Hybrid cable for reinforcing polymer article and reinforced article

Abstract

A hybrid cable having a core and a belting; the core is made of carbon fiber yarns or carbon fiber strands or bundles of yarns; and the wrapping tape is made of a plurality of metal wires wrapped around the core in a spiral shape, and the plurality of metal wires are laid side by side without crossing each other. The fibers, yarns, or cores may be sized with a polymer, finished with a binder, or binder. The wire may be steel and may have a coating such as a brass or zinc plating, or a polymer coating or finish. The hybrid cable may be used to reinforce a composite article such as a tape, track or hose.

Description

[0001] This application is a divisional application of the invention patent application entitled “Hybrid cables and reinforced products for reinforced polymer products”, with an international application date of April 7, 2017, an international application number of PCT / US2017 / 026686, and a national application number of 201780029980.X. Background of the Invention

[0003] The present invention relates generally to multi-component cables useful for reinforcing polymeric articles, more particularly to hybrid cables reinforcing steel and carbon fibers for reinforcing elastomeric or plastic products such as reinforced thermoplastic elastomers or rubber articles, including reinforced articles such as belts, hoses and rails.

[0004] US Patent No. 7814740 B2 discloses a cord for rubber reinforcement. US Patent Publication No. 2015 / 0233027 A1 discloses a hybrid cord for tires. US Patent No. 6334293 B1 discloses a steel cord with a polymer core. Summary of the invention

[0005] The present invention relates to systems and methods that provide hybrid cables of steel wires wrapped around a carbon fiber core. The hybrid cables can provide reduced weight while providing comparable or enhanced strength and increased flexibility compared to conventional all-metal cables or steel cables. The present invention also relates to hoses, tapes, and other enhanced products incorporating the hybrid cables.

[0006] The hybrid cable comprises a core and a tape; the core is formed of carbon fiber yarn or a bundle of carbon fiber yarns; and the tape has a plurality of metal wires wrapped helically around the core, the plurality of metal wires being laid side by side without crossing each other. The tape may preferably be a single layer of metal wires. The plurality of metal wires may be laid side by side in a layer, typically filling the layer, with no spaces between the wires. Alternatively, the plurality of metal wires may be laid side by side in a layer, not completely filling the layer and with some spaces between the wires.

[0007] The core may advantageously comprise a finish, for example a polymer-based composition, which at least partially penetrates the interstices between the carbon fibres of said core. Alternatively, the core may have no other finish than the optional sizing applied to the carbon fibres.

[0008] The carbon fiber yarn of the core can be in a plurality of carbon fiber yarns in a cabled configuration, each twisted in a first twist direction with a first twist coefficient, and then combined and twisted together in a second twist direction with a second twist coefficient. The second twist direction can be opposite to the first twist direction. The first and second twist coefficients can be approximately equal, or the second twist coefficient can be greater than the first twist coefficient. For example, the ratio of the second to first twist coefficients can be 2-6 or about 4-5.

[0009] The direction of wrapping the thread may be the same as the first twisting direction. The direction of wrapping the thread may be opposite to the first twisting direction.

[0010] The core may be a laid bundle of carbon fiber filaments or yarns, with only a first twist direction. The direction of the wrapping threads may be the same as or opposite to the core laid direction.

[0011] The wire may be carbon steel or stainless steel and may have a coating such as brass, zinc, copper, tin or a polymer or polymer-based coating. The hybrid cable may be coated with a polymer coating or embedded in one or more polymer materials. Alternatively, the hybrid cable may be uncoated.

[0012] The present invention also relates to a composite article comprising a polymer body in which the hybrid cable of the present invention is embedded. The material of the polymer body can penetrate between the filaments and can at least partially contact the core or penetrate into the core. Examples of such composite articles include hoses, strips, or rails for rail-bound vehicles reinforced with hybrid cables.

[0013] The hose...

[0014] The strip ...

[0015] The foregoing has broadly summarized the features and technical advantages of the present invention so that the detailed description of the present invention below can be better understood. Additional features and advantages of the present invention will be described below, which form the subject matter of the claims of the present invention. Those skilled in the art will appreciate that the disclosed concepts and specific embodiments can be used as a basis for improving or designing other structures to carry out the same purpose of the present invention. Those skilled in the art will also appreciate that such equivalent constructions do not depart from the scope of the present invention described in the appended claims. From the following description, when considered in conjunction with the accompanying drawings, the new features (which are believed to be the characteristics of the present invention, both its organization and method of operation) and additional objects and advantages will be better understood. However, it will be clearly understood that each of the accompanying drawings is provided for display and illustration purposes only and is not intended to be a definition of limiting the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings, which are incorporated in and form a part of the specification (in which like numerals represent like components), illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. In the drawings:

[0017] Figure 1 is a schematic cross-sectional view of a hybrid cable according to one embodiment of the present invention;

[0018] Figure 2is a schematic cross-sectional view of a hybrid cable according to another embodiment of the present invention; and

[0019] Figure 3 is a schematic cross-sectional view of a hybrid cable according to another embodiment of the present invention;

[0020] Figure 4 is a partial fragmentary perspective view of a strip having hybrid cable reinforcement;

[0021] Figure 5 is a cross-sectional view of a hose having hybrid cable reinforcement;

[0022] Figure 6 is a partial fragmentary diagram of a hose having two layers of hybrid cable reinforcement;

[0023] Figure 7 is a partial fragmentary diagram of a hose having six layers of hybrid cable reinforcement;

[0024] Figure 8 is a fragmentary view of a portion of a V-belt according to one embodiment of the present invention; and

[0025] Fig. 9 FIG. 4 is a partial fragmentary diagram of a synchronous belt according to an embodiment of the present invention. DETAILED DESCRIPTION

[0026] The hybrid cable of the present invention has a carbon fiber cord as a core and steel wires wrapped around the core. Figure 1 A schematic cross-sectional view of one embodiment of a hybrid cable is shown. Figure 1 , the hybrid cable 10 includes a core 12, which is shown as a cord made of bundles of six strands 14. The six strands 14 are each a bundle of carbon fibers. The core 12 is wrapped with fourteen wraps 16. The fourteen individual wraps 16 are arranged in a single layer around the core so that they do not cross each other. The fourteen wraps 16 are each a single solid filament, so they are preferably not a bundle of more than one filament, i.e., not a "strand". The wraps are spirally wrapped around the core, laid side by side in a parallel manner, not crossing each other, i.e., "parallel laid". Adjacent wraps may be in contact with each other, or there may be spaces or gaps between adjacent wraps, such as Figure 1 It should be understood that Figure 1 The drawings are not to scale and the shapes are representative and not necessarily accurate. For example, the shape of the strand 14 is Figure 1The centerline strand does not necessarily represent a permanent centerline strand, as it may migrate to other locations along the length of the core. The cross-sectional shape of the wire 16 may be slightly out of round (due to manufacturing tolerances) or appear elliptical in the cable cross section (due to the helix angle of the wire). Alternatively, the wire may be flattened or have another desired shape instead of the circular shape typically shown.

[0027] The following definitions apply herein and in the claims.

[0028] "Base yarn" or "single yarn" refers to a bundle of filaments or fibers, which is the form purchased from the base yarn manufacturer, which may include twisted yarns or untwisted yarns. "Strand" or "yarn" or "ply" refers to the base yarn or such yarn, which has been closed or twisted or ply in the intermediate step of forming the cord. "Strand" therefore refers to one of many yarns, which are twisted together to form the cord. "Ply" refers to one or more bundles of yarns that each have minimal or no initial twist and are twisted together in the first direction. Usually in the field of cables, similar terms are used. The smallest component or basic element of the cable is a single "wire". The strands that are said to constitute the cable usually include many wires, which are laid around the central wire. Finally, the strands of many wires are typically wrapped around the core to make the cable. But in this case, the sheath is a single single wire, so that they will not be so-called strands here. "Cord" refers to one or more strands, plies or yarns that have been twisted or ply together in the final step of forming the cord for the core. "Cable" or "hybrid cable" refers to a rope-like structure comprising a core carbon fiber cord wrapped with filaments. "Filaments" are metal filaments of generally circular cross-section that can be combined to make a cable, rope, or more specifically, wrapped around a core to form a hybrid cable of the present invention.

[0029] The term "twist factor" or "TM" as it applies to the practice of the present invention will be used to describe the twist characteristics and is defined as the ratio of twists per inch (TPI) to the square root of the number of yarns. The number of yarns is defined as the ratio of 5315 to the end denier (g) per 9000m. Thus, the following equation defines the twist factor:

[0030]

[0031] The carbon fiber cord in the core of the hybrid cable can be a monofilament bundle base yarn (or single yarn) with minimal or no twisting, or it can be a plying construction greater than one base yarn. The carbon fiber cord can be composed of many carbon fiber strands. Each strand can be composed of one or more base yarns, which can have a first twist amount and a twist coefficient in a first twisting direction. The strand can be plyed or merged with a strand twisted together with a second twist amount and a second twist coefficient to form a cord. The number of base yarns and strands in the cord can usually be selected to produce a cord of any desired size in a hybrid cable. For the enhanced application of flexible polymer composite products, when using a cable diameter up to about 8mm, etc., some useful ranges for hybrid cable design parameters can be claimed.

[0032] Regarding the design of the carbon fiber core, the strands can be made of 3k-24k or greater (based on conventional filament count) carbon fiber single yarns. The strands can be composed of 1-8 such yarns. The first twist amount can be 0 or 0.3-3.0 tpi (twists / inch), or 10-120 tpm (twists / meter). The strands can be plied with a second twist amount of 0, or plied with the same range as the first twist of the strands, the same twist direction, or the opposite direction of the first twist of the strands, but preferably the second twist direction is opposite to the first twist direction. Preferably, the second twist amount is greater than the first twist amount. Preferably, the second twist coefficient is greater than the first twist coefficient. The ratio of the second twist to the first twist can be 2-6 or about 4-5. Optionally, the first and second twist coefficients can be approximately equal. Optionally, the core can be a bundle of carbon fiber filaments or yarns, that is, one or more single yarns can be folded together in a single twist direction to form the core.

[0033] To describe the number of base yarns and strands used to construct the cord, the following convention will be followed: "yn / m" = an integer "n" of base yarns with "y" filaments per end forming each "m" strand of cord. Therefore, the total strand size after the first twisting step is the product of "y" times "n". The total cord size (number of filaments) after the second twisting step is the product of "y" times "n" times "m". Therefore, Figure 1 The core cord of the embodiment shown (assuming the strands have 12k (12,000) filaments each) would be a 12k-1 / 6 cord construction, and the total filament count would be 72k.

[0034] The method and machine used for twisting and plying the strands and cords are not particularly limited. Suitable textile twisting machines include, for example, ring twisting machines, two-in-one twisting machines, direct cabling machines, and any other twisting machines known in the art.

[0035] Carbon fibers for cords may include sizing by the carbon fiber manufacturer to enhance processability or performance. Sizing is typically applied at about 1% by weight. For carbon fibers for hybrid cables, any commercially available sizing or no sizing may be specified, depending on the desired cord handling properties, compatibility with subsequent finishing, or performance characteristics. In one embodiment, the core has no additional finishing other than sizing.

[0036] Carbon fiber cords for hybrid cables can advantageously be finished with one or more subsequent finishing compositions and application methods using any suitable and / or conventional materials in order to protect the fibers, bind them together, or establish or improve their adhesion to the surrounding polymer components of the article. For example, the cord can be finished with one or more adhesives to bind the filaments to each other and promote adhesion of the cord to the elastomeric portion of the article. As a non-limiting example, the cord can first be finished with a primer (or only with a primer), which can be a water-based or solvent-based primer, such as a polyisocyanate, polyurethane or epoxy compound. The primed cord (or primer-free cord) can then be finished with another suitable adhesive such as resorcinol formaldehyde latex (RFL), or other polymer-based formulations. After each finish, the cord is typically sent through an oven or a series of ovens, typically at a temperature of 100°C-300°C, to dry or cure the finish. The finish can increase the weight of the cord by 5%-30%. Optionally, the cord can then be finished with an additional outer coating binder, such as a high emulsion, a mixture of a pigment and a curing agent in a water-based medium, or a mixture of a pigment and a curing agent with a dissolved polymer in a solvent solution, or other suitable rubber glue, for additional adhesion improvement or bonding. The outer coating can increase the weight of the cord by 2%-10%. One or more of the above-mentioned finishes can be applied to the base yarn or individual strands (before or after twisting) instead of the final cord (or in addition to the final cord). The finish can be applied by dipping, spraying, wiping, pultrusion, etc. All of the above finishes can be solvent-based, water-based, thermoplastic or thermosetting. The finish can at least partially penetrate or fill the gaps between the carbon filaments of the core.

[0037] With respect to the wire wrap, any desired number of wire wraps may be used, but preferably 4-20 wire wraps are used. The coverage of the core by the wire wrap will depend on the diameter of the core, the diameter of the wire wrap, the number of filaments and the lay length. Lay length is commonly used in the cable industry to describe the wrap rate or helix angle of the wire wrap, replacing the tpi or tpm (turns or twists per inch or meter) used in textile cord construction. Lay length is the distance along the core where the filaments complete a full wrap (360°). Typically, the wire wrap may completely cover the core, or there may be spaces or gaps between the filaments.

[0038] The wire envelope can be all Figure 1 Alternatively, wires of more than one diameter may be used. Figure 2 A hybrid cable is shown comprising an 8-strand core and a so-called Warrington wire wrapping tape, which alternates two diameters of sheath around the core. Figure 2 In the embodiment, the hybrid cable 20 has a core 22 composed of 8 carbon fiber strands 24, with smaller diameter wires 26 and larger diameter wires 25 wrapped alternately. Other constructions can be used, including additional wire layers, seale constructions, filled wire constructions, etc. The core can include a coating or core finish 28 as described above.

[0039] Figure 3 A third embodiment of a hybrid cable is shown. Figure 3 In FIG. 4 , hybrid cable 30 has a single stranded carbon fiber core 32 that is surrounded by seven wrapping wires 36. Cable finish 38 may coat or encompass the entire cable, as described further below.

[0040] The direction of the wire wrapping can be in either direction, but preferably the wire wrapping direction is the same direction as the first twist direction in the core, or opposite to the second twist direction of the core. The wire can be produced, for example by drawing a rod, using any device known in the art.

[0041] The wire may be carbon steel or stainless steel. The wire may have a coating for adhesion or for corrosion protection, such as brass, bronze, tin, copper or zinc plating or an organic coating material such as a silane coupling agent or an epoxy sizing formulation or a polymer-based formulation.

[0042] In order to maximize the weight reduction resulting from replacing a metal core with a carbon fiber cord, a single layer of sheathing is preferred, which has a small wire diameter relative to the core diameter. The theoretical weight reduction potential from a metal core of the same diameter to a carbon fiber core is relatively easy to calculate from the density of the carbon fiber cord and metal wires, the number and diameter of the sheathing wires, and the core diameter. For example, if the core and sheathing wires are approximately the same diameter, 6 wires will fill the tape layer and the potential weight reduction is only about 11%. However, if the sheathing wire is about 2 / 3 the diameter of the core wire, 7 wires will complete the tape layer and the potential weight reduction is about 19%. If the sheathing wire is about 1 / 4 the diameter of the core wire, 14 wires will fill the tape layer and the potential weight reduction reaches about 40%.

[0043] Tables 1 and 2 provide some examples ("Ex.") of hybrid cables and some comparative examples ("Comp.Ex.") of conventional cables to show the potential for weight reduction at comparable strength, and to show the diversity of hybrid constructions that are expected. Comp.Ex.1 is a conventional 1x19 cable (1+6+12). In some exemplary embodiments, as shown in Ex.2 and Ex.6, the carbon fiber core diameter of the hybrid cable can be 2.00-3.00 mm, and the cable diameter can be 3.00-4.00 mm, and the single layer, sheath diameter can be 0.50-1.00 mm. Such a hybrid cable can be approximately 30% lighter than a comparable all-metal cable (as shown in Comp.Ex.1 and Comp.Ex.5), but can have comparable or better tensile strength and modulus. Some of the examples are based on actual measurements, while others are based on empirical predictions, estimates or inferences of similar materials. These examples should be considered estimates of the possible performance of the hybrid cables of the present invention.

[0044] In other embodiments, as shown in Ex. 4, the carbon fiber core diameter of the hybrid cable can be 0.5-1.00 mm, and the cable diameter can be 1.00-2.00 mm, and the single layer, the sheath diameter can be 0.30-0.80 mm. Such a hybrid cable (as shown in Ex. 4) can be almost 20% lighter than a comparable all-metal cable as shown in Comp. Ex. 3, but can have comparable or better tensile strength and modulus.

[0045] In other embodiments, as shown in Ex.7-Ex.9, the carbon fiber core diameter of the hybrid cable can be 2-5 mm, and the cable diameter can be 3-6 mm, and the single layer, sheath diameter can be 0.50-1.0 mm. Such hybrid cables are as much as 50% lighter or more than all-metal cables of comparable diameter. Alternatively, a hybrid cable of similar weight to the cable can have significantly higher strength, as can be seen by comparing Ex.9 (actual strength unknown, but expected to be well above 20 kN) with Comp.Ex.5.

[0046] Ex.6 in Table 2 represents a Warrington tape, hybrid cable, which uses 7 wraps of two diameters each, namely 0.56 and 0.77 mm in diameter, alternating around the core. Comp. Ex.5 is a conventional 1x24W cable. Likewise, other conventional types or arrangements of wire wraps are contemplated.

[0047] Table 1.

[0048] Comp.Ex.1 Ex.2 Comp.Ex.3 Ex.4 type Cable Hybrid Cable Cable Hybrid Cable <![CDATA[Structure 1 > 1x19 12k-1 / 6+12(0.70) 1(0.84)+7(0.56) 12k-1+7(0.56) Core diameter(mm) 2.15 2.3 0.84 0.838 Overall diameter(mm) 3.55 3.7 1.96 1.96 Linear density (g / m) 59 43 18 14.7 Weight reduction (%) - 27 - 19 Tensile strength(kN) 17.4 17.8 5.5 5.3

[0049] 1 The wire diameters in brackets are in mm.

[0050] Table 2.

[0051]

[0052]

[0053] 1 The wire diameters in brackets are in mm.

[0054] The hybrid cable has many potential uses, for example replacing ropes or cables where weight reduction is desired. The hybrid cable may be flexible enough to be used as a tensile element in a dynamic composite article such as a belt, rail or hose.

[0055] "Belt" includes flat belts, V-belts, round belts, ribbed or otherwise profiled belts, and toothed belts, whether endless or open-ended, used, for example, for transmitting mechanical power, motion control, transportation, etc. Figure 4 A tape 40 is shown having hybrid cables 10, 20, 30 as tensile elements embedded in a polymer tape body material 45. "Tracks" refers to various belt-like circular tracks used for traveling vehicles such as snowmobiles, construction equipment and agricultural equipment. "Hose" includes hydraulic hoses, delivery hoses, etc. Figure 5 A cable reinforced hose 50 is shown having hybrid cables 10 , 20 , 30 embedded as reinforcement material in a polymeric hose body material 55 .

[0056] The hybrid cable can be coated with a polymer material or protected with a binder finish or for compatibility with the polymer body of the composite material product that can be embedded therein to enhance the product. The outer coating can be applied using a method similar to the above-mentioned cord finish. The material of the polymer body can penetrate between the filaments and can contact with the core or at least partially penetrate into the core. Therefore, the space between the wires can be allowed to mechanically adhere to the polymer body of the composite material product.

[0057] Polymer products can be based on rubber composites, which are normally mixed with different fillers, antidegradants and curing agents, and are vulcanized into the shape of final products.Polymer products can be based on thermoplastics or thermoplastic elastomers, which can also be mixed for specific performance.This composite polymer product can include multiple polymer materials, for example, in different layers, or different other types of reinforcing materials such as fibers or textiles.

[0058] In other embodiments, for example Figure 6 and 7In the hose embodiment shown, the hybrid cable can advantageously have a carbon fiber core diameter of 0.5-1.00 mm, and the cable diameter can be 0.75 or 1.00 up to about 2.00 mm, and the single layer, the sheath diameter can be 0.15 or 0.20 or 0.30 mm up to 0.80 mm. A specific example of such a hybrid cable is Ex.4 above. The hybrid cable is mainly used for relatively large hose sizes where wire reinforcement is impractical. The practical limitation for wire-reinforced hoses is that the wire diameter is a maximum of about 0.8 or 0.9 mm. Thicker wires are difficult to process, which exhibit fatigue problems, and tensile strength problems. Therefore, cables are required for larger diameter hoses. Such hoses that require high working pressures will benefit from the present invention. Including, for example, hydraulic hoses and various oil and gas field hoses such as blowout preventer hoses, rotary drilling hoses, etc. The hydraulic hose can include 2-6 spiral hybrid cable layers, preferably an even number. The nominal inside diameter of a hydraulic hose may be from 3 / 4 inch to approximately 3 inches.

[0059] Oilfield hoses may typically have larger nominal inside diameters, such as about 2 inches to about 6 inches. Hybrid cables for these hose applications may advantageously be in the range of about 2 mm and higher, or 2 mm to 4 mm. About 3.5 mm hybrid cables may advantageously be used to construct these sizes. Ex. 2 and Ex. 6 above are examples of suitable hybrid cable constructions for oilfield hoses, as shown in Ex. 7-9. Higher operating pressure requirements for hydraulic or oilfield hoses require more hybrid cord reinforcement layers, preferably 2-6 or 2-8 layers.

[0060] The hose of the present invention may include one or more additional layers. The hose may have a friction layer, a rubber and / or fabric layer between each layer of the hybrid cable to prevent friction between cable sections. The hose may have one or more fabric layers, for example as an additional reinforcement or to support the cable during the hose construction process. The hose may have one or more inner tube layers, an outer covering, a protective outer layer, etc., which may be a plastic or elastomer, or a textile. The hybrid cable is preferably applied by spiraling, but may be applied by braiding. The hybrid cable may be applied by conventional methods with conventional design parameters, including using a neutral angle for spiraling the hybrid cable.

[0061] Possible hose configurations are Figure 6 and 7 shown. Figure 6 The embodiment of FIG. 1 shows a hose 60 having an outer cover 62, two spiral reinforcement layers 64 and 66 made of hybrid cable and wrapped in opposite directions, and an inner tube 68. Between the reinforcement layers 64 and 66 is a friction layer 65. The composition of the inner tube, outer cover, and friction layer can be any composition described herein.

[0062] Figure 7 A hose 70 is shown having an outer cover 72 and an inner tube 78. There are three pairs of spiraled cable layers, with layers 74, 74' and 74" spiraled in one way, and layers 76, 76' and 76" spiraled in the opposite direction. Between each hybrid cable layer is a friction layer 75. Included in the hose 70 is a fabric buffer layer 77, which is between the inner tube 78 and the first applied cable layer 76". The layer composition can be as described anywhere herein.

[0063] Strip

[0064] Figure 4 A flat strip 40 is shown which may represent various specific flat strip applications such as conveyor belts and various other long distance transport belts, lifting belts for elevators, garage doors and other lifting systems, etc. Other strip embodiments using hybrid cords are shown in FIG. Figure 8 and 9 middle.

[0065] Figure 8 A portion of a belt 80 is shown in the form of a relatively wide V-belt, which is a configuration commonly used in variable speed applications. However, any V-belt may use the hybrid cord. Variable speed applications and other high load, heavy or high speed applications may particularly benefit from the high strength and flexibility of the hybrid cord. Figure 8 8, V-belt 80 has relatively angled sides 81 and 82, which are the normal contact surfaces when the belt is used on a V-shaped pulley or sheave. The inner surface 83 and the outer or back surface 87 are shown as smooth, but either or both of them can be cogged, i.e., have a corrugated profile to improve flexibility or reduce noise. The helically wound hybrid cable 10, 20 or 30 can be embedded in an elastomeric adhesive layer 85, with a compression layer 84 below the cord layer and an expansion layer 86 above the cord layer. Layers 84, 85 and 86 can include any suitable elastomeric composition, fabric covering or embedded fabric layer, etc. When the hybrid cable reinforcement is spirally taped in a thick sheet manufacturing process and then cut into individual strips, there will be exposed cable cut portions at the edges of the strip, as shown by edge cords 88.

[0066] Fig. 9A portion of a timing belt 90, also referred to as a toothed belt, is shown. The belt 90 includes a tensile layer 92, which is composed of a hybrid cable 10, 20 or 30 embedded in an elastomeric compound 95. The belt 90 is shown with a different elastomeric compound as a back layer 93, although the same compound can be used throughout the belt. The belt body 91 can therefore be a single compound, or, depending on the design of the belt, have multiple materials and multiple layers. The belt 90 can have a series of transverse (or inclined) teeth 97 alternating with a base 96 on one or both sides. The toothed surface is typically covered with a sheath 98, which can be a fabric or a rubberized fabric or a thermoplastic or a combination thereof.

[0067] For belt applications, any of the above embodiments may be used, depending on the belt size. Larger diameter cables such as Ex.2, 8 or 9 may be recommended primarily for larger toothed belts, up to 32 mm pitch toothed belts or for so-called "XH" or "XXH" tooth profiles, or for large agricultural equipment with variable speed V-belt travel. Ex.2 and 4 may be recommended for heavy industrial belts, such as 14 mm pitch toothed belts or "H" tooth profiles. Some cable designs (which may be suitable for smaller toothed belts) are shown in Table 3. Ex.11 is a hybrid cable with a 6k carbon core and a 0.25 mm diameter wire wrap, which produces a final diameter of approximately 1.11 mm, suitable for automatic timing belts and "L" profile industrial toothed belts. The cable diameter can be further reduced by using smaller wires, such as using 0.15 mm or 0.08 mm wires as wraps. Ex.11 can be compared to a full metal cable of similar overall diameter in Comp.Ex.10. Ex. 13 is a smaller hybrid cable that uses a 3k carbon fiber core and a set of 0.08 filaments wrapped around the core. For rail, Ex. 2 is one example size for a hybrid reinforced cable, but again, other examples may be used, depending on the size or scale of the rail and the target application of rail-traveled vehicles.

[0068] Thus, generally for tapes, hybrid cables may advantageously have carbon fiber core diameters in the ranges described, and the cable diameter may be about 0.3 mm up to about 6.00 mm, or 0.5-1.5 mm, or 1-2 mm, or 2-4 mm, 0.75 or 1.00 up to about 2.00 mm, and the single layer, sheath diameter may be 0.08 or 0.15 or 0.20 or 0.30 mm up to 0.5 or 0.6 or 0.7 or 0.80 mm. In tapes, the hybrid cables may provide advantages over all-steel cables, such as lower weight at the same or higher tensile strength to reduce inertial forces. The hybrid cables may provide advantages over all-carbon fiber cords, such as improved adhesion to the tape body elastomer or improved tensile or other physical properties.

[0069] Table 3.

[0070]

[0071]

[0072] 1 The wire diameters in brackets are in mm.

[0073] The tape comprises a tensile element embedded in a polymer body, the tensile element comprising a hybrid cable including a core and a tape; the core comprising a trimmed, twisted carbon fiber yarn or a bundle of carbon fiber yarns; and the tape comprising a plurality of metal wires helically wrapped around the core, the plurality of metal wires being laid side by side without crossing each other.

[0074] The strip is in the form of a power transmission strip, ie a toothed strip, a V-shaped strip, a flat strip or a multi-ribbed strip.

[0075] The strip is in the form of a support strip for an elevator.

[0076] The tape, wherein the wrapping tape comprises a single layer of the plurality of solid metal wires.

[0077] The tape, in which the plurality of metal wires are laid side by side in a layer, typically fills the layer, leaving no spaces between the wires.

[0078] The tape, in which the plurality of metal wires are laid side by side in a layer, does not completely fill the layer and has some spaces between the wires.

[0079] The tape wherein the finish comprises an elastomeric solution or dispersion, such as RFL, latex, primer, ionomer or polyelectrolyte or a combination thereof.

[0080] The tape wherein the carbon fiber yarn of the core comprises a plurality of carbon fiber yarns in a cabled configuration, each twisted in a first direction at a first twist multiplier and then combined to be twisted together in a second direction at a second twist multiplier.

[0081] The strip, wherein the second direction is opposite to the first direction.

[0082] The ribbon, wherein the first and second twist coefficients are substantially equal, or the second twist coefficient is greater than the first twist coefficient, for example, the ratio of the second twist coefficient to the first twist coefficient is 2-6 or approximately 4-5.

[0083] A track for vehicle travel, comprising a hybrid cable including a core and a tape; the core comprising a trimmed, twisted carbon fiber yarn or a bundle of carbon fiber yarns; and the tape comprising a plurality of metal wires helically wrapped around the core, the plurality of metal wires being laid side by side without crossing each other.

[0084] A cable-reinforced hose comprising a helically wrapped reinforcement layer comprising a hybrid cable including a core and a tape; the core comprising a trimmed, twisted carbon fiber yarn or a bundle of carbon fiber yarns; and the tape comprising a plurality of metal wires helically wrapped around the core, the plurality of metal wires being laid side by side without crossing each other.

[0085] The hose is in the form of a BOP hose, a blowout prevention hose, or a rotary drilling hose.

[0086] The hose, wherein the wrapping tape comprises a single layer of said plurality of solid metal wires.

[0087] The hose, in which the plurality of metal wires are laid side by side in a layer, typically fills the layer, leaving no spaces between the wires.

[0088] The hose, in which the plurality of metal wires are laid side by side in a layer, does not completely fill the layer and has some spaces between the wires.

[0089] The hose, wherein the finish comprises...

[0090] The hose, wherein the finish has a modulus, etc., which is in the following ranges...

[0091] The hose, wherein the carbon fiber yarn of the core comprises a plurality of carbon fiber yarns in a cabled configuration, each of which is twisted in a first direction at a first twist coefficient and then twisted together in a second direction at a second twist coefficient to be combined.

[0092] The hose, wherein the second direction is opposite to the first direction.

[0093] The hose, wherein the first and second twist factors are substantially equal, or the second twist factor is greater than the first twist factor, for example, the ratio of the second twist factor to the first twist factor is 2-6 or approximately 4-5.

[0094] Although the present invention and its advantages have been described in detail, it should be understood that different changes, substitutions and variations can be made therein without departing from the scope of the invention as defined by the appended claims. In addition, the scope of the present application is not intended to be limited to the specific embodiments of the processing, machines, manufactures, material compositions, means, methods and steps described in the specification. Because the content disclosed by the present invention will be understood by those skilled in the art that can perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein using existing or later developed methods, machines, manufactures, material compositions, means, methods or steps according to the present invention. Therefore, the purpose of the appended claims is to include such processing, machines, manufactures, material compositions, means, methods or steps within their scope. The invention disclosed herein can be appropriately practiced in the absence of any element specifically disclosed herein.

Claims

1. A tape comprising a polymer body and a hybrid cable embedded in the polymer body, the hybrid cable comprising a core and a tape; the core comprising a carbon fiber yarn or a bundle of carbon fiber yarns and comprising a twist; and the tape comprising a plurality of metal wires wrapped helically around the core, the plurality of metal wires being laid side by side without crossing each other, wherein the tape comprises a single layer of said plurality of metal wires, and wherein the plurality of metal wires are laid side by side in a layer, filling the layer and completely covering the core with no spaces between the wires; and wherein the material of the polymer body penetrates between the wires and at least partially contacts or penetrates into the core.

2. The tape according to claim 1, wherein the core comprises a treatment comprising causing a polymer-based composition to at least partially penetrate the interstices between the carbon fibers of the core.

3. The tape of claim 1, wherein the core contains no treatment other than sizing to the carbon fibers.

4. The tape of claim 1 , wherein the carbon fiber yarn of the core comprises a cabled construction of a plurality of carbon fiber yarns, each of the plurality of carbon fiber yarns being twisted in a first twist direction at a first twist multiplier and then combined by being twisted together in a second twist direction at a second twist multiplier.

5. The tape of claim 4, wherein the second twist direction is opposite to the first twist direction.

6. The tape of claim 5, wherein the first twist factor and the second twist factor are the same.

7. The tape of claim 5, wherein the direction of wrapping the filaments is the same as the first twist direction.

8. The tape of claim 5, wherein the direction of wrapping the filaments is opposite to the first twist direction.

9. The tape of claim 1, wherein the core comprises a cohesive bundle of carbon fiber filaments or a cohesive bundle of yarns.

10. The strip of claim 1 wherein the wire is carbon steel with a coating comprising brass, zinc, copper, tin or a polymer.

11. The tape of claim 1 , wherein the hybrid cable is coated with a polymer coating.

12. The tape of claim 1, wherein the hybrid cable is uncoated.

13. The tape of claim 1, wherein the tape is a cable reinforced hose.

14. The tape of claim 1, wherein the tape comprises a tensile element embedded in a polymeric tape body, the tensile element comprising the hybrid cable.

15. The tape of claim 5, wherein the first twist coefficient and the second twist coefficient are as follows: the second twist coefficient is greater than the first twist coefficient, and a ratio of the second twist coefficient to the first twist coefficient is 2-6.

Images