Woven Pull Rope with Low-Friction Monofilament Jacket
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Solution Overview
Problem
Existing methods face difficulties in efficiently introducing elongated items, such as cables, into small conduits with multiple turns due to high friction, which can damage the conduit and require excessive pulling tension.
Innovation Solution
A woven rope with a core of continuous multifilament fibers and a jacket of monofilament fibers, where the monofilament fibers form the outer surface and have a low coefficient of friction, allowing easier sliding and reduced pulling tension, while the multifilament fibers provide high tensile strength to support cable pulls.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pull methods are used in small conduits with multiple turns, then the cables can be installed, but high friction and excessive pulling tension occur which can damage the conduit
Solution Approach 1:
The patent changes the surface friction parameter by using a woven rope with a specific jacket material that has a low coefficient of friction (0.2-0.4). This parameter change allows the rope to slide easily through small conduits with multiple turns, reducing pulling tension by up to 50% compared to conventional pull tapes, while preventing conduit damage
Solution Approach 2:
The patent employs a composite structure consisting of an inner portion made of continuous multifilament fibers (providing high tensile strength) and an outer jacket made of monofilament fibers with low friction properties. This composite material combination simultaneously achieves high strength-to-failure (exceeding 300 lbs) and low surface friction, resolving the contradiction between needing high pulling force and minimizing conduit damage risk
2Ease of manufacture
If conventional pull tapes are used, then installation can proceed, but the high friction generates heat that can cut through the duct
Solution Approach 1:
The patent changes the friction parameter by selecting a jacket material with a low coefficient of friction (0.2-0.4), which significantly reduces the frictional heat generated during cable installation. This prevents the heat from reaching levels that could cut through the duct, while still maintaining ease of installation through small conduits
Solution Approach 2:
The patent converts the potentially harmful high-friction condition into a beneficial low-friction condition by carefully selecting the jacket material properties. The low-friction surface, which might seem to reduce grip, actually benefits the installation by minimizing heat generation and preventing duct damage, while the high-tensile-strength core ensures adequate pulling force is transmitted
3Force
If a woven rope with low friction outer surface is used, then sliding is easier and pulling tension is reduced, but the rope must still provide sufficient tensile strength to support cable pulls
Solution Approach 1:
The patent uses a composite structure where the inner portion is made of continuous multifilament fibers providing high tensile strength (strength-to-failure exceeding 300 lbs), while the outer jacket is made of monofilament fibers with low friction properties (coefficient of friction 0.2-0.4). This composite design allows the rope to simultaneously provide sufficient strength to support cable pulls and low friction for easy sliding through conduits
Solution Approach 2:
The patent applies different material properties to different parts of the rope: the inner core is optimized for high tensile strength to withstand pulling forces, while the outer jacket is optimized for low surface friction to facilitate smooth sliding through the conduit. This local differentiation of material properties resolves the contradiction between needing high strength and low friction
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 woven rope effectively protects both the cables and the conduit by reducing friction and pulling tension, facilitating the insertion of elongated items into smaller conduits without damaging them.
Implementation Method 1
the monofilament fibers form the majority of the outer surface of the woven rope
Data Source
Figure 1~2
Figure 3~4
AI summary
A rope (10) comprising an inner portion (10a) comprising a plurality of multifilament fibers (100) in the length direction of the rope (10) and a woven jacket portion (10b) covering the inner portion (10a). The woven jacket portion (10b) contains a plurality of monofilament fibers (200) in the length direction of the rope (10) and at least one multifilament fiber (300) in the circumferential direction interwoven with the monofilament fibers (200). The monofilament fibers (200) of the woven jacket portion (10b) form the majority of the outer surface of the rope (10). The rope (10) can be used as a pulling rope facilitating the positioning of elongate items, such as electrical or optical cables within conduits (510) or protective sleeves (520).