Composite Rope Steel Core Kevlar Polyester Layering
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Solution Overview
Problem
Current cable and rope safety systems, particularly those with steel cores, suffer from limited material options for outer layers, electrical conductivity issues, and instability during use, leading to inadequate safety and high accident rates, especially in construction and mountaineering applications.
Innovation Solution
A composite cable and rope design featuring a steel core covered with layers of Kevlar and polyester, optionally with an additional Dyneema layer, enhancing mechanical strength, electrical insulation, and wear resistance, while providing stable anchorage and reduced risk of accidents through improved friction and residual strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel core cables are used, then high mechanical strength is achieved, but electrical conductivity and electrostatic conduction occur causing serious problems
Solution Approach 1:
The patent introduces an intermediate layer (polyester or nylon) between the steel core and the outer environment. This intermediary layer acts as an electrical insulator, blocking the conduction of electrical and electrostatic energy from the steel core, while maintaining the mechanical strength provided by the steel core.
Solution Approach 2:
The patent creates a composite cable structure combining steel core with polyester/nylon layers and Kevlar outer layers. This composite material approach allows the steel core to provide mechanical strength while the polyester/nylon layer provides electrical insulation, and Kevlar provides abrasion resistance and additional strength.
2Device complexity
If uncovered steel cables are used, then simplicity is maintained, but they cause damage such as cuts and abrasions to persons in contact
Solution Approach 1:
The patent applies flexible protective coverings (polyester, nylon, and Kevlar layers) around the steel core. These flexible shell layers prevent direct contact between persons and the hard steel core, thereby preventing cuts and abrasions while maintaining cable flexibility and functionality.
3Ease of manufacture
If limited material options are used for outer layers, then manufacturing simplicity is maintained, but special performance characteristics are insufficient
Solution Approach 1:
The patent employs a multi-layer composite structure with each layer made of different materials optimized for specific functions: steel core for strength, polyester/nylon for electrical insulation and flexibility, and Kevlar for abrasion resistance and additional tensile strength. This composite approach achieves superior reliability without significantly complicating manufacturing.
4Ease of operation
If support elements allow rope sliding, then rope freedom of movement is maintained, but instability occurs during operator use
Solution Approach 1:
The patent uses dynamic friction properties of the composite cable surface to provide controlled resistance to sliding. The Kevlar and polyester/nylon layers create a surface with optimal friction characteristics that allow the cable to remain stable when an operator applies load, preventing unwanted sliding while maintaining operational flexibility.
Data Source
AI summary
A cable or rope (10-1; 10-2), of the composite type, comprising: a inner metallic rope or core (10-A), consisting of a plurality of metal strands (10-A'), and a plurality of covering layers formed around the inner metallic core (10-A), wherein the covering layers comprise a first layer (10-B) of Kevlar formed around the inner metallic core (10-A), and a second layer (10-C) of polyester that is formed around and covers the first layer (10-B) of Kevlar, and wherein the first and the second coating layer, respectively Kevlar and polyester, are made with a fabric of braided yarns, or, according to a further embodiment (10-2) of the composite cable, the covering layers comprise a further third layer (10-C), of Kevlar and/or Dyneema, which is formed around and covers the second layer (10-C) of polyester, in turn formed and arranged around the first layer (10-B) of Kevlar. The cable or rope of the invention substantially innovates over the known conventional cables. The invention also relates to an innovative anchoring and safety system (20), based on the use of a rope and directed to put in safety roofs (RO) and the roofing of buildings against accidental falls from an height of the people working on them, comprising one or more anchorages (21), fixed to the roof (TE) to make safe and sure, in each of which the rope (E) is stably locked by screwing, so as not to create problems of instability for the people that is attached to the rope.