Composite rope structures and systems and methods for making composite rope structures

Abstract

A rope structure comprising a plurality of formed composite strands. Each of the formed composite strands comprises fiber material and matrix material. The fiber material within the matrix material is twisted. The shapes of the plurality of formed composite strands are predetermined to facilitate combination of the plurality of composite strands into the rope structure.

1 . A rope structure comprising:
 a plurality of formed composite strands comprising fiber material and matrix material; wherein   the fiber material within the matrix material is twisted; and   the shapes of the plurality of formed composite strands are predetermined to facilitate combination of the plurality of composite strands into the rope structure.   
   
   
       2 . A rope structure as recited in  claim 1 , in which the formed composite strands are substantially helical. 
   
   
       3 . A rope structure as recited in  claim 1 , in which the shapes of the formed composite strands are predetermined based on geometry of the rope structure. 
   
   
       4 . A rope structure as recited in  claim 1 , in which the matrix material of the formed composite strands is cured. 
   
   
       5 . A rope structure as recited in  claim 1 , in which the fiber material is made from at least one fiber selected from the group consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers. 
   
   
       6 . A rope structure as recited in  claim 1 , in which the matrix material is at least one material selected from the group of materials consisting of thermoplastic polyurethane, polyester, polyethylene, polypropylene, PVC, and nylon. 
   
   
       7 . A rope structure as recited in  claim 1 , in which:
 the fiber material is at least one fiber selected from the group of fibers consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers; and   the matrix material is at least one material selected from the group of materials consisting of thermoplastic polyurethane, polyester, polyethylene, polypropylene, PVC, and nylon.   
   
   
       8 . A rope structure as recited in  claim 1 , in which the formed composite strands comprise a plurality of yarns. 
   
   
       9 . A rope structure as recited in  claim 8 , in which the formed composite strands comprise substantially between 70% and 98% by weight of the fiber material. 
   
   
       10 . A rope structure as recited in  claim 8 , in which the formed composite strands comprise substantially between 2% and 30% by weight of the matrix material. 
   
   
       11 . A rope structure as recited in  claim 8 , in which the formed composite strands comprise:
 substantially between 70% and 98% by weight of the fiber material; and   substantially between 2% and 30% by weight of the matrix material.   
   
   
       12 . A rope structure as recited in  claim 8 , in which the formed composite strands comprise substantially between 50% and 95% by weight of the fiber material. 
   
   
       13 . A rope structure as recited in  claim 8 , in which the formed composite strands comprise substantially between 5% and 50% by weight of the matrix material. 
   
   
       14 . A rope structure as recited in  claim 8 , in which the formed composite strands comprise:
 substantially between 50% and 95% by weight of the fiber material; and   substantially between 5% and 50% by weight of the matrix material.   
   
   
       15 . A method of forming a rope structure, comprising the steps of:
 providing fiber material;   providing matrix material;   arranging the fiber material within the matrix material to obtain blank material;   twisting the fiber material within the matrix material of the blank material to obtain unformed composite strands; and   working the plurality of unformed composite strands to obtain formed composite strands, where each of the formed composite strands has a predetermined shape; and   combining the formed composite strands into the rope structure.   
   
   
       16 . A method as recited in  claim 15 , in which the step of working the plurality of the formed composite strands comprises the step of heating the unformed composite strands. 
   
   
       17 . A method as recited in  claim 15 , further comprising the step of predetermining the shapes of the formed composite strands based on geometry of the rope structure. 
   
   
       18 . A method as recited in  claim 15 , further comprising the step of curing the matrix material of the formed composite strands. 
   
   
       19 . A method as recited in  claim 15 , further comprising the steps of:
 selecting the fiber material from the group consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers; and   selecting the matrix material from the group of materials consisting of polyurethane, polyester, polyethylene, polypropylene, PVC and nylon.   
   
   
       20 . A rope structure comprising:
 a plurality of formed composite strands comprising fiber material and matrix material; wherein   the fiber material within the matrix material is twisted; and   at least one of the formed composite strands is substantially cylindrical;   a plurality of the formed composite strands are substantially helical; and   the substantially helical formed composite strands are formed around the at least one substantially cylindrical formed composite strand to obtain the rope structure.   
   
   
       21 . A rope structure as recited in  claim 20 , in which the matrix material of the formed composite strands is cured. 
   
   
       22 . A rope structure as recited in  claim 20 , in which:
 the fiber material is at least one fiber selected from the group of fibers consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers; and   the matrix material is at least one material selected from the group of materials consisting of thermoplastic polyurethane, polyester, polyethylene, polypropylene, PVC, and nylon.   
   
   
       23 . A rope structure as recited in  claim 20 , in which:
 the formed composite strands comprises substantially between 70% and 98% by weight of the fiber material; and   the formed composite strands comprise substantially between 2% and 30% by weight of the matrix material.   
   
   
       24 . A rope structure as recited in  claim 20 , in which:
 the formed composite strands comprises substantially between 50% and 95% by weight of the fiber material; and   the formed composite strands comprise substantially between 5% and 50% by weight of the matrix material.