Synthetic Cable Splice Termination Design
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Solution Overview
Problem
Current cable construction technologies using high modulus threads for offshore anchorage lines face inefficiencies due to thread wear, traditional manufacturing methods, and low elongation, leading to reduced strength and increased likelihood of breakage at splice regions, especially under high mechanical loads.
Innovation Solution
A synthetic cable with a core of high modulus threads arranged in parallel, connected to splice-type termination ends, where each splice comprises parallel threads forming an eyelet, and the splice threads and core threads are arranged in parallel at an interpenetration region, allowing for improved tension transfer and increased failure strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used for high modulus thread cables, then production experience is gained, but thread wear and material loss occur reducing cable strength
Solution Approach 1:
The patent applies preliminary action by pre-assembling threads into a mandrel before the actual cable manufacturing process. This pre-arrangement ensures proper thread alignment and distribution from the start, preventing wear and misalignment issues that occur during traditional manufacturing. The mandrel serves as a preliminary structure that guides thread placement, eliminating the need for repeated adjustments that cause material loss and strength reduction.
2Ease of operation
If hand manufacturing of splices is used, then flexibility is maintained, but alignment and stress control of threads on the seam are problematic
Solution Approach 1:
The patent replaces the manual mechanical process of hand-splicing with an automated mechanical system. The mandrel-based assembly apparatus automatically positions and secures threads at precise intervals, eliminating the alignment and stress control problems associated with hand manufacturing. This mechanical substitution maintains operational flexibility through automated adjustment mechanisms while achieving precise thread alignment and uniform stress distribution along the splice region.
3Strength
If high modulus threads are used, then material performance is improved, but low elongation causes intolerance to local mobility differences increasing breakage risk
Solution Approach 1:
The patent applies segmentation by dividing the cable structure into distinct functional regions: a rigid high-strength core region with parallel threads for maximum load bearing, and a flexible transition zone with woven or braided threads that accommodate local mobility differences. This segmentation allows the high modulus threads to provide their full strength benefit while the transition zones absorb local deformations and stress concentrations, preventing breakage at splice points and other vulnerable areas.
4Productivity
If parallel construction is used for high modulus threads, then efficiency is maximized, but splice-type terminations become difficult to implement
Solution Approach 1:
The patent uses the mandrel as an intermediary device that enables both parallel construction and splice-type terminations. During manufacturing, the mandrel maintains the parallel thread arrangement for maximum efficiency. At the termination points, the mandrel structure provides a built-in mechanism for creating splices, where threads can be securely anchored to the mandrel surface. This intermediary structure resolves the contradiction by providing a unified platform that supports both the efficient parallel construction and the feasible splice terminations.
Data Source
AI summary
The present invention relates to synthetic cables comprising core and splicing threads with high modulus threads, wherein the ends of the cable comprise looped or eyelet splice-type termination ends (1), and wherein each leg of the parallel splicing threads (13, 13′) is connected to parallel core threads (21) at an interpenetration region (12). The method comprises individually connecting each leg of the splicing threads (13) with a positive splice to a core thread(s) (21) of the beginning end of the cable (2); looping; straining all the threads and applying a normal compression force at the interpenetration region (12); applying a protective element(s) (32) along the cable and further individually connecting each leg of the splicing threads (21) to form a negative splice to a core thread(s) (21) of the final end of the cable core (2); and looping, straining and applying a normal compression force (12) on the negative splice at the interpenetration region.