it. The rope (4) comprises a core wire (2), around which are outer wire layers (L), which comprise wires (3) . In the embodiment illustrated in Figs. 3 and 4 the wires (3) of the three next outermost wire layers (L) from the core wire (2) are in a helical formation of the same direction and against the outermost of these layers is such an outer wire layer (L) , the handedness of the helical formation of which is opposite with respect to the wire layers (L) on the inside of it. The outermost wire layer (L) is surrounded by an elastomer layer of polyurethane . The elastomer layer protects the wires and prevents the fraying of wires, if wires are damaged in use. The layer also preferably functions as a friction surface. The wires (3) are, in the embodiment of Figs. 3 and 4, preferably carbon composite or glass fiber composite, the polymer matrix of which is epoxy or e.g. polyurethane. Fig. 5 diagrammatically presents the cross-section of a rope according to a third embodiment of the invention and Fig. 6 a three-dimensional cross-sectional view of it. The rope (6) comprises a core wire (2), around which are outer wire layers (L), which comprise wires (3). The wires (3) of the three next outermost wire layers (L) from the core wire

(2) are in a helical formation of the same direction in the manner illustrated in Figs. 5 and 6. Of these wire layers

(L) the outer surface of the outermost is against an elastomer layer (e) , against the outer surface of which is a metal wire layer (5) . Most preferably a layer comprising metal wires is the outermost, in which case the metal layer protects the inner layers from wear caused by use of the rope, because the abrasion resistance of metal is generally better than that of composite. The helical formation of the wires of the outer wire layers (L) is of the opposite handedness than that of the metal wire layer (5) . The wires

(3) are, in the embodiment of Figs. ,5. and 6, preferably carbon composite or glass fiber composite, the polymer matrix of which is epoxy or e.g. polyurethane .

In the embodiments presented in Figs. 1-6, the wires (3) of each outer wire layer (L) are essentially at the same distance from the core wire (2) . The wires are wedge-shaped and the inner surface and outer surface of them are curved. In this case when placed side by side together they form a cylindrical outer surface and inner surface. Thus the wires of different layers can made to settle densely in relation to each other.

The advantages, the operation and the variation methods of the embodiments presented as examples in Figs. 1-lOb are also listed elsewhere in this application. The figures are not drawn to scale. In one preferred embodiment of the invention at least a part of the wires (3) presented in the figures are surrounded with a thin polymer film (10) (not shown in Figs. 1-6) , which allows better movement of the wires (3) in relation to each other, because polymer can be selected to have such advantageously small friction properties that the films surrounding adjacent wires (3) move against each other as the rope (1) bends. The films isolate the wires (3) from each other, in which case wear caused by abrasion between the composite wires (3) essentially does not occur. This lengthens the service life of the rope (1) .

When at least a part of the outer wire layers (L) of the rope are manufactured to be helical e.g. in the manner illustrated in the figures, the rope (1) behaves advantageously at the point of deflection. When the rope (1) changes direction into a curve at the point of deflection, the surface structure of the outer curve of the bending rope (1) endeavors to lengthen and the inner curve to compact. The helical formation in this case allows adaptation of the wires (3) in the preferred manner to the change in shape of the rope (1) caused by the change in direction. It is preferable that all, or at least most, of the outer wire layers (L) are in a helical formation. The helical angle can be selected to be suitable for the specific circumstances depending on the desired angle of deflection, the requirements set for the longitudinal rigidity of the rope, and the weight targets.

It is preferred that an elastomer layer (e) is disposed between two outer wire layers (L) in the manner illustrated in Figs. 1, 2, 5 and 6. Most preferably the elastomer layer (e) is between those layers between which the helical handedness of the wires (3) changes, because it is at that point that most relative movement between the layers occurs . Preferably the handedness of the wire layers that are in helical formation changes only once as viewed in the direction of the radius of the rope, so that large relative movement does not happen between unnecessarily many layers. The advantage of changing the helicality is, among other things, that it reduces the inclination of the rope to twist or rotate. If all the layers were helical in the same direction, this phenomenon could be problematic in connection with use. The advantages of the polymer layer (e) can of course also be achieved if its material is a polymer that isolates the layers but allows sliding, e.g. polyethylene, Teflon or an industrial sliding coating.

Utilizing the method according to the invention it is possible to manufacture e.g. a rope (1,4,6,14,15) as defined in the claims, or a part of it. The rope (1,4,6,14,15) can be e.g. one comprising the structure according to Figs. 1-6, 8c, 9b or 10b. In the following the manufacture of the rope (1,4,6,14) is described. In the method according to the invention the wires (3) of the wire layer to be joined as a part of the rope (1,4,6,14) are directed into layers abreast on top of the core wire (2) essentially at the same distance from the core wire (2) such that abreast they form a dense outer wire layer (L) . Of the wires (3) of the rope (1) manufactured with the method, at least a part can move with respect to each other. Especially when the wires of at least some wire layer (L) are directed into a helical formation, even sharp deflection angles of the rope are possible.

The wires (3) can be fashioned into their final shape in advance, but according to one preferred embodiment the wires (3) are shaped by means of compression into their final shape only when they are joined as a part of the rope (1, 4, 6, 14) being manufactured. This is implemented such that a type of thin polymer layer is arranged in advance around at least a part of the wires (3) intended for the wire layer (L), i.e. a film (10), which essentially retains the properties of its surface that are dependent on temperature in those conditions when the composite wire inside it can be formed into its final permanent shape with compression. The wires (3) coated thus with films do not stick to each other, which can happen if the film e.g. softened too much in the treating temperature of the composite inside it. Before the wires (3) are directed to become a part of the surface of the rope they are thus coated. This is implemented preferably by wrapping or braiding a polymer film (10) around the wires (3), which covers their surface. The coating can be implemented also by spraying or by immersing the wires in a polymer tank. The coated wires (3) are directed to be a part of the rope as an outer layer of the rope around the core wire (2) . Preferably the rope (1) is manufactured as a continuous process such that a number of wires that are previously manufactured, and possibly coated with a film, are fed from the reel simultaneously through a constricting nozzle (12), which forces the parts of the rope into the proximity of each other and thus produces the aforementioned compression, in the radial direction of the rope, on the rope running through it and on the parts of it. The compression could of course be implemented also in other ways than with a nozzle (12), e.g. with a separate compressor. The force of the compression must be selected to be such that it is sufficient to compress the wires into becoming wedge-shaped, in order for the wires (3) to form a dense wire layer. Fig. 8a presents a cross-sectional view of the wires (3) directed to the nozzle (12) in the phase in which the wires (3) are collected into the proximity of each other. Preferably also the assembling occurs by means of the same nozzle (12), which is at least partly tapered and which assembles the wires (3) around the core wire (2) or other semi-manufactured rope e.g. that has come from an earlier phase e.g. into a bundle in the manner illustrated in Fig. 8a. The wires (3) are not yet in their final shape in terms of their cross-section in this phase yet but instead they are e.g. round. The wires (3) are directed to pass through the type of nozzle (12) presented in Fig. 8b, the increasing constriction of which forces the wires (3) to densely interlock with each other and thus compresses the wires into the wedge-shaped form illustrated by Fig. 8c. According to one preferred embodiment the wires are heated in conjunction with compression exerted on the wires (3). In this case the thin polymer film arranged beforehand around the wires (3) intended for the wire layer (L) are of such a material that it still essentially retains the properties of its surface that are dependent on temperature at the temperature when the composite wire inside it can be formed into its final permanent shape with heat and compression. The wires (3) coated thus with films do not stick to each other, which can happen if the film e.g. softened too much in the treating temperature of the composite inside it. In practice the temperature of the wire is raised most preferably to a temperature clearly below the softening point of the film. The material of the thin polymer film is selected depending on what the other composition and the heating temperature of the composite wires (3) are. It can be some known polymer. For example, a coating material suited to carbon fiber epoxy is polyethylene .

According to one preferred embodiment so-called prepreg resin is used as the material of the composite wire (3) . Prepeg is a semi-finished product, in which the reinforcing fibers are pre-impregnated with a resin that hardens in heat and is generally of a thermosetting plastic base. The prepreg resin is kept in the wires in a partly hardened and solid state, from which it is finally hardened by heating. During heating the resin initially becomes a low-viscosity liquid, after which it quickly hardens. Preferably epoxy, phenols or polyesters are used as the resin material. Most preferably epoxy resin is used, with which good strength characteristics are achieved. By utilizing prepreg resin the temperature required in conjunction with compressing into shape is not so high that the polymer films of the wires (3) attach to each other.

As mentioned earlier, heating of the wires (3) is performed in conjunction with compression. The heating can be implemented before compression, after it and/or at least partly simultaneously during compression. Since the wires (3) are resin their hardening accelerates as the temperature rises. In one embodiment the hardening is started before commencement of the compression, in which case the compression can be performed on wire that is already slightly hardened. In this case an advantage is easier control of the compression into shape as the hardening process of the wire (3) is already more advanced. In this case the temperature of the wires (3) starts to rise even before performance of the compression. The raising or maintenance of the temperature can be continued during compression and/or after it also, in which case the final hardness is achieved only after the nozzle. The wires can be heated with some prior-art method such as e.g. with hot air, with the heat of the surrounding air, with radiation or with the heat of the nozzle that gathers the wires into rope. At its most simple the heating is implemented simply with a hot nozzle. In compression a compression is exerted on the wires (3) evenly from around the rope in the radial direction of it, in which case the wires are molded from the force of the compression into parts of the wire layer that are wedge-shaped in the shape of their cross-section. The wires harden in this shape owing to the heat, forming a densely filled outer wire layer. With the method according to the invention it is possible to join one or more wires of a wire layer at a time to the rope, which is formed from the core wire (2) in this phase of the manufacturing method or from a partly manufactured wire that has come from a previous phase. The compression can be performed either a number of wire layers at a time or one layer at a time. The method described can thus be repeated a number of times if desired until the desired amount of layers are in the rope. This is illustrated in Figs. 9a and 9b. The outermost wire layer of the rope (14) of Fig. 9a is compressed onto the surface of the partly manufactured rope that was earlier compressed into its shape, in which case the rope (14) of Fig. 9a is molded into the shape presented in Fig. 9b. If so desired, a polymer layer (e) can be added between the outer wire layers (L) in a separate phase, in which case the next outer wire layer (L) is formed on top of the polymer layer (e) either in a similar manner to that described earlier or also according to an embodiment e.g. by gathering preformed wires on top of the polymer layer.

In the method the wires (3) are arranged into wire layers (L) preferably such that at least a part of the outer wire layers and most preferably all the outer wire layers are in a helical formation in the manner illustrated in Figs. 1-6 or explained earlier in the description. Most preferably all the wires (3) of the same outer wire layer (L) are directed to the same distance from the longitudinal axis of the rope .

Fig. 7 illustrates a method according to one embodiment of the invention for coating the wires. In the figure a continuous fiber reinforcement cable (11) is unwound from the reel (7), which goes into the polymer priming tank (8) . After this a polymer film (10) is unwound from the second reel (9) around the composite wire (3) arriving from the priming tank (8), e.g. by rotating the reel (9) around the wire. After this the wire (3) is reeled for storage. The implementation method illustrated by Fig. 7 can be applied regardless of whether prepreg resin is involved or not. The method presented by the figure can also be utilized when operating according to another embodiment method in which special prepreg resins are not needed. In this embodiment method the wire (3) is formed by wetting the fibers (11) in resin, e.g. in a tank (8), and wrapping a plastic film (10) immediately around the fiber cable (11) and the composite wire preform produced is cooled to a temperature so cold that the hardening reaction essentially slows or even stops. When there are sufficient wires, they are taken from the cold space and twisted into the final shape to become rope, compressed into the precise shape and heated in conjunction with the compression to become hard.

In one embodiment of the method according to the invention the material of the polymer matrix of the wire is thermoplastic. In this case the previously described heating of the wires is performed such that the temperature of the polymer matrix is raised to above the softening point, but at the highest to close to the melting point. The wires comprise preferably a film surrounding them, the softening point and the melting point of which are higher than the corresponding ones of the polymer matrix. The temperature of the wire is in this case raised to at least the temperature corresponding to the softening point of the matrix, but however to a temperature lower than the softening point of the film. With this the adhesion of the surfaces of the wires to each other is prevented simultaneously with when the polymer matrix can be formed with compression. For example, a suitable film material for a polypropylene matrix could be polytetrafluoroethylene, nylon, polyester or some other material, which withstands heat better than the material of the matrix. The treating temperature of a polypropylene wire could be e.g. between 145-165°C, depending however on the properties of the grade used. The compression is exerted on the wires in the manner described elsewhere in this application.

Fig. 10a presents one rope (15) according to the invention in a phase according to one embodiment of the method according to the invention. In the figure the part corresponding to the core wire (16) is formed from a multiwire structure, preferably from composite wire, which most preferably is essentially similar to the structure of the rope described earlier in this application. The rope of Fig. 10a is compressed into the shape presented in Fig. 10b in a manner corresponding to that described earlier in this application, preferably such that the temperature of the wires is affected in conjunction with the compression. The wire bundles (17) of the rope (15) are each comprised of a number of wires (3) and the wire bundles (17) are placed to be at least one of the outer wire layers of the rope. The wire bundles (17) of the same wire bundle layer are essentially at the same distance from the longitudinal axis of the rope. The wire bundles (177) are wedge-shaped and settle against each other. The wires (3) of a wire bundle are preferably, but not necessarily, coated with a plastic film in a manner presented in connection with the preceding embodiments. Likewise the wire bundles are preferably isolated from each other by surrounding them with a plastic film. One advantage of this is that the wire bundles are thus able to move in the rope in relation to each other. The embodiments of Figs. 10a and 10b are thus preferably manufactured otherwise in the same way as the ropes presented elsewhere in this application, but in place of the wire bundles is a wire bundle (17) , which for its part is preferably manufactured by directing wires into a group of layers in the proximity of each other, of which wires (3) preferably at least a part are comprised of composite. Most preferably the wires (3) of this embodiment are manufactured in the manner presented in Fig. 7 or described elsewhere in this application. The wire bundles of the rope illustrated in Fig. 10b are preferably in a helical formation. The rope of Fig. 10b can also comprise other wire layers or wire bundle layers in a helical formation preferably of different handedness e.g. in the manner corresponding to that illustrated in Figs. 1-6.

The outer surface of the rope (1,4,6,14,15) is preferably coated with polymer. In this case the surface is protected and its friction properties can be selected separately. Most preferably polyurethane, which has a high co-efficient of friction, is used as the coating. A coating or composite wires and wire layers can also be utilized as an indicator of wear of the rope e.g. by detecting changes in the optical values of the rope such as e.g. utilizing the color or fluorescence of the rope. Preferably the colors of the coating and/or of the layers of the rope can be strongly- contrasting to each other. Different protrusions such as toothing patterns can also be formed on the surface if it is desired to assist transmission with a positive contact based on shape. It is preferable to place lubricant between the wire layers, in which case the wires of the rope are better able to move with respect to each other. This is especially preferred in the embodiments in which the wires are not isolated from each other with the aforementioned thin polymer film.

The elevator according to the invention comprises an elevator car, or similar, roping for moving the elevator car e.g. in the elevator shaft. The roping is moved with some prior-art method, such as by means of a traction sheave moved by an electric motor. The roping comprises a previously described rope (1,4,6,14,15) of one of the claims. The elevator also preferably comprises guide rails. The elevator is preferably an elevator of high lifting height, in which case the advantages of the invention are of their utmost importance .

In this application the term composite refers to a polymer- based material or similar reinforced with long or short fibrous parts. The fibers most preferred are as long as possible and fill the wire densely. The fibers are preferably longitudinal with the wire. Preferably e.g. carbon fiber, glass fiber, aramid fiber, metal fiber or several of these together can function according to the invention as fiber reinforcement. The term composite is also used for composite that still has not reached its final hardness. If it is desired to manufacture a rope of high tensile strength and tensile rigidity it is preferable to use carbon fiber. If it is desired to manufacture an inexpensive rope e.g. for low-rise elevator systems, in which case the maximal tensile rigidity is not required of the rope, it is preferable to use fiber glass. Some prior- art composite matrix material such as e.g. polyurethane, rubber, polyethylene, polyester, vinyl ester, epoxy, bismaleimide, polyimide or a mixture of these can function as the polymer matrix surrounding the reinforcements . The most preferred polymer matrix is epoxy or polyurethane or polyester.

The core wire or similar can be manufactured from composite or metal, but most preferably it is the same composite material as the wires of the outer wire layers . According to one embodiment the core wire can be widely understood, in -which case the core wire can itself be a braid or other structural part comprised of numerous wires. The wire of different wire layers in the embodiments according to our invention are in essentially the same size class, preferably such that the wedge angle decreases in steps with each layer owing to the growth in the radius. In this case the number of wires per layer is greater in the outer layers than in the inner ones. It is obvious, however, that 'the outer wire layers could be assembled also from wires of different sizes, in which case the number of wires of the layers can be selected to be suitable. There can be one or more wire layers, preferably at least two, most preferably at least three. The most preferred amount of wire layers depends on the application such that the strength requirements and deflection radius requirements demanded of the rope are the most essential factors. These factors also affect the angle of the helical formation and the thickness of individual wire layers, which angle and thickness can vary very much in different applications of the invention. The invention can be applied also such that the juxtaposed side surfaces of the wires of the outer wire layers are in different places, in which case the seams are not one on top of the other. In this case the structure of the rope is dense and durable. The side surfaces of the wire refers to the surfaces formed by the sides of the wires as viewed in the radial direction of the rope. It is obvious to the person skilled in the art that the amount of wire layers can be other than the amounts presented in the figures. It is also obvious that the composites referred to in the embodiments described can comprise combinations of part materials of a composite or other modern constituents of a composite. It is further obvious that the method according to the invention can be utilized regardless of how the other layers of the rope are formed. Likewise it is also obvious that within the scope of the inventive concept there may also be separate additional layers upon the ropes according to those presented earlier, which can be comprised e.g. of wires or braids or can be formed from layers of one material. Likewise, it is obvious that the invention can be utilized also in other ropes than those possessing a completely round cross-section. It is also obvious that it is possible to manufacture an embodiment from the rope according to the invention in which the outer sides and inner sides of the wires are essentially straight. In this case an advantage is a simple shape and easy manufacture. It is also obvious that the wire layer can comprise both wedge-shaped and other wire^'s? such as e.g. those possessing a rectangularly shaped cross-section. Most preferred however is that essentially all the wires of a wire layer are wedge-shaped.

It is obvious to the person skilled in the art that the invention is not limited to the embodiments described above, in which the invention is described using examples, but that many adaptations and different embodiments of the invention are possible within the scope of the inventive concept defined by the claims presented below.

Claims

1. Rope (1,4,6,14,15) of a hoisting appliance, which comprises a core wire (2) or similar and a plurality of outer wire layers (L) , each of which outer wire layers (L) comprises a plurality of wires (3) charac ter i z ed in that the rope comprises at least one such wire layer (L) , essentially all the wires (3) of which are at essentially the same distance from the core wire (2) and contain composite material and of which at least a part are essentially wedge-shaped in the shape of their cross-section, and in that the aforementioned composite material comprises fibers in a polymer matrix.

2. Rope according to claim 1, charac teri z ed in that the rope (1,4,6,14,15) comprises at least two such wire layers (L), essentially all the wires (3) of which are at essentially the same distance from the core wire (2) and contain composite material and of which at least a part are essentially wedge-shaped in the shape of their cross-section.

3. Rope according to any of the preceding claims, charac teri z ed in that at least one of the outer wire layers (L) comprises composite wires in a helical formation with respect to the longitudinal direction of the rope.

4. Rope according to claim 3, charac teri z ed in that the composite wires in the helical formation of at least one outer wire layer (L) are of different handedness than the wires in the helical formation of the outer wire layer surrounding it.

5. Rope according to any of the preceding claims, charac teri z ed in that a layer (e) comprising essentially just polymer, preferably elastomer, is between the outer surface of at least one outer wire layer (L) and the inner surface of the next outer wire layer (L) .

6. Rope according to any of the preceding claims, charac teri z ed in that the wires (3) of two outer wire layers (L) are of different handedness in the helical formation and between the aforementioned two different-handed wire layers is an elastomer layer (e) .

7. Rope according to any of the preceding claims, charac teri z ed in that the aforementioned composite material contains carbon fiber, glass fiber or aramid fiber.

8. Rope according to any of the preceding claims, charac teri z ed in that the wires (3) of the next outer wire layer (L) from the polymer layer are metal .

9. Rope according to any of the preceding claims, charac teri z ed in that the inside sides and the outside sides of all the wires of at least one outer wire layer are curved.

10. Rope according to any of the preceding claims, charac teri z ed in that at least a part of the individual wires (3) of at least one outer wire layer comprises a thin polymer layer around it, which isolates the parts that comprise composite of adjacent wires from each other.

11. Rope (15) of a hoisting appliance, which comprises a core wire (2) or similar and at least one outer layer comprised of wires, which layer comprises a plurality of wire bundles (17), charac t eri z ed in that the rope (15) comprises at least one such wire bundle layer that comprises wire bundles (17) essentially at the same distance from the longitudinal axis of the rope and which wire bundles comprise wires (3) comprised of composite, and at least a part of which wire bundles (17) are essentially wedge-shaped in the shape of their cross-section.

12. Method for manufacturing the rope (1,4,6,14,15) of a hoisting appliance, in which method a plurality of wires (3) are directed into at least one outer wire layer (L) as a part of the rope (1,4,6,14,15), charac teri z ed in that at least a part of the wires (3) of the rope are composite and in the method a) at least a part of the composite wires (3) intended to be a part of the rope (1,4,6,14,15) are coated with polymer b) the wires (3) are directed to be a part of the rope (1, 4, 6, 14, 15) .

13. Method according to claim 12, charac teri z ed in that the method comprises in addition a phase c, in which the formed rope is compressed in order to shape the wires (3) .

14. Method according to claim 13, charac teri z ed in that in the method the wires (3) are heated in conjunction with phase c.

15. Method according to claim 13 or 14, charac t eri z ed in that in phase a the polymer matrix of the composite wire (3) is still in an unhardened state and between phases a and b the composite wires (3) are cooled in order to slow down the hardening of the composite wire (3).

16. Method according any of claims 12-15, charac teri z ed in that in phase a the wires (3) are coated by wrapping a polymer film around them.

17. Method according to any of claims 14-16, charac teri z ed in that the wires contain resin that hardens in heat and in conjunction with phase c the wires (3) are heated to speed up the hardening of the resin of the wires (3) .

18. Method according to claim 16, charac teri z ed in that the wires (3) are heated to a temperature between the softening point of their polymer matrix and the softening point of the polymer film.

19. Method for manufacturing the rope of a hoisting appliance, in which method a plurality of wire bundles (17) are directed into at least one outer wire bundle layer as a part of the rope (15) , charac teri z ed in that at least a part of the wires (3) of which the wire bundles (17) of the rope

(15) are composite and in the method a) at least a part of the wire bundles (17) intended to be a part of the rope (15) are coated with polymer and b) the wire bundles (17) are directed to be a part of the rope (15) .

20. Method according to claim 19, charac teri z ed in that the method comprises in addition a phase c, in which the formed rope is compressed in order to shape the wire bundles (17) .

21. Method according to claim 20, charac teri z ed- in that in the method the wire bundles (17) are heated in conjunction with phase c.

22. Elevator, preferably an elevator of a high lifting height, which comprises an elevator car, roping for moving the elevator car, and a power source for moving the roping, characteri zed in that the roping comprises a rope according to one of claims 1- 11.