Spliced synthetic rope and related technique

Abstract

A rope for carrying a tension load having an end. The rope includes a sleeve comprised of a plurality of sleeve fibers, a core comprised of a plurality of core fibers, a high performance rope segment and a splice at the end having an eye. The core positioned within the sleeve. The splice comprised of the high performance rope segment and the core positioned within the sleeve around the eye and at a base of the eye.

Description

Attorney Docket No: 690256.0033 / 1 WOTITLE OF THE INVENTIONSpliced Synthetic Rope and Related TechniqueCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the benefit of U.S. Provisional Patent Application No. 63 / 692,254, filed September 9, 2024 and titled, “Spliced Synthetic Rope and Related Technique,” the entire contents of which is incorporated herein by reference in its entirety.BACKGROUND OF THE INVENTION

[0002] Synthetic lines and ropes have been used in various industries. Specifically, synthetic climbing lines and ropes have been used in the arborist industry for many years. The construction and assembly of current climbing lines is usually a single-braid, doublebraid or kernmantle rope made with industrial-type synthetic fibers, e.g. polyester and nylon.

[0003] Climbing lines are characterized by their construction and the number of strands in the outermost layer of the rope. Some of the most common strand counts for the outermost layer of arborist climbing lines include twelve (12), sixteen (16), twenty- four (24), thirty-two (32) and forty-eight (48).

[0004] The number of strands in the lines or ropes reflects the feel or hand of the rope. A sixteen- strand rope generally feels nubby while a forty-eight-strand typically feels smooth. This interface also impacts how the rope slides through different types of hardware, such as carabiners, ascenders, descenders and other related climbing or arborist hardware. One rope type is not necessarily better than another. Selection of the rope or climbing line is determined by the type of climbing system along with the situation, climber preferences and environmental factors.

[0005] Terminations or ends of the rope are critical for climbing ropes. A rope is most useful with the appropriate termination. There are two main methods for creating a rope termination, with a knot or with a splice. A splice joins or connects a rope by interweaving the strands of the rope to create the terminal splice or termination. A splicecan be made with or without hardware in the eye and typically has a lower profile than a knot. A knot can be formed when a rope twists or interlaces around itself. Knots can usually be untied and retied as needed, while a splice is more permanent. An incorrectly tied knot could also come undone while in use, which is a safety risk for the climber or other user of the rope.

[0006] Eye splices for sixteen- strand and twelve-strand climbing lines were some of the first to go to market. These units were made with relatively large eyes and were offered with different types of thimbles and hardware. As climbers used these splices, there were issues with how the line worked in tandem with the carabiner and other climbing hardware. The carabiner was loose and could move in the eye, which gave too much room for activity. If the carabiner had a twisting locking mechanism, the eye of the rope could slide over this mechanism and the rope could twist and unlatch the carabiner. These eye splices with relatively large eyes, accordingly, may create a safety hazard for the climber and any other user.

[0007] The eye sizes eventually evolved to better fit the standard carabiners in the arborist and related industries. These smaller eye sizes in climbing lines are commonly referred to as tight eyes because they fit tight on the carabiner. A tight eye fits snugly on the carabiner and does not slide over the twisting mechanism. The tight eye made climbing safer and has become an industry-standard in climbing lines. When larger twenty -four-strand splices started to be implemented, the tight eye splice was a clear favorite. Today the tight eye splice with no hardware is one of the most common splices offered for arborist climbing lines.

[0008] There are still inconveniences caused by the tight eye splice. The width of the tight eye and the diameter in the splice zone is larger than the initial diameter of the body of the rope, so a standard tight eye splice on a rope that is, for example, eleven and seven tenths millimeters (11.7 mm) in diameter may not fit through a piece of hardware that has an inner diameter of thirteen millimeters (13 mm), because the width of the tight eye and the diameter of the bury exceed the constraint of the hardware.

[0009] If an arborist or climber is set on using a piece of hardware that has a diameter constraint and is not midline attachable, they have a few choices. Spend the extra time and energy to feed the hardware from the other end of the rope, use a rope that doesn’thave a tight eye splice and tie a knot after the rope is drawn through the hardware, or use a low profile splice that has material taken out of the splice zone to reduce the diameter or profile of the splice so that the tight eye fits through the hardware.

[0010] The third option works by removing material from the rope during the splice to reduce the diameter, but because of this loss in material, the rope's rated strength is lower. The low profile splice allows the climber or other end user to install hardware from the spliced end of the rope but reduces the rated strength of the rope because of the lowered strength of the tight eye, which is undesirable.

[0011] Prior art US Patent No. 10,132,033 is directed to a cord eye or eye splice, wherein the rope includes a core 8 and a sheath surrounding the core 8 to protect the core 8 from abrasions and other foreign objects / substances. The cord eye or eye splice is created at a rope end 1 by folding a rope end piece 3 into a loop 2 without the core 8 therein. A reinforcing element 7 is provided in the sheath in the loop 2. A core-less end portion of the rope end piece 3 with the reinforcing element 7 therein is attached by a sewing 6 to a rope section 4 with the core 8 therein. The strength of the loop 2 is significantly less than the rope with the core 8 therein, such that the cord eye or eye splice will necessarily fail before the rope. In addition, the core 8 and the rope end piece 3 with the end of the reinforcing element 7 are only connected by the sewing 6 such that the eye splice at the rope end 1 is mainly dictated by the strength of the sewing 6. Although this design results in a relatively low profile eye splice, strength of the rope is compromised at the eye or loop 2.

[0012] It would be desirable to design, develop and deploy a rope that has a tight eye splice, a slim profile in the splice zone and a high-performance fiber in the splice zone and through the eye to increase strength performance. The preferred synthetic rope splice addresses the shortcomings of the prior art rope splices by having a tight eye, a slim profile in the splice zone and increased strength performance at the splice.BRIEF SUMMARY OF THE INVENTION

[0013] Briefly stated, the preferred invention is directed to a spliced synthetic rope or a splice for a synthetic rope utilizing a hand-splicing technique. The preferred handsplicing technique utilizes a non-mechanical hand-splice for a synthetic rope having asleeve and a core, which may preferably be comprised of a thirty -two strand double braid rope, such as a Yale Cordage, Inc. XTC-32 rope. The purpose of this preferred splice is to match the strength and peak force requirements of American National Standards Institute (“ANSI”) standard for Arbori cultural Operations - Safety Requirements or ANSI Z133 while maintaining a small enough profile to fit through popular arborist hardware. The synthetic rope may be comprised of a braided sleeve with a central core and, more particularly, may include the XTC-32 rope having a sixteen (16) part braided core covered by a thirty-two (32) part braided sleeve. In addition to the rope being terminated, the splice may contain a Technora flat braid, waxed twine and one thousand six hundred (1600) denier high molecular weight polyethylene (“HMPE”) flat yam or other varieties of materials. The splicing technique may utilize a rope fid, such as a seven-sixteenths inch (7 / 16”) fid, electrical tape, pins, fop tool or pulling fid, a marlinspike, markers, sewing needles, scissors, knife, taper tool, measuring tape, ruler, torch and / or other related rope splicing tools, although these specifically listed tools and equipment are not limiting and the technique may use alternative tools and equipment or may not utilize certain of the tools listed above.

[0014] In another aspect, the preferred invention is directed to a synthetic climbing line or rope spliced such that the eye is tight, the splice has a low profile to fit through arborist hardware that is not mid-line attachable and the break strength exceeds standards and requirements of the arborist or climbing industry. It is preferred that the spliced line or rope has a strength incorporating a factor of safety above minimum break strength requirements for the application of the line or rope.

[0015] To achieve a strong and resilient product for the preferred line or rope, some of the industrial synthetic material from the core and the sleeve of the rope is removed to reduce the profile of the splice zone, and a high-performance fiber having an increased strength compared to the fibers of the sleeve and core is incorporated into the splice and through the eye to reinforce the strength of the splice.

[0016] The fiber used to reinforce the splice may be made of one or more synthetic fiber materials, including, but not limited to, ultra-high molecular weight polyethylene (“UHMPE” or “HMPE”, such as Dyneema® or Spectra®), aromatic polyesters (e.g. liquid crystal polymers (“LCP”) such as Vectran®), para-aramids (such as Kevlar®,Twaron®, or Technora®), meta-aramids (such as Nomex®), poly(p-phenylene benzobisoxazole) (“PPBO”) (e.g. Zylon) or other high performance synthetic fibers.

[0017] In an additional aspect, the preferred invention is directed to a rope for carrying a tension load having a standard part, a transition part and a tight eye splice end. The rope includes a sleeve, a core and a high performance rope segment. The sleeve includes of a plurality of sleeve fibers, wherein the plurality of sleeve fibers include a first plurality of sleeve fibers and a second plurality of sleeve fibers. The first plurality of sleeve fibers is greater than the second plurality of sleeve fibers. The tight eye splice includes the second plurality of sleeve fibers. The core includes of a plurality of core fibers, wherein the plurality of core fibers includes a first plurality of core fibers and a second plurality of core fibers. The first plurality of core fibers is greater than the second plurality of core fibers. The tight eye splice includes the second plurality of core fibers. The core is positioned within the sleeve in the standard and transitions parts and the tight eye splice. The high performance rope segment is positioned within the sleeve in the transition part and the tight eye splice. The tight eye splice defines an eye.

[0018] In a further aspect, the preferred invention is directed to a rope for carrying a tension load having a standard part, a transition part and a tight eye splice end. The rope includes a core constructed of a braided core material, a sleeve constructed of a braided sleeve material and a high performance rope segment constructed of a braided polymeric material. The core and high performance rope segment are positioned within the sleeve in the transition part and the tight eye splice end. The core and high performance rope segment define a high performance / core cross-over point within one of the transition part and the tight eye splice end. The core is positioned around the high performance rope segment on a first side of the high performance / core cross-over point and the core is positioned within the high performance rope segment on a second opposite side of the high performance / core cross-over point.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0019] The foregoing summary, as well as the following detailed description of a preferred embodiment of the device and method of the herein described spliced synthetic rope, will be better understood when read in conjunction with the appended drawings.For the purposes of illustrating the spliced synthetic rope, there is shown in the drawings a preferred embodiment. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings:

[0020] Fig. 1 illustrates a top plan view of a high performance rope segment in accordance with a preferred embodiment of the present invention;

[0021] Fig. 2a illustrates a top plan view of a portion of a synthetic rope and a pin in accordance with a preferred embodiment of the present invention;

[0022] Fig. 2b illustrates a top plan view of an end of the synthetic rope of Fig. 2a and fids that may be utilized in a preferred method of the present invention, wherein a sleeve of the synthetic rope is marked in preparation for creating a tight eye splice;

[0023] Fig. 2c illustrates a top plan view of a portion of the synthetic rope of Fig. 2a, wherein a core is exposed from the sleeve and marked at a second eye mark;

[0024] Fig. 2d illustrates a top perspective view of the end of the rope of Fig. 2b, wherein a portion of the core is removed from the sleeve;

[0025] Fig. 2e illustrates an enlarged top plan view of a portion of the rope of Fig. 2a, wherein the sleeve is milked and a rebalanced point of the core is marked;

[0026] Fig. 2f illustrates a top plan view of a portion of the core of Fig. 2e, wherein the core is cut two short fids from the rebalanced point;

[0027] Fig. 3a illustrates a top plan view of the core of Fig. 2f, wherein core tapers of the core are marked starting one fid from an end of the core;

[0028] Fig. 3b illustrates a portion of the sleeve of the rope of Fig. 2a, wherein sleeve tapers of the sleeve are marked starting at a sleeve taper mark;

[0029] Fig. 3c illustrates a top plan view of the end of the rope of Fig. 2d, wherein the core is removed from the sleeve and the core and sleeve tapers are cut and removed;

[0030] Fig. 3d illustrates a top plan view of portions of the core and sleeve of the synthetic rope of Fig. 3c, wherein the core and sleeve are marked at a distance from ends of the core and sleeve, respectively;

[0031] Fig. 3e illustrates a top plan view of the end of the synthetic rope of Fig. 3c, wherein a portion of the core is urged into the high performance rope segment of Fig. 1;

[0032] Fig. 3el 1 illustrates a cross-sectional view of the portion of the synthetic rope taken along line 1-1 of Fig. 3e;

[0033] Fig. 3f illustrates a top plan view of the end of the synthetic rope of Fig. 3e, wherein a portion of the core is fed through the sleeve at a four and three-quarters inch mark;

[0034] Fig. 3g illustrates a top plan view of a portion of the end of the synthetic rope of Fig. 3f, wherein a portion of the core is cut;

[0035] Fig. 3g 11 illustrates a cross-sectional view of the portion of the synthetic rope taken along line 1-1 of Fig. 3g;

[0036] Fig. 3h illustrates a top plan view of a portion of the end of the synthetic rope of Fig. 3g, wherein the core is fed through the sleeve at the four and three-quarters inch mark of Fig. 3f;

[0037] Fig. 3i illustrates a top plan view of a portion of the end of the synthetic rope of Fig. 3h, wherein the sleeve is cut;

[0038] Fig. 3i 11 illustrates a cross-sectional view of the portion of the synthetic rope taken along line 1-1 of Fig. 3i;

[0039] Fig. 3j illustrates a top plan view of a portion of the synthetic rope of Fig. 3i, wherein a portion of the core is box stitched to the sleeve;

[0040] Fig. 3k illustrates a top perspective view of a portion of the end of the synthetic rope of Fig. 3j, wherein the splice is milked and balanced by hand;

[0041] Fig. 4a illustrates a top plan view of a portion of the end of the synthetic rope of Fig. 3k, wherein the high performance rope of Fig. 1 is slid over the core toward a core / sleeve cross-over point;

[0042] Fig. 4al 1 illustrates a cross-sectional view of the portion of the synthetic rope taken along line 1-1 of Fig. 4a;

[0043] Fig. 4b illustrates a top plan view of the end of the synthetic rope of Fig. 2a, wherein the high performance rope of Fig. 1 is milked over a splice zone and an end of the high performance rope is inserted through the core at a high performance / core crossover point;

[0044] Fig. 4b 11 illustrates a cross-sectional view of the portion of the synthetic rope taken along line 1-1 of Fig. 4b

[0045] Fig. 4c illustrates a top plan view of the end of the synthetic rope of Fig. 4b, wherein a fop tool is inserted for use;

[0046] Fig. 4d illustrates a top plan view of the end of the synthetic rope of Fig. 4c, wherein the high performance rope of Fig. 1 is pulled through the sleeve;

[0047] Fig. 4dl 1 illustrates a cross-sectional view of the portion of the synthetic rope taken along line 1-1 of Fig. 4d;

[0048] Fig. 4e illustrates a front perspective view of the end of the synthetic rope of Fig. 4d, wherein the sleeve is milked over a splice zone of the synthetic rope;

[0049] Fig. 4f illustrates a top plan view of the end of the synthetic rope of Fig. 4e with a splice having an eye is formed at the end;

[0050] Fig. 5 illustrates a top perspective view of the splice of Fig. 4f with a box stitch at a base of the eye; and

[0051] Fig. 6 illustrates a top perspective view of the splice of Fig. 4f.DETAILED DESCRIPTION OF THE INVENTION

[0052] Certain terminology is used in the following description for convenience only and is not limiting. Unless specifically set forth herein, the terms “a”, “an” and “the” are not limited to one element but instead should be read as meaning “at least one”. The words "right", "left", "lower" and "upper" designate directions in the drawings to which reference is made. The terminology includes the above-listed words, derivatives thereof and words of similar import.

[0053] It should also be understood that the terms “about,” “approximately,” “generally,” “substantially” and like terms, used herein when referring to a dimension or characteristic of a component of the preferred invention, indicate that the described dimension / characteristic is not a strict boundary or parameter and does not exclude minor variations therefrom that are functionally the same or similar, as would be understood by one having ordinary skill in the art. At a minimum, such references that include a numerical parameter would include variations that, using mathematical and industrial principles accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.), would not vary the least significant digit.

[0054] Referring to Fig. 1, in a preferred although not limiting technique, a high performance rope segment 10 having a predetermined size, preferably a seven sixteenths inch (7 / 16”) Technora flat braid or other high performance rope segment 10 is selected toprovide high strength in a tight eye splice. The high performance rope segment 10 is preferably cut to a predetermined length and has a strength that is greater than a strength of the synthetic high performance rope segment 10 to which the tight eye splice is applied. The high performance rope segment 10 also has a lower elasticity compared to the synthetic high performance rope segment 10, wherein the greater elasticity of the synthetic high performance rope segment 10 is preferred for climbing applications such that the synthetic high performance rope segment 10 provides stretch during a sudden fall event. The high performance rope segment 10 is not limited to being comprised of a seven sixteenths inch Technora flat braid, but this rope is a preferred example due to its braided construction and high strength, which is preferably stronger than other components of the synthetic rope 12 that is being spliced. The predetermined length of the high performance rope segment 10 may be thirty-six inches (36”) but is not so limited and may be nearly any length that may be utilized for the tight eye splice of the synthetic rope 12 described herein. The high performance rope segment 10 is preferably marked at first and second performance marks 10a, 10b along a length of the high performance rope segment 10, such as the first performance mark 10a being at three and one-quarter inches (Ski”) from a performance end 10c of the high performance rope segment 10 and the second performance mark 10b at eighteen inches (18”) from the performance end 10c, although the first and second marks 10a, 10b are not limited to these dimensions and may be otherwise positioned or may not be utilized in the splicing technique. The high performance rope segment 10 is then placed aside for later use.

[0055] Referring to Figs. 2a-2f, the technique for creating the preferred tight eye splice on a synthetic rope 12 including use of the high performance rope segment 10 may also include measuring a predetermined length of the synthetic rope 12. The synthetic rope 12 may be comprised of an arborist rope, such as a Yale Cordage XTC-32 rope, although the synthetic rope 12 is not so limited. The synthetic rope 12 includes a core 12a and a sleeve 12b. The core 12a may be constructed of a braided polyester and the sleeve 12b may be constructed of a high-performance polyester, although not so limited, as the core 12a and sleeve 12b may be constructed of other materials, such as a nylon, that are able to take on the general size and shape of these components, withstand the normal operating conditions and perform the preferred functions of these components of the rope12, as is described herein. The synthetic rope 12 may be designed and utilized as an arborist climbing rope or a climbing rope in general. The synthetic rope 12 preferably provides smooth handling and a static, low-bounce yet flexible feel during use. The core 12a generally provides a portion of the strength for the rope 12 and the sleeve 12b protects the core 12a, provides the remainder of the strength for the rope 12, as well as abrasion resistance.

[0056] A pin 16 is preferably slid through or positioned within the core 12a and the sleeve 12b of the synthetic rope 12 to limit movement of the sleeve 12b relative to the core 12a, such as at approximately nine feet (9’) from an end 12c of the rope 12. The sleeve 12b is preferably marked at several locations in preparation for forming the tight eye splice, such as at a sleeve taper or a first eye 18a spaced a short fid from the end 12c of the synthetic rope 12, a second eye 18b which may be approximately three inches (3”) from the first eye mark 18a and an exit point 18c spaced at a short fid from the second eye mark 18b. The fid is a rope splicing tool that has a length that is typically twenty-one to twenty-two times a diameter of the rope that is being spliced. The fid typically has markings thereon for full fid and short fid lengths that are used to make measurements and markings on the rope being spliced. The core 12a may be exposed from the sleeve 12b at or near the exit point 18c, such as by using a Marlinspike. The core 12a may be marked at an initial exit point 20 and pulled out of the sleeve 12b (Figs. 2c and 2d). The sleeve 12b is preferably milked to rebalance the exit point on the core 12a to identify a rebalanced exit point 22. The rebalanced exit point 22 is preferably marked on the core 12a. The core 12a is preferably cut two short fids from the rebalanced point 22 (Fig. 2f) and an excess core 24 is disposed. The sleeve 12b is, accordingly, approximately two short fids longer than the core 12a at this stage of the splice process.

[0057] Referring to Figs. 3a-3k, the core tapers are marked at core taper marks 12t of the core 12a at approximately one (1) fid from a new end 12n of the core 12a or starting from a core taper designation 12d. The core tapers are preferably marked at the core taper marks 12t to identify the tapers that will be removed from the core 12a. The strand pairs (4S & 4Z) of the core 12a are marked moving from the core taper designation 12d one (1) fid from the end of the core 12a toward the new end 12n of the core 12a (Fig. 3 a). The sleeve tapers are then preferably marked at sleeve taper marks 18t starting approximatelyone (1) fid from an end of the sleeve 12b at the sleeve taper or first eye 18a, and the strand pairs (8S & 8Z) are preferably marked moving toward the end 12c of the sleeve 12b (Fig. 3b). The core and sleeve tapers are preferably cut with a taper tool or other cutting tool (Fig. 3c) such that portions of the core 12a and sleeve 12b extending from the core taper designation 12d and the sleeve taper or first eye 18a to the ends 12n, 12c of the core 12a and sleeve 12b, respectively, have a reduced fiber count at a distance approximately one (1) fid from ends 12n, 12c of the core 12a and the sleeve 12b. The core 12a and sleeve 12b are then preferably marked at core and sleeve near end marks 26, 28 at a predetermined distance from and ends 12n, 12c of the core 12a and the sleeve 12b, respectively, such as at four and three-quarters inches (4 %” ) (Fig- 3d).

[0058] Following this step, the core 12a defines a core end section 46 between the core taper designation 12d and the new end 12n with a reduced number of core fibers compared to the core 12a on the opposite side of the core taper designation 12d and the sleeve 12b defines a sleeve end section 48 between the sleeve taper or first eye 18a and the sleeve end 12c with a reduced number of sleeve fibers compared to the sleeve 12b on the opposite side of the sleeve taper or first eye 18a. In the core end section 46, the core 12a has a second plurality of core fibers and in the core 12a on the opposite side of the core taper designation 12a, the core 12a has a first plurality of core fibers. The first plurality of core fibers is greater than the second plurality of core fibers. In addition, in the sleeve end section 48, the sleeve 12b has a second plurality of core fibers and in the sleeve 12b on the opposite side of the sleeve taper or first eye 18a, the sleeve 12b has a first plurality of sleeve fibers. The first plurality of sleeve fibers is greater than the second plurality of sleeve fibers. In an assembled configuration, the core end section 46 and the sleeve end section 48 are positioned in a tight eye splice end 106 and a transition part 104 of a rope 100 produces from the herein described splice creation process, which is described in further detail below. The first plurality of sleeve fibers may be comprised of thirty -two strands of polyester fibers and the first plurality of core fibers may be comprised of sixteen strands of polyester fibers, although the first plurality of sleeve and core fibers are not so limited and may include nearly any number of strands that is desired by the user or designer, is able to take on the general size and shape of the rope 100 and is able to withstand the normal operating conditions of the rope 100.

[0059] The new end 12n of the core 12a is attached to the fid 14 and is inserted at the first performance mark 10a of the high performance rope segment 10 to position the core 12a inside of the high performance rope segment 10. The core 12a may be positioned inside the hollow center of the high performance rope segment 10 of the preferred braided high performance rope segment 10. The fid 14 is run through the high performance rope segment 10 from the first performance mark 10a to the second performance mark 10b to exit at the second performance mark 10b, such as at eighteen inches (18”), or the core 12a is otherwise slid through the high performance rope segment 10 such that the core 12a is positioned within the high performance rope segment 10 between the first and second performance marks 10a, 10b (Figs. 3e and 3el 1). The core 12a is slid through the high performance rope segment 10 until the first performance mark 10a is near the rebalanced point 22 where the core 12a exits the sleeve 12b. The tapered end of the core 12a is positioned inside the fid 14 and the core 12a is taped to the fid 14. The core 12a is pulled through the high performance rope segment 10 until the high performance rope segment 10 is touching the sleeve 12b or such that the first performance mark 10a is near or at the rebalanced point 22 (Fig. 3e). The fid 14 is then inserted at the sleeve near end mark 28 and exits approximately one inch (1”) past the sleeve taper or first eye 18a, which is preferably approximately one (1) fid from the sleeve end 12b such that the core 12a is fed through the sleeve 12b at the four and three- quarters inch (4 %”) mark from the end 12b of the sleeve 12b (Fig. 3f). Accordingly, between the sleeve near end mark 28 and the sleeve taper mark 18a, the core 12 is positioned within the sleeve 12b wherein both have a reduced fiber count based on removal of the tapers in this area. The core 12a is removed from the fid 14 and the end of the core 12a is cut at an approximately forty-five degree (45°) angle at the new end 12n (Fig. 3g). The core 12a may be pinned in place with the pin 16 to the sleeve 12b approximately one inch (1”) past the one (1) fid mark or the sleeve taper mark 18a or at the sleeve taper mark 18a on the sleeve 12b.

[0060] The tapered end or sleeve end 12c of the sleeve 12b is then positioned inside the fid 14 and the fid 14 is inserted into the core 12 where the core 12a is exposed from the sleeve 12b to exit approximately one inch (1”) past the one (1) fid mark or the core taper designation 12d on the core 12a (Fig. 3h). The sleeve 12b is positioned inside thecore 12a in this area with both the sleeve 12b and the core 12a having reduced fiber count in this portion or area. The sleeve 12b is removed from the fid 14 and the end of the sleeve 12b exposed from the core 12a approximately one inch (1”) past the core taper designation 12d and is cut at approximately forty -five degrees (45°) (Fig. 3i). The pin 16 is removed and a box stitch 30 is performed at a core / sleeve cross-over point 32 of the core 12a and the sleeve 12b using a stitching yarn, such as 1600 denier HMPE yarn, and may be finalized with a surgeon’s knot (Fig. 3j). The core 12a and the sleeve 12b define the core / sleeve cross-over point 32 that is ultimately positioned within the transition part 104 or the tight eye splice end 106 where the core 12a is positioned around the sleeve 12b on a first side of the core / sleeve cross-over point 32 and the core 12a is positioned within the sleeve 12b on an opposite side of the core / sleeve cross-over point 32. The core / sleeve cross-over point 32 facilitates transfer and carrying of loads applied to the rope 100 and the tight eye splice 106 through friction between the fibers of the core 12a and the sleeve 12b at and near the core / sleeve cross-over point 32, thereby not relying on the load carrying capacity of stitching or other bonding of prior art systems. The end-for-end splice is milked evenly by hand such that a sleeve / core exit point 34 abuts or is positioned within the high performance rope segment 10 at the second performance mark 10b (Fig. 3k).

[0061] Referring to Figs. 4a-4f, the high performance rope segment 10 slides over the core 12a with the tapered sleeve 12b therein until the second performance mark 10b of the high performance rope segment 10 is proximate the box stitch 30 and core / sleeve cross-over point 32 where the sleeve 12b is inserted in the core 12a. The core 12a extends out of the exit point 18c of the sleeve 12b further in this operation. The fid 14 is then used to insert the high performance rope segment 10 proximate the first performance mark 10a into the core 12a at an end of the sleeve taper and the high performance rope segment 10 exits at approximately three inches (3”) where the high performance rope segment 10 is butt at approximately forty -five degrees (45°) (Figs. 4a, 4b and 4b 11). This creates a high performance / core cross-over point 36, wherein the high performance rope segment 10 transitions from being outside the core 12a to inside the core 12a. The high performance / core cross-over point 36 is positioned within the transition part 104 or the tight eye splice end 106 in the assembled configuration, as is described in greater detailbelow. The core 12a is positioned around the high performance rope segment 10 on a first side of the high performance / core cross-over point 36 and the core 12a is positioned within the high performance rope segment 10 on a second opposite side of the high performance / core cross-over point 36. This high performance / core cross-over point 36 assist distribution and carrying of the load applied to the rope 100 and the tight eye splice end 106 based on the friction applied between the fibers of the core 12a and the high performance rope segment 10 in and around the high performance / core cross-over point 36. The core / sleeve cross-over point 32 and the high performance / core transition point 50 both similarly function to assist in carrying loads applied to the rope and, particularly to the tight eye splice end 106. The high performance rope segment 10 proximate the second performance mark 10b is milked over the end-for-end splice zone or the coresleeve cross-over point 32, preferably approximately one-half inch (1 / 2”) past the sleeve taper mark 18a (Fig. 4b).

[0062] A fop tool 38 is then inserted at a crotch of the eye to exit approximately one inch (1”) from the sleeve taper mark or the exit point 18c, wherein the exit point of the fop is approximately one-half inch (1 / 2”) from the high performance rope segment 10. The fop tool 20 preferably passes through the sleeve 12b but not through the core 12a, although is not so limited (Fig. 4d). The high performance rope segment 10 is pulled from near the second performance mark 10b through the sleeve 12b at a high performance / core transition point 50 toward and past the exit point 18c and exits the sleeve 12b at a transition zone start 44 (Fig. 4d). At the high performance / core transition point 50, the high performance rope segment 10 transitions from being wrapped around the core 12a to being positioned parallel to the core 12a with in the sleeve 12b, although this configuration is not so limited and the high performance rope segment 20 may be positioned within the core 12a or may be otherwise configured. The high performance / core transition point 50 is defined in the transition part 104 or the tight eye splice 106 in the assembled configuration. The core 12a is positioned within the high performance rope segment 10 at one side of the high performance / core transition point 50 and is positioned parallel to the high performance rope segment 10 on an opposite side of the high performance / core transition point 50 (Fig. 4dl 1). The high performance / core transition point 50 facilitates transfer of loads applied to the rope 100 between the highperformance rope segment 10 and the core 12a in and around the area of the high performance / core transition point 50 based on friction between the fibers and strands of the high performance rope segment 10 and the core 12a. The sleeve 12b is then milked over the splice until a tight eye 106a is formed and the pin 16 (Fig. 2a) is preferably removed to assist this process (Figs. 4e and 4f). An extra portion of the high performance rope segment 10 extending out of the sleeve 12b is preferably cut at the transition zone start 44 such that the sleeve 12b is exposed at the transition zone start 44 with an end of the high performance rope segment 10 positioned beneath the sleeve 12b.

[0063] Referring to Figs. 5 and 6, a thread 42, such as wax twine, may be used in a box stitch to stabilize the tight eye 106a and the wax twine 42 may be melted with a heating implement, such as a torch to further secure the tight eye 106a and the related individual fibers. An additional thread (not shown) may be utilized to create a leader line that may be used to pull the eye 106a through hardware, such as arborist hardware, during use.

[0064] Referring to Figs. 1-6, the above-described splicing procedure produces the rope, generally designated 100, for carrying a tension load having a standard part 102, the transition part 104 and the tight eye splice end 106. The rope 100 includes the sleeve 12b having the second plurality of sleeve fibers in the sleeve end section 48 and the core 12a having the second plurality of core fibers in the core end section 46. The rope 100 also includes the first plurality of sleeve fibers in the sleeve 12b and the first plurality of core fibers in the core 12a in the standard part 102. The first plurality of sleeve fibers is greater than the second plurality of sleeve fibers and the first plurality of core fibers is greater than the second plurality of core fibers, such that a size of the tight eye splice end 106 has a reduced size because of the reduced or lower number of fibers in the core end section 46 and the sleeve end section 46 than in the standard part 102 of the rope 100. The high performance rope segment 10, however, is positioned in the tight eye splice end 106 to compensate for any lost strength of the missing fibers of the core 12a and the sleeve 12b in the tight eye splice end 106 and the transition part 104, such that strength of the rope 100 is generally not compromised at the tight eye splice end 106 and the transition part 104. In addition, the multiple cross-over points where the sleeve 12b, the core 12a and the high performance rope segment 10 are transitioned from being inside and / or outside ofeach other improve strength of the tight eye splice end 106 and the transition part 104, as tension between the fibers in the core 12a, sleeve 12b and high performance rope segment 10 at an near these cross-over points assists with efficient transfer of loading between the fibers in these portions of the rope 100.

[0065] In the preferred embodiment, the sleeve 12b, the core 12a and the high performance rope segment 10 are connected by the thread 42 at a base of the tight eye 106a, although the thread 42 is not limiting and the tight eye 106a may be otherwise stabilized using other securement systems and techniques, such as clamping, wrapping, heat melting or other systems and methods to secure the sleeve 12b, core 12a and high performance rope segment 10 at the base of the tight eye 106a or at the exit point 18c.

[0066] The high performance rope segment 10 of the preferred embodiment may be constructed of filaments of polymeric material, wherein the polymeric material may be an ultra-high molecular weight polyethylene, an aromatic polyester, a para-aramid, a metaaramid and a poly(p-phenylene benzobisoxazole) (“PPBO”). The high performance rope segment 10 may be comprised of a braided synthetic rope segment, wherein the braided synthetic rope may be comprised of a braided aramid rope segment. The high performance rope segment 10 is not limited to the above constructions with the described materials and may be otherwise constructed, as long as the high performance rope segment 10 is able to take on the general size and shape of the high performance rope segment 10, withstand the normal operating conditions of the high performance rope segment 10 and perform the described functions of the high performance rope segment 10, such as carrying the expected loads of the rope 100 and generally reinforcing the tight eye splice end 106.

[0067] In the preferred embodiment, the rope 100 is comprised of an arborist rope 100 designed for the demands of three climbing and rigging, although the rope 100 is not so limited and may be otherwise designed for general climbing or other purposes. The rope 100 preferably has high durability, abrasion resistance, typically resulting from the sleeve 12b, and is able to withstand the outdoor environment required for arborist ropes 100, such as trees, abrasion, wet conditions, constant loading and unloading and other conditions encountered by arborist ropes 100. The rope 100 may have a sleeve with a bright color to provide high visibility during climbing, relatively high flexibility for knot-tying and various numbers of strands in the plurality of sleeve fibers to permit different hand feels for user preferences.

[0068] In the preferred embodiment, the standard part 106 of the rope 100 may have a break strength of six thousand two hundred pounds (6,200 lbs) but is not so limited and may have a greater or lower break strength. The core 12a typically comprises approximately forty percent (40%) of the strength of the rope 100, thereby having a core break strength of approximately two thousand four hundred eighty pounds (2,480 lbs) with the sleeve 12b thereby having a sleeve break strength of approximately three thousand seven hundred twenty pounds (3,720 lbs). These preferred example break strengths of the rope 100, core 12a and sleeve 12b are not limiting and may be otherwise designed and configured for various applications, user preferences, designer preferences, climbing scenarios or based on other factors. The high performance rope segment 10, which may be comprised of the seven sixteenths inch (7 / 16”) Technora flat braid, may have a break strength of approximately six thousand pounds (6,000 lbs), but is similarly not limiting and may be otherwise designed and configured based on similar factors to the core 12a and sleeve 12b. The high performance rope segment 10 is typically less elastic compared to the rope 100, such that constructions of the rope 100 with the high performance rope segment 10 acting as the core 10a is impractical for the arborist rope 100, which preferably has a preferred amount of elasticity to accommodate sudden shock or fall loads of the climber.

[0069] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the present description.

Claims

CLAIMSWe claim:

1. A rope for carrying a tension load having a standard part, a transition part and a tight eye splice end, the rope comprising: a sleeve including of a plurality of sleeve fibers, the plurality of sleeve fibers including a first plurality of sleeve fibers and a second plurality of sleeve fibers, the first plurality of sleeve fibers being greater than the second plurality of sleeve fibers, the tight eye splice including the second plurality of sleeve fibers; a core including of a plurality of core fibers, the plurality of core fibers including a first plurality of core fibers and a second plurality of core fibers, the first plurality of core fibers being greater than the second plurality of core fibers, the tight eye splice including the second plurality of core fibers, the core positioned within the sleeve in the standard and transitions parts and the tight eye splice; and a high performance rope segment, the high performance rope segment positioned within the sleeve in the transition part and the tight eye splice, the tight eye splice defining an eye.

2. The rope of claim 1 , wherein the sleeve, the core and the high performance rope segment are connected by a thread at a base of the eye.

3. The rope of claim 1, wherein the high performance segment is constructed of filaments comprised of a polymeric material.

4. The rope of claim 3, wherein the polymeric material is selected from the group consisting of an ultra-high molecular weight polyethylene, an aromatic polyester, a para-aramid, a meta-aramid and a poly(p-phenylene benzobisoxazole) (PPBO).

5. The rope of claim 1, wherein the high performance rope segment is comprised of a braided synthetic rope.

6. The rope of claim 1, wherein the braided synthetic rope is comprised of a braided aramid rope.

7. The rope of claim 1 , wherein the plurality of sleeve fibers is comprised of thirty-two strands of polyester fibers and the plurality of core fibers is comprised of sixteen strands of polyester fibers.

8. The rope of claim 1, wherein a high performance / core transition point is defined in one of the transition part and the tight eye splice, the core positioned within the high performance rope segment at one side of the high performance / core transition point and positioned parallel to the high performance rope segment on a opposite side of the high performance / core transition point.

9. The rope of claim 1, wherein a core / sleeve cross-over point is defined in one of the transition part and the tight eye splice, the core positioned around the sleeve at a first side of the core / sleeve cross-over point and the core positioned within the sleeve at a second side of the core / sleeve cross-over point.

10. The rope of claim 1, wherein a high performance / core cross-over point is defined in one of the transition part and the tight eye splice, the high performance rope segment positioned around the core at one side of the high performance / core cross-over point and the high performance rope segment positioned within the core at an opposite side of the high performance / core cross-over point.

11. The rope of claim 1, wherein the first plurality of sleeve fibers is comprised of thirty-two strands of polyester fibers and the first plurality of core fibers is comprised of sixteen strands of polyester fibers.

12. The rope of claim 1, wherein the high performance rope segment is comprised of a seven sixteenths inch Technora flat braid.

13. A rope for carrying a tension load having a standard part, a transition part and a tight eye splice end, the rope comprising: a core constructed of a braided core material; a sleeve constructed of a braided sleeve material; and a high performance rope segment constructed of a braided polymeric material, the core and high performance rope segment positioned within the sleeve in the transitionpart and the tight eye splice end, the core and high performance rope segment defining a high performance / core cross-over point within one of the transition part and the tight eye splice end, the core positioned around the high performance rope segment on a first side of the high performance / core cross-over point and the core positioned within the high performance rope segment on a second opposite side of the high performance / core crossover point.

14. The rope of claim 13, wherein the core and the sleeve define a core / sleeve cross-over point within one of the transition part and the tight eye splice end, the core positioned around the sleeve on a first side of the core / sleeve cross-over point and the core positioned within the sleeve on a second opposite side of the core / sleeve cross-over point.

15. The rope of claim 13, wherein the high performance rope segment and the core define a high performance / core transition point, the high performance rope segment positioned around the core on a first side of the high performance / core transition point and positioned in parallel with the core on a second opposite side of the high performance / core transition point.

16. The rope of claim 13, wherein the braided polyester core material is comprised of a sixteen part braided polyester core material.

17. The rope of claim 13, wherein the braided polyester sleeve material is comprised of a thirty-two part braided polyester sleeve material.

18. The rope of claim 13, wherein the high performance rope segment is comprised of a seven sixteenths inch Technora flat braid.

19. The rope of claim 13, wherein the sleeve is positioned around the core and the high performance rope segment in each of the standard part, the transition part and the tight eye splice end.

20. The rope of claim 13, wherein the core defines a core end section and the sleeve defines a sleeve end section, the core end section and the sleeve end section each having a reduced fiber count.

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