Composite lengthy body
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Solution Overview
Problem
High-performance polyethylene fiber ropes suffer from bend fatigue due to external and internal abrasion, frictional heat, and complex manufacturing processes involving non-load bearing components like PTFE or silicone compositions, leading to handling issues and material leaching.
Innovation Solution
A manufacturing process involving high-performance polyethylene fibers coated with an aqueous suspension of a polymeric resin, which is partially dried and optionally heated and compacted, resulting in a composite material with improved bending performance and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If PTFE filaments or silicone compositions are added to reduce friction during bending, then bending fatigue resistance is improved, but the rope structure becomes compromised and handling issues arise
Solution Approach 1:
The invention changes the chemical composition parameters by using polymeric resins (polyester, polyamide, acrylic) with specific properties instead of PTFE or silicone. This parameter change maintains bending fatigue resistance while eliminating the handling issues associated with excessive lubricity
Solution Approach 2:
The invention creates a composite coating material by combining polymeric resin with inorganic fillers (such as silica, alumina, or titania). This composite structure provides both the adhesion and mechanical properties needed for bending fatigue resistance while controlling surface friction to maintain good handling characteristics
2Reliability
If substantial amounts of non-load bearing components like PTFE or silicone are added, then bending performance is improved, but manufacturing complexity increases and material leaching occurs
Solution Approach 1:
The invention extracts and eliminates the problematic PTFE and silicone components from the coating formulation. By removing these substances entirely and replacing them with simpler polymeric resins, the manufacturing process complexity is reduced and material leaching issues are eliminated while maintaining bending performance
Solution Approach 2:
The invention changes the material composition parameters by specifying polymeric resins with particular properties (polyester, polyamide, or acrylic with controlled molecular weight and functional groups). This parameter specification simplifies the manufacturing process by eliminating the need for specialized PTFE or silicone processing while achieving the desired bending fatigue resistance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process enhances the rope's bending fatigue resistance, tenacity, and knot slippage force while reducing the risk of damage from foreign materials, matching or exceeding the performance of cross-linked silicone rubber coated fibers without the drawbacks of previous methods.
Implementation Method 1
applying an aqueous suspension of the polymeric resin to the HPPE fibres before, during or after assembling the HPPE fibres to form a lengthy body and at least partially drying the aqueous suspension of the polymeric resin applied to the HPPE fibres
Implementation Method 2
applying a temperature in the range from the melting temperature of the resin to 153° C. to the lengthy body before, during and/or after at least partially drying the suspension to at least partially melt the polymeric resin
Data Source
AI summary
Articles such as a net, a round sling or a splice include a resin-impregnated lengthy body having multifilamentary yarns comprised of high performance polyethylene (HPPE) fibres and a polymeric resin dispersed throughout a cross-section of the multifilamentary yarns. The the polymeric resin is a homopolymer or copolymer of ethylene and/or propylene, wherein the polymeric resin has a density as measured according to ISO1183 in the range from 860 to 930 kg/m3, a melting temperature in the range from 40 to 140° C. and a heat of fusion of at least 5 J/g.