Patent ID: 12252843

BEST MODE FOR CARRYING OUT THE DISCLOSURE

FIG.2andFIG.3illustrate essential constructional components of one of the most preferred embodiments for use with high tension powered blocks of the long lived synthetic rope for powered blocks of the present disclosure that is identified by the general reference character1.FIG.2depicts a preferably thermoplastic shaped supportive core3enclosing an optional core2that can be an elongatable conductive structure capable of transmitting information and/or data, or that can be a lead core, or other, the shaped supportive core3being enveloped within a flow shield sheath5. Strength member7encloses the combination of the shaped supportive core3, its enveloping flow shield sheath5and its optional core2. The strength member is formed of several individual primary strands19. The various individual primary strands19preferably are of uniform construction, or of similar construction. Each of the individual primary strands19is enclosed within a distinct primary strand sheath21. The individual primary strands19are each formed of fibres and/or filaments that are formed of the second synthetic substance, that preferably is an Aramid. Each of the distinct primary strand sheaths21are formed of the third synthetic substance, and preferably formed of either a wrapped tape of PTFE or a braided sheath formed of PTFE, HMPE or UHMWPE.

Exterior sheath8preferably is of a braided construction and is adhered to strength member7by elastic adhesive substance layer9, that preferably is formed of a settable adhesive substance such as an adhesive polyurethane having a high elasticity and a high shear strength, such as a two or more component PUR. Preferably braided exterior sheath8is formed of multiple coverbraid strands10by use of a braiding machine, the coverbraid strands10preferably are of a laid construction. Preferably, there are thirty-two individual strands10forming the coverbraided exterior sheath8, each strand10having between twenty-four to thirty-six UHMWPE or HMPE fibers in each strand, preferably of a abrasion resilient construction. However, any quantity of strands10forming the coverbraided exterior sheath8that provide sufficient wear resistance and strength transfer to the strength transfer to the strength member are useful, including but not limited to twenty-four, twenty-eight, thirty-six, forty-two, forty-eight, up to sixty-four and even much more. The braid tension on each strand10forming the coverbraided exterior sheath8during braiding operations is preferably about sixty-three kilogram, and can be from forty to one hundred sixty kilograms. Importantly, the braid tension on each strand forming a braided primary strand sheath21during braiding operations of any such braided primary strand sheath21when a braided sheath variant is selected for the primary strand sheaths21is lesser per strand forming a braided sheath21in comparison to the braid tension used per strand10during braiding operations when forming the coverbraided exterior sheath8. The braid tension on each strand forming a braided primary strand sheath21during braiding operations of any such braided primary strand sheath21is preferably about seven kilograms, and can be from ten grams to thirty kilograms, though optionally it is nine times less than the braid tension used per strand10during braiding operations when forming the coverbraided exterior sheath8, and is at least forty percent less.

Optionally, and preferably, as shown in more easily visible detail inFIG.3, elastic adhesive substance gap filling surface layer13fills in depressions on the surface of rope1formed in between adjacent coverbraid strands10. The core2is optional, and is preferred for deep sea deployment and retrieval applications, trawl warp applications and in the case of certain other applications, but not necessarily in the case of anchor lines and deep water oil derrick mooring and/or anchoring lines or yachting lines, although in some cases it may be used in such applications.

Shaped supportive core3also defines the first synthetic portion of the rope of the present disclosure mentioned above, and elastic adhesive substance layer9also defines the second synthetic portion of the rope of the present disclosure as mentioned above.

In order to form the rope of the present disclosure:

Preferred Fabrication Methods

There are two preferred embodiments of the present disclosure: one is a rope of the present disclosure for use in applications where the rope of the present disclosure is subject to storage under high compressive pressure, such as when used with high tension winches and drums, such as when used as a trawler's warp; another is where the rope of the present disclosure is not subject to storage under high compressive pressure, such as is common in many yachting applications.

In forming a preferred embodiment of the present disclosure for use in applications where the rope of the present disclosure is subject to storage under high compressive pressure:

First is provided a plurality of fibres and/or filaments formed of the second synthetic substance, that preferably is an Aramid, and preferably a new fibre known as T200WD. The fibres and/or filaments are used in forming several distinct primary strands19. Preferably, twelve distinct primary strands19are formed. The primary strands19may be stranded directly from the fibres and/or filaments, or, first yarns may be formed and the yarns used to form the primary strands19. The primary strands19may be braided, including loosely braided so as to provide noticeable constructional elongation, but twisted, and especially lightly twisted, as suitable for Aramids, and using known methods for forming strands formed of Aramids for use in forming a braided rope, is preferred.

Second, each of the distinct (the term “distinct” herein including “individual”) primary strands19is enclosed within a distinct sheath21, known also herein as a “primary strand sheath”. Each distinct primary strand sheath21preferably is formed of a third synthetic substance having properties taught supra, and especially is formed of PTFE, but less preferably of HMPE or UHMWPE. The individual primary strand sheaths21may be formed by wrapping a tape formed of PTFE about each strand in such a fashion that edges of the tape overlap one another. The extent of the overlapping is such that after stretching steps taught herein the tape continues to cover all of the exterior of any distinct primary strand19about which the tape is used to form a distinct primary strand sheath21. A fifty percent overlap is considered useful. However, it is presently preferred to form each of the distinct primary strand sheaths21as a braided sheath, where strands formed of PTFE may be used as strands to form each such braided primary strand sheath21. Alternatively to PTFE, UHMWPE is also a suitable substance for the third synthetic substance, or tape like filaments of HMPE. When a braided sheath is selected for the individual primary sheaths21, it is preferred to select to form the braided individual primary sheaths21with a braid angle that differs from the braid angle of any exterior sheath8that may be formed in subsequent steps as described herein and below. Most preferably, the braid angle selected for forming the braided individual primary sheaths21is a braid angle that is lesser than a braid angle selected for forming the exterior sheath8, i.e. that is a “longer braid angle” or a “more acute” braid angle in comparison to a braid angle selected for forming the exterior sheath8, the terms “longer braid angle” and “more acute braid angle” having the same meaning and being readily understood by those skilled in the art. The braid angle selected for the individual sheaths21may be similar (including “same”) as the twist angle selected for forming primary strands19from fibers. That is, the same angle defined by fibers and/or filaments, or by yarns, forming primary strands19, relative to the long axis of a straight (not bent) primary strand19, can be selected as the braid angle for forming the individual sheaths21when it is selected to form the individual sheaths21with a braided construction, and preferably with a hollow braided construction, as described in more detail below

Third, several, and preferably twelve of distinct primary strands19each enclosed within a distinct prima strand sheath21.

Fourth, the primary strands19now enclosed within primary strand sheaths21are used to form a braided strength member having a hollow braided construction that is achieved by using a braiding machine to form the twelve (or other quantity) of primary strands19each enclosed within a distinct sheath21about a thermoplastic rod that forms the core3, where the primary strands19are formed in a hollow braided construction about the thermoplastic rod forming the core3. While twelve strands19are preferably preferred, it is possible to use from eight to forty-eight. Alternative to hollow braided, the strength member may be parallel laid, laid (including twisted) or plaited, but a hollow braided construction is preferred. It is highly preferably and important for a preferred embodiment of the instant disclosure that a hollow braided strength member is selected that has a thermoplastic core shaped so as to support the natural interior shape of the hollow braided strength member under tension approaching breaking strength of the strength member. Preferably, for a strength member is provided a braided strength member where the primary strands19forming the strength member have been stretched so as to remove constructional elongation and so as to cause compaction of the rope body, e.g. of the strength member and all contained within it, after the primary strands19have been braided into the strength member, so that the resultant strength member is unable to elongate greater than 5% before reaching break point when measured at an original tension of 1000 Kg, and preferably so that the resultant strength member is unable to elongate greater than 4% before reaching break point when measured at an original tension of 1000 Kg.

In forming a strength member for the preferred form of the instant disclosure the following further steps are employed:

First; a thermoplastic elongate object and especially a core formed of Polyethylene is provided, e.g. a PE rod, that ultimately forms core3.

Second; a tightly woven braided flow-shield sheath5is braided around the thermoplastic rod. Filaments are selected to form the flow-shield sheath that are not made either liquid or semi-liquid at a temperature selected to change the phase of the thermoplastic rod, but rather that have a much higher softening point, and that are made of a synthetic substance unlike the synthetic substances of either the first, second, third or fourth synthetic substances, thus defining a fifth synthetic substance. Polyester is suitable.

Third; the primary strands19where each strand19is enclosed by a distinct primary strand sheath21are loaded onto bobbins that are loaded onto cars of a braided machine capable of forming hollow braids and are braided around the thermoplastic rod surrounded by a flow-shield sheath, so as to form a hollow braided strength member including a thermoplastic core surrounded by a flow-shield sheath.

Fourth; the braided strength member having the thermoplastic rod surrounded by the flow-shield sheath as its core is then subject to tension and to heat, preferably by being subject first to tension and secondly to heat, while maintaining the tension, in such a fashion and under such conditions that the thermoplastic selected to form the thermoplastic core becomes semi-liquid, i.e. molten, at a temperature that is used to permanently elongate the braided strength member by applying about thirteen percent of the cool strength member's breaking force to the heated strength member. The flow shield-sheath mainly or entirely stops the phase changed thermoplastic core from exiting the flow-shield sheath. That is, the majority of the thermoplastic core is unable to exit the flow-shield sheath even when the thermoplastic core is either liquid or semi-liquid, i.e. molten, despite enormous constrictive and compressive forces applied to the phase changed thermoplastic core as a result of the high tensions applied to the strength member, such high tensions able to permanently elongate the strength member under the conditions taught supra and herein.

A preferred tension to be used in the disclosed processes for forming the disclosed rope is about thirteen to fifteen percent (13-15%) of the break strength of the strength member when such break strength is measured at room temperature, with up to twenty-two percent being useful, and in some cases even more.

Importantly, the tension applied to the strength member, and thus necessarily also applied to the filaments forming the strength member, preferably is a static tension and/or a generally static tension and/or a very slowly fluctuating tension. After applying a predetermined tension (including approximately a predetermined tension), and while under such predetermined tension simultaneously the strength member, its filaments, and its thermoplastic core are heated to a predetermined temperature and/or to approximately a predetermined temperature as taught above and herein, with a minimum temperature of eighty (80) degrees C. being most preferred. The use of a long oven having many capstans able to accommodate a very long length of the strength member and turning at varying speeds and/or rates of rotation so as to maintain the tension on differing portions of the strength member located between different capstans, and thus by extension on the filaments forming the strength member as well as on the thermoplastic core also forming the strength member is highly useful, especially for permitting an endless flow production process.

Fifth; when the braided strength member and its thermoplastic core and the thermoplastic core's flow shield have been elongated to a predetermined amount so as to create an ultra-compact rope, and to experience a reduction in overall exterior diameter of the rope of thirty and up to forty-five percent in comparison to the rope's overall exterior diameter prior to the stretching and heat processing steps, the now elongated strength member and its elongated thermoplastic core are cooled while sufficient tension is maintained and applied to the strength member and thus by extension to its primary strands19and to its thermoplastic core3during the cooling process so that all such components are cooled to their respective solid states while under a tension that results in the cooled primary strands19as well as the cooled distinct primary strand sheaths21enclosing the primary strands19, as well as the strength member and its thermoplastic core3, having been permanently elongated so as to cause the strength member:a) to acquire a lower elongation than it had prior to its having been permanently elongated;b) to acquire a substantially lesser diameter and a greater compactness than it had prior to its having been permanently elongated;c) to acquire to its thermoplastic content core a permanent solid shape, having at its surface the flow shield sheath also taking the same shape as the exterior of the core, that supports the interior cavity of the permanently elongated hollow braided strength member in such a fashion that the filaments and braid strands forming the strength member are sufficiently less able to move relative to one another in a direction perpendicular to the long dimension of the permanently elongated strength member in comparison to prior to the strength member having been permanently elongated so as to reduce filament to filament abrasive wear, and also so as to preclude crushing of the rope, especially under high compressive forces such as occurs during winding and storage on a high tension drum, the necessary tension to achieve such result for any particular filament type able to be experimentally determined by one of ordinary skill in the art after having read the present disclosure.

This cooling also is best accomplished and undertaken using capstans turning at varying speeds so as to maintain a tension on the elongated strength member and its components during the entire cooling process and period that precludes their shortening, so that the final cooled strength member has the values of elongation to break point as taught above and herein for a most preferred embodiment of the instant disclosure, and also the other properties taught as above and herein, as also is accomplishable in an endless flow production method.

Sixth; optionally, and preferably, an elastic adhesive substance, that is a fourth synthetic substance, is used to adhere the formed strength member to an exterior braided sheath8. The fourth synthetic substance is chosen as a flowable settable adhesive substance. While it is in a liquid and/or semi-liquid (including “flowable”) phase it is situated upon the outside surface of the preferably permanently elongated strength member, in contact with surfaces of multiple of the distinct primary strand sheaths21formed of the third synthetic substance. Then a preferably braided exterior sheath8is formed about the combination of the permanently elongated strength member and the flowable settable adhesive substance. The settable adhesive substance is situated upon the strength member at temperature that is lower than a phase change temperature of third synthetic substance. When a braided sheath is selected for the individual primary strand sheaths21, it is preferred to select to form the braided individual primary strand sheaths21with a braid angle that differs from the braid angle of the exterior sheath8. Most preferably, a braid angle selected for forming braided individual primary strand sheaths21is a braid angle that is lesser than a braid angle selected for forming the exterior sheath8. The braid angle of the inner sheath21is an angle defined between (i) an imaginary line lying coaxial and parallel to the long axis of the primary strand19enclosed by the braided primary strand sheath21when the primary strand19is not curved or bent, but is straight; and (ii) a long dimension visible for any individual braid strand forming the braided construction of a primary strand sheath21when viewed in plan photographic view and when the primary strand19enclosed by the primary strand sheath21is straight (not bent). Similarly, the braid angle of the exterior sheath8is an angle defined between: (a) an imaginary line lying coaxial and parallel to the long axis of the rope when the rope is straight; and (b) a long dimension visible for any individual braid strand forming the braided construction of exterior sheath8, when viewed in plan photographic view when the rope is straight.

Contrary to the state of the art, knowledge in the field and trend in the industry for forming braided sheaths, the braid angle selected for the individual sheaths21may, preferably, be similar (including “same”) as the twist angle selected for forming primary strands19from fibers. That is, the same angle defined by fibers and/or filaments, or by yarns, forming primary strands19, relative to the long axis of an straight primary strand19, can be selected as the braid angle for forming the individual sheaths21when it is selected to form the individual sheaths21with a braided construction, and preferably with a hollow braided construction.

When selecting to form at least one and preferably all of the individual primary strand sheaths21with a braided construction; this process step is further, and most preferably, modified by additionally selecting a braid tension for forming at least one, and preferably all, of the braided individual sheaths21that is a braid tension that is lesser than a braid tension selected for forming the exterior sheath8about the final formed and final processed strength member that preferably has had the elastic adhesive substance situated exterior the itself, i.e. situated exterior the final processed form of the strength member, prior to the exterior sheath8being braided about the strength member.

INDUSTRIAL APPLICABILITY

Ropes formed by teachings of the present disclosure may be used as crane ropes, deep sea deployment and recovery ropes, tow ropes, towing warps, trawl warps (also known as “trawlwarps”), deep sea lowering and lifting ropes, powered block rigged mooring ropes, powered block rigged oil derrick anchoring ropes used with blocks and also with powered blocks, deep sea mooring ropes, deep sea winch lines, superwides and paravane lines used in seismic surveillance including but not limited to being used with towed arrays, yachting ropes, rigging ropes for pleasure craft including but not limited to sail craft, running rigging, powered block rigged anchor ropes, drag lines, and other.

Although the present disclosure has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is purely illustrative and is not to be interpreted as limiting. Consequently, without departing from the spirit and scope of the disclosure, various alterations, modifications and/or alternative applications of the disclosure are, no doubt, able to be understood by those ordinarily skilled in the art upon having read the preceding disclosure. Accordingly, it is intended that the following claims be interpreted as encompassing all alterations, modifications or alternative applications as fall within the true spirit and scope of the disclosure.