A quick-drying composite rope and a manufacturing method thereof

Abstract

The present application relates to a kind of quick-drying composite rope and its manufacturing method, polyethylene is mixed with ethylene-vinyl acetate copolymer and added antioxidant, ultraviolet inhibitor, light stabilizer and blowing agent, heating to obtain first melt, heating acrylonitrile-butadiene-styrene copolymer to obtain second melt, two melt co-extrusion melt mixing, by the extrusion die that the circumferential groove is provided on the forming surface, the outer peripheral surface of core wire is configured with multiple convex edges extending along the length direction once, flow guide groove is formed between adjacent convex edges, blowing agent is decomposed in pipe wall to form micropore, connect hollow inner cavity with flow guide groove, finally weave cotton thread protective layer on the outer periphery of core wire.The method process is concentrated, die directly forms flow guide structure, without secondary processing, the rope prepared can quickly discharge when infiltrating moisture, dry speed is fast, and service life is long.

Description

Technical Field

[0001] This invention relates to the field of outdoor products technology, and more specifically, to a quick-drying composite rope and its manufacturing method. Background Technology

[0002] For ropes employing a composite structure of core wire and braided protective layer, achieving fast-drying performance largely depends on the structural design and material composition of the core wire. However, in existing manufacturing methods, improvements in both aspects are often difficult to achieve simultaneously.

[0003] On the one hand, to give ropes rapid drainage and drying capabilities, a more effective approach is to form a guide groove structure extending along the length of the core wire, allowing moisture that has seeped between the core wire and the protective layer to be directionally guided and quickly discharged. However, in existing processes, such groove structures are mostly formed on the surface of the formed core wire through secondary processing methods such as mechanical cutting and embossing. This not only increases the number of processes but also makes it difficult to guarantee the dimensional accuracy and consistency of the grooves, and can also damage the integrity of the core wire surface, affecting its mechanical strength. If the grooves are formed directly during the extrusion molding process, it places higher demands on the mold design, material flowability, and matching of molding process parameters. Existing technologies lack a manufacturing solution that integrates material formulation and mold structure.

[0004] On the other hand, the material composition of the core wire directly affects the rope's weight, hydrophobicity, and dimensional stability in humid environments. Traditional single materials such as polyethylene, while hydrophobic, lack flexibility and resilience, resulting in ropes that feel stiff. Furthermore, when adjusting properties through blending modification, the compatibility between different polymers and differences in processing temperature become new obstacles. Especially when attempting to introduce polymer components with specific functions, if the processing windows of each component do not match, it becomes difficult to complete the formation of a tubular core wire through a single co-extrusion process, let alone precisely construct a flow-guiding structure on its surface during molding.

[0005] Therefore, how to provide a manufacturing method that can simultaneously complete the melt mixing of the polymer blend system and the precise forming of the tubular core wire with a flow-guiding structure in a one-time molding process has become an urgent technical problem to be solved in the field of preparing fast-drying composite ropes. Summary of the Invention

[0006] The main objective of this invention is to propose a fast-drying composite rope and its manufacturing method, which can form a tubular core wire with a flow-guiding structure in one step, and has multiple polymer blend systems.

[0007] To address the aforementioned technical problems, this invention proposes a method for manufacturing a quick-drying composite rope, comprising the following steps: mixing a matrix material with additives and heating to a molten state to obtain a first melt; the matrix material includes polyethylene and ethylene-vinyl acetate copolymer; heating an acrylonitrile-butadiene-styrene copolymer to a molten state to obtain a second melt; co-extruding the first melt and the second melt to melt and mix the acrylonitrile-butadiene-styrene copolymer with the matrix material; forming a tubular core wire through an extrusion die; the forming surface of the extrusion die has grooves distributed circumferentially to form multiple convex ridges extending along the length direction on the outer circumference of the formed core wire; and weaving a protective layer around the core wire to obtain a composite rope.

[0008] In the above technical solution, the mass ratio of polyethylene to ethylene-vinyl acetate copolymer is further 1:3 to 3:1.

[0009] In any of the above technical solutions, the mass ratio of polyethylene to ethylene-vinyl acetate copolymer is further 1:1.

[0010] In any of the above technical solutions, the additives further include antioxidants, UV stabilizers, light stabilizers, and foaming agents.

[0011] In any of the above technical solutions, the foaming agent further decomposes during the co-extrusion process, forming micropores inside the core tube wall.

[0012] In any of the above technical solutions, a guide groove extending along the length of the core wire is further formed between adjacent protrusions.

[0013] In any of the above technical solutions, the core wire is further formed by rolling a sheet containing an acrylonitrile-butadiene-styrene copolymer and a matrix material, and the surface of the sheet is pre-formed with raised ridges.

[0014] In any of the above technical solutions, the protective layer is further made of cotton thread.

[0015] A quick-drying composite rope includes: a core wire, which is a tubular structure with multiple protruding ridges extending along its length on its outer circumference, forming a flow-guiding groove between adjacent ridges; the core wire is composed of a melt blend of polyethylene, ethylene-vinyl acetate copolymer, and acrylonitrile-butadiene-styrene copolymer; the inner wall of the core wire has micropores formed by the decomposition of a foaming agent, and the micropores are in fluid communication with the hollow inner cavity of the core wire and the flow-guiding groove; and a protective layer covering the outer circumference of the core wire.

[0016] Beneficial effects: Compared with existing technologies, 1. By co-extruding and melting PE, EVA and ABS in one step and simultaneously molding them into tubular core wires, the problem of mismatched processing windows of multi-component polymer systems is solved. There is no need for separate plasticizing and granulation or multiple heating. The process is centralized and simple.

[0017] 2. The extrusion die directly constructs raised ridges and guide grooves on the outer circumference of the core wire while forming it, without the need for secondary machining. The dimensional accuracy of the grooves is guaranteed by the die, resulting in good consistency and without damaging the surface structure of the core wire.

[0018] 3. The composite rope prepared by the above method has surface drainage grooves that are connected to the hollow cavity and foamed micropores, allowing water to be quickly drained and dried rapidly. The rope is not prone to mold growth in humid environments, thus extending its service life. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a flowchart of the manufacturing method of the present invention; Figure 2 This is a schematic diagram of the cross-sectional structure of the integrated core wire of the fast-drying composite rope of the present invention; Figure 3 This is a schematic diagram of the cross-sectional structure of the quick-drying composite rope core wire of the present invention; Figure 4 This is a side view of the quick-drying composite rope of the present invention. Figure 5 This is a physical representation of the quick-drying composite rope of the present invention.

[0021] The annotations in the attached figures are explained as follows: 1. Core wire; 11. Raised ribs; 2. Protective layer Detailed Implementation

[0022] Hereinafter, exemplary embodiments according to this application will be described in detail with reference to the accompanying drawings. Obviously, the described embodiments are merely a part of the embodiments of this application, and not all of the embodiments of this application. It should be understood that this application is not limited to the exemplary embodiments described herein. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without inventive effort are within the scope of protection of this invention.

[0023] It should be noted that, as shown in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" do not specifically refer to the singular and may also include the plural. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, and these steps and elements do not constitute an exclusive list; the method or apparatus may also include other steps or elements.

[0024] If the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0025] In this invention, unless otherwise explicitly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0026] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the meaning of "and / or" throughout the text includes three parallel solutions; for example, "A and / or B" includes solution A, solution B, or a solution where both A and B are satisfied simultaneously. Furthermore, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0027] This invention proposes a quick-drying composite rope and its manufacturing method.

[0028] The quick-drying composite rope and its manufacturing method of this application will be described in detail below through the following embodiments.

[0029] Example 1: like Figure 1 , 2As shown in Figures 4 and 5, this embodiment proposes a method for manufacturing a quick-drying composite rope. This method completes the entire process from material preparation to structural molding through a single co-extrusion process, resulting in a simple process route. The manufactured rope can quickly drain internal moisture and return to a dry state after being exposed to dampness.

[0030] In the initial stage of manufacturing, polyethylene and ethylene-vinyl acetate copolymer are added to a mixing device in a certain proportion, along with antioxidants, UV stabilizers, light stabilizers, and foaming agents. After thorough mixing, the mixture is heated to a molten state to obtain the first melt. Polyethylene itself is hydrophobic and does not absorb moisture in humid environments, providing a good water-repellent foundation for core wire 1. Meanwhile, the ethylene-vinyl acetate copolymer is flexible and has good resilience. The combination of these two materials ensures that the final core wire 1 has sufficient softness and is not prone to irreversible deformation under stress. The addition of additives further ensures the thermal stability of the material during processing and its resistance to aging under outdoor sunlight and rain conditions.

[0031] Simultaneously, the acrylonitrile-butadiene-styrene copolymer is heated separately to a molten state to obtain a second melt. Compared to the aforementioned matrix material, the acrylonitrile-butadiene-styrene copolymer is more rigid, and its introduction aims to adjust the collapse resistance of the core wire 1 tube wall. In existing multi-component blending processes, due to the non-overlapping processing temperature windows between different polymers, uneven mixing or interfacial delamination is prone to occur. Often, it is necessary to first mix and granulate the components, followed by a second heating process before molding. This method bypasses this intermediate step, directly co-extruding the first and second melts, allowing the acrylonitrile-butadiene-styrene copolymer to be melt-mixed with polyethylene and ethylene-vinyl acetate copolymer in a single step within the extruder. This reduces the degradation effect of multiple thermal processes on the molecular chains, making the process more focused. Furthermore, the blend obtained through melt mixing is uniform and continuous in material composition, with the acrylonitrile-butadiene-styrene copolymer dispersed within the matrix, thus improving the overall rigidity of the tube wall and preventing the guide grooves from being flattened and closed under stress.

[0032] During co-extrusion, the molten mixture is pushed onto the extrusion die. The die's forming surface is pre-machined with circumferentially arranged grooves. Therefore, as the mixture passes through the forming surface, multiple longitudinally extending ridges 11 are simultaneously formed on its outer circumference. The cross-sectional dimensions and spacing of the ridges 11 are entirely determined by the groove dimensions on the die's forming surface, resulting in high groove forming precision and good product consistency. Existing groove processing methods often involve embossing or cutting after forming, which not only increases the manufacturing process but also leaves processing marks or weak areas on the material surface. This method, however, utilizes the die to directly generate the ridges 11 during extrusion, without damaging the surface of the core wire 1, ensuring the overall strength of the core wire 1. After the ridges 11 are formed, adjacent ridges naturally form drainage channels. Combined with the subsequent weaving of the protective layer 2, these channels become the main drainage and ventilation channels inside the rope.

[0033] After the core wire 1 is formed and cooled to set, it is woven with cotton thread around its periphery to form a tightly wrapped tubular braided protective layer 2. The cotton thread braided layer provides physical protection for the core wire 1 to prevent external wear. On the other hand, there are a large number of pores naturally present between its fibers. These pores are connected to the drainage grooves on the surface of the core wire 1, forming a continuous breathable network from the inside to the outside of the rope.

[0034] The composite rope produced by the above method has a hollow tubular core 1 with micropores formed by the decomposition of a foaming agent distributed inside the tube wall. These micropores connect the hollow inner cavity with the surface drainage grooves. When the rope is exposed to rain or soaked in water outdoors, moisture seeps in through the pores of the outer braided protective layer 2 and is discharged towards the rope end along the drainage grooves under the action of gravity or swinging motion. Moisture that has entered the tube wall can flow into the hollow inner cavity through the micropores and be discharged together. After the free water is drained, external air can enter from the rope end or the surface of the braided layer and circulate along the drainage grooves, micropores, and hollow inner cavity, continuously carrying away residual moisture and allowing the rope to gradually dry under natural conditions. The entire process does not require drying equipment; the rope can dry quickly by hanging it after swinging, and it is not prone to mold or fiber strength reduction even when used in a humid environment for a long time.

[0035] Example 2: This embodiment is a further improvement based on Embodiment 1.

[0036] like Figure 1 As shown, in this embodiment, the mass ratio of polyethylene to ethylene-vinyl acetate copolymer is limited to the range of 1:3 to 3:1. Along the direction of change of this ratio from low to high, the performance of core wire 1 exhibits a continuous gradient transition.

[0037] When the proportion of polyethylene is low and the proportion of ethylene-vinyl acetate copolymer is high, for example, a ratio close to 1:3, the matrix material is mainly composed of flexible components. Core wire 1 exhibits strong flexibility and resilience, a small bending radius, easy knotting, and a secure knot. The protective layer 2 can be tightly woven into the surface of core wire 1, resulting in a rounded rope appearance and a soft feel. As the proportion of polyethylene gradually increases, the proportion of ethylene-vinyl acetate copolymer decreases accordingly. The rigid components in core wire 1 gradually increase, and the ring stiffness of the tube wall begins to rise, with the feel transitioning from soft to moderately stiff. When the ratio reaches the intermediate range, such as around 1:1, rigidity and flexibility tend to be balanced. Core wire 1 maintains sufficient softness to meet the needs of normal operation while also providing sufficient tube wall support to prevent the guide groove from being flattened during use. When the proportion of polyethylene continues to increase and approaches 3:1, the matrix material is mainly composed of rigid components, and the ring stiffness of the core wire 1 tube wall reaches a high value within this range. When subjected to large binding tension or external extrusion, the tubular structure is not easily deformed, the cross-section of the flow channel remains intact, and the durability of the drainage and ventilation channels is better. It is suitable for occasions with high pressure resistance requirements, such as binding heavy objects and industrial hoisting assistance.

[0038] This continuous ratio range allows the performance of rope products to be adjusted between soft and lightweight and stiff and durable according to actual needs. During the manufacturing process, only the weighing ratio of polyethylene to ethylene-vinyl acetate copolymer needs to be changed at the feeding stage. The extrusion die, co-extrusion temperature and subsequent weaving process do not need to be changed. The same production line can flexibly produce ropes with different hand feel orientations.

[0039] Example 3: This embodiment is a further improvement based on any of the above embodiments.

[0040] like Figure 1 As shown, in this embodiment, the mass ratio of polyethylene to ethylene-vinyl acetate copolymer is set to 1:1. This ratio exhibits a relatively balanced overall performance in many aspects.

[0041] From a processing perspective, when polyethylene and ethylene-vinyl acetate copolymer are mixed in equal proportions, the viscosity difference between the two materials in the molten state is within a moderate range. During co-extrusion, they can be dispersed relatively evenly, without forming isolated flow areas in the melt due to the low proportion of one component. The overall melt flowability is stable, and it is fully filled when passing through the extrusion die. The grooves on the forming surface can be completely replicated on the surface of core wire 1, the ridges 11 are full, the cross-section of the guide grooves is regular, and the dimensional accuracy is easy to ensure.

[0042] From a material performance perspective, the 1:1 ratio balances the rigidity and hydrophobicity of polyethylene with the flexibility and resilience of the ethylene-vinyl acetate copolymer, avoiding any imbalance caused by an overemphasis on either property. If the polyethylene content is too high, the core wire 1 becomes too stiff, making knotting difficult; if the ethylene-vinyl acetate copolymer content is too high, the tube wall becomes too soft, easily collapsing under stress. After equal mixing, the core wire 1 can withstand the gripping force and binding tension of normal use, preventing the tubular structure and guide grooves from being flattened, while also possessing sufficient flexibility, allowing the rope to bend and knot smoothly, resulting in a good user experience.

[0043] From the perspective of drainage and drying function, the core wire 1 tube wall with a 1:1 ratio maintains structural stability while exhibiting a more uniform distribution of micropores formed by the decomposition of the foaming agent. Because the melt viscosities of the two components are similar, the nucleation and growth environment of bubbles in the melt is consistent, making it less likely for micropores to aggregate locally or exhibit excessive size differences. The uniformly distributed micropores provide more reliable connectivity with the hollow inner cavity and surface drainage channels, ensuring unobstructed migration of moisture from the tube wall to the hollow inner cavity or drainage channels, resulting in stable drying efficiency.

[0044] From the perspective of product consistency, a 1:1 ratio is a well-symmetrical formulation, simplifying weighing and mixing operations, and minimizing the impact of proportioning errors on the final product performance. In continuous production, batch-to-batch performance fluctuations are small, and the product's drainage drying effect and mechanical properties can remain stable within a narrow range, which is beneficial for quality control.

[0045] Example 4: This embodiment is a further improvement based on any of the above embodiments.

[0046] like Figure 3 As shown, in this embodiment, the core wire 1 is formed by rolling a sheet.

[0047] Polyethylene, ethylene-vinyl acetate copolymer, and acrylonitrile-butadiene-styrene copolymer are melt-mixed and then extruded or calendered into sheets through a sheet die. Before cooling and setting, the sheet passes through a grooved roller to press out longitudinally extending ridges 11 on one or both sides of the sheet. After cooling, the sheet is wound into a tube, and the overlaps are fixed by heat sealing or adhesive bonding to form a tubular core wire 1. Finally, a cotton thread protective layer 2 is braided around the core wire 1.

[0048] This forming method does not require specialized tube extrusion molds; adjustments to the production tube diameter can be achieved simply by changing the winding diameter of the sheet. The specifications of the raised ridges 11 on the sheet surface are also determined by the grooves on the pressure rollers, ensuring the dimensional accuracy of the raised ridges 11. After winding, the raised ridges 11 are located on the outer circumference of the core wire 1, forming a guide groove in conjunction with the protective layer 2. The foamed micropores, hollow inner cavity, and guide groove are interconnected, ensuring the rope's fast-drying function is consistent with the extrusion molding scheme. For small-batch or multi-specification rope production needs, the sheet winding method offers greater flexibility.

[0049] The various embodiments of this disclosure have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or improvement of the technology in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A method for manufacturing a quick-drying composite rope, characterized in that, Includes the following steps, The matrix material and additives are mixed and heated to a molten state to obtain a first melt. The matrix material includes polyethylene and ethylene-vinyl acetate copolymer. The acrylonitrile-butadiene-styrene copolymer was heated to a molten state to obtain a second melt. The first melt and the second melt are co-extruded to melt and mix the acrylonitrile-butadiene-styrene copolymer with the matrix material. The mixture is then formed into a tubular core wire through an extrusion die. The forming surface of the extrusion die has grooves distributed circumferentially so that multiple convex ridges extending along the length direction are formed on the outer circumference of the formed core wire. A protective layer is woven around the core wire to obtain a composite rope.

2. The manufacturing method according to claim 1, characterized in that, The mass ratio of the polyethylene to the ethylene-vinyl acetate copolymer is 1:3 to 3:

1.

3. The manufacturing method according to claim 2, characterized in that, The mass ratio of the polyethylene to the ethylene-vinyl acetate copolymer is 1:

1.

4. The manufacturing method according to claim 1, characterized in that, The additives include antioxidants, UV stabilizers, light stabilizers, and foaming agents.

5. The manufacturing method according to claim 4, characterized in that, The foaming agent decomposes during co-extrusion, forming micropores inside the core tube wall.

6. The manufacturing method according to claim 1, characterized in that, A guide groove is formed between adjacent convex ridges, extending along the length of the core wire.

7. The manufacturing method according to claim 1, characterized in that, The core wire is formed by rolling a sheet containing the acrylonitrile-butadiene-styrene copolymer and a matrix material, and the surface of the sheet is pre-formed with the protruding ridges.

8. The manufacturing method according to claim 1, characterized in that, The protective layer is woven from cotton thread.

9. A quick-drying composite rope, characterized in that, include: The core wire (1) has a tubular structure with multiple protruding ridges (11) extending along its length on its outer circumference. A flow-guiding groove is formed between adjacent protruding ridges (11). The core wire (1) is composed of a melt blend of polyethylene, ethylene-vinyl acetate copolymer, and acrylonitrile-butadiene-styrene copolymer. The inner wall of the core wire (1) has micropores formed by the decomposition of a foaming agent. These micropores are in fluid communication with the hollow inner cavity of the core wire (1) and the flow-guiding grooves. A protective layer (2) is wrapped around the outer periphery of the core wire (1).

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