Twisted Filament Mesh Rope Manufacturing
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Solution Overview
Problem
Conventional rope manufacturing methods are laborious and complex due to the need to handle small-diameter filaments individually, which can lead to tangling and damage, and do not produce robust ropes.
Innovation Solution
A method of forming a rope by twisting a mesh of filaments where the filaments are attached at intersecting points, allowing for easier handling and increased robustness, using either woven or extruded meshes with fusion at points, and potentially incorporating biodegradable thermoplastics and natural fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods are used to handle small-diameter filaments individually to form strands, then the rope can be manufactured, but the process becomes laborious and complex with increased risk of tangling and damage
Solution Approach 1:
The patent merges multiple individual filaments into a single mesh structure before twisting. Instead of handling numerous separate filaments through the entire manufacturing process, the filaments are first combined into a mesh where they are interconnected at intersection points, creating a single handleable unit that maintains the integrity of all constituent filaments.
Solution Approach 2:
The patent segments the manufacturing process into distinct stages: first forming a mesh from multiple filaments, then twisting the mesh into a strand, and finally assembling strands into a rope. This segmentation allows each stage to be optimized independently, with the mesh formation stage handling filament organization and the twisting stage handling strand formation.
2Reliability
If conventional twisting methods are used on individual filaments, then strands can be formed, but the filaments are prone to damage and tangling
Solution Approach 1:
The patent merges multiple individual filaments into a single mesh structure before twisting. Instead of handling numerous separate filaments through the entire manufacturing process, the filaments are first combined into a mesh where they are interconnected at intersection points, creating a single handleable unit that maintains the integrity of all constituent filaments.
Solution Approach 2:
The mesh structure acts as a protective framework that cushions and protects individual filaments during the twisting process. The intersection points in the mesh provide structural support that prevents filaments from becoming tangled or damaged, effectively cushioning them against harmful mechanical stresses before the twisting operation occurs.
3Strength
If ropes are made from conventionally manufactured strands, then the rope can be produced, but the resulting rope lacks robustness
Solution Approach 1:
The patent merges multiple individual filaments into a single mesh structure before twisting. Instead of handling numerous separate filaments through the entire manufacturing process, the filaments are first combined into a mesh where they are interconnected at intersection points, creating a single handleable unit that maintains the integrity of all constituent filaments.
Solution Approach 2:
The patent creates a composite structure where multiple filaments are combined into a mesh that forms a strand, which then becomes part of the final rope. This composite approach, where the mesh integrates multiple filaments into a unified structure with interconnected intersection points, enhances the overall robustness and strength of the resulting rope compared to conventional single-filament or loosely-bound multi-filament constructions.
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
This method simplifies the rope manufacturing process, reduces the risk of filament damage, and produces a more robust rope with improved mechanical characteristics and lower environmental impact.
Implementation Method 1
a strand of twisted mesh is formed by twisting a mesh
Implementation Method 2
the filaments of one of said two bundles are attached to the filaments of the other one of said two bundles at the intersecting points by means of fusion of the material forming said filaments
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a method of manufacturing a rope formed by a plurality of strands of filaments, and to a corresponding rope. The method comprises the following steps: [a] providing a mesh (2) comprising at least two bundles of extruded filaments (3) intersecting with one another at intersecting points (4), the filaments (3) of the two bundles being attached to one another at the intersecting points (4); [b] twisting the mesh (2) to form a strand (5) of twisted mesh; and [c] forming a rope by making a composition from a plurality of strands (5) including at least the strand (5) of twisted mesh formed in step [b], said composition being one from the group consisting of a twist, a braid, and a combination of twist and braid.