Fiber structures, systems, and methods for fabricating rope structures with improved lubricity

Abstract

A fiber structure for forming a rope structure has a base matrix of base fiber material and at least one lubricity portion of lubricity material. The lubricity material determines a lubricity of at least a portion of a surface of the fiber structure.

What is claimed is: 
     
         1 . A fiber structure for forming a rope structure, comprising:
 a base matrix of base fiber material; and   at least one lubricity portion of lubricity material; wherein   the lubricity material determines a lubricity of at least a portion of a surface of the fiber structure.   
     
     
         2 . A fiber structure as recited in  claim 1 , in which:
 the base fiber material is formed by at least one material selected from the group of materials: Nylon, Polyester, Polypropylene (PP), Olefin, Polyolefin, Polyethylene (PE), Polyacrylonitrile, Carbon, Aramid, PBO (Poly(p-phenylene-2,6-benzobisoxazole), LCP (Liquid Crystal Polymer), PIPD (Poly[2,6-diimidazo(4,5-b:4′,5′-e)pyridinylene-1,4(2,5-dihydroxy)phenylen]), PBI (Polybenziadazole), PEN (Polyethylene Naphthalate), Glass, Basalt, Metals and metal alloys, PVC (Polyvinyl Chloride), PVDC (Polyvinylidene Chloride), Polyurethane-polyurea, Polyvinyl Alcohol, PPS (Polyphylene Sulfide); and   the lubricity material is at least one material selected from the group of materials comprising Wax, Hydrogenated polyolefins, Silicones, Fluorocarbons, Graphite, Molybdenum Disulfide, Tungsten disulfide, Polyalpha-olefin (PAO), Synthetic esters, Polyalkylene glycols (PAG), Phosphate esters, Alkylated napthalenes (AN), Hexagonal boron nitride, Silicate esters, Glycerin, Polyvinyl alcohol (PVA), and Cellulose ether.   
     
     
         3 . A fiber structure as recited in  claim 1 , in which:
 the base fiber material is formed by at least one material selected from the group of materials consisting of Nylon, Polyester, High Modulus Polypropylene (HMPP), Olefin, Polyolefin, High Modulus Polyethylene (HMPE), Polyacrylonitrile, Carbon, Aramid, PBO (Poly(p-phenylene-2,6-benzobisoxazole), LCP (Liquid Crystal Polymer), PIPD (Poly[2,6-diimidazo(4,5-b:4′,5′-e)pyridinylene-1,4(2,5-dihydroxy)phenylen]), PBI (Polybenziadazole), PEN (Polyethylene Naphthalate), Glass, Basalt, Metals and metal alloys, PVC (Polyvinyl Chloride), PVDC (Polyvinylidene Chloride), Polyurethane-polyurea, Polyvinyl Alcohol, PPS (Polyphylene Sulfide); and   the lubricity material is at least one material selected from the group of materials consisting of Wax, Hydrogenated polyolefins, Silicones, Fluorocarbons, Graphite, Molybdenum Disulfide, Tungsten disulfide, Polyalpha-olefin (PAO), Synthetic esters, Polyalkylene glycols (PAG), Phosphate esters, Alkylated napthalenes (AN), Hexagonal boron nitride, Silicate esters, Glycerin, Polyvinyl alcohol (PVA), and Cellulose ether.   
     
     
         4 . A fiber structure as recited in  claim 1 , in which the at least one lubricity portion is distributed throughout the matrix of base fiber material. 
     
     
         5 . A fiber structure as recited in  claim 4 , in which at least some of the at least one lubricity portion defines at least a portion of the surface of the fiber structure. 
     
     
         6 . A fiber structure as recited in  claim 4 , in which the at least one lubricity portion is a coating applied to the base matrix. 
     
     
         7 . A fiber structure as recited in  claim 1 , in which the at least one lubricity portion is bonded by a binder matrix to the base matrix. 
     
     
         8 . A method of forming a fiber structure for forming a rope, comprising the steps of:
 providing a base fiber material;   providing an lubricity material; and   forming a fiber structure comprising a base matrix formed of the base fiber material and at least one lubricity portion formed of the lubricity material such that the lubricity material defines a lubricity of at least a portion of the base matrix.   
     
     
         9 . A method as recited in  claim 8 , in which the step of forming the matrix comprises one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process. 
     
     
         10 . A method as recited in  claim 8 , in which the step of forming the fiber structure comprises the step of combining the base fiber material and the additive fiber material when forming the base matrix. 
     
     
         11 . A method as recited in  claim 8 , in which the step of forming the fiber structure comprises the steps of:
 forming the base matrix using one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process; and   applying the lubricity material to the base matrix.   
     
     
         12 . A method as recited in  claim 8 , in which the step of forming the fiber structure comprises the steps of:
 forming the base matrix using one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process; and   forming a coating comprising the lubricity material on the base matrix.   
     
     
         13 . A method as recited in  claim 8 , in which the step of forming the fiber structure comprises the steps of:
 forming the base matrix using one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process; and   forming a resin matrix such that the resin matrix adheres the lubricity material to the base matrix.   
     
     
         14 . A method as recited in  claim 8 , in which:
 the step of the providing the base fiber material comprises the step of selecting at least one material from the group of materials consisting of Nylon, Polyester, High Modulus Polypropylene (HMPP), Olefin, Polyolefin, High Modulus Polyethylene (HMPE), Polyacrylonitrile, Carbon, Aramid, PBO (Poly(p-phenylene-2,6-benzobisoxazole), LCP (Liquid Crystal Polymer), PIPD (Poly[2,6-diimidazo(4,5-b:4′,5′-e)pyridinylene-1,4(2,5-dihydroxy)phenylen]), PBI (Polybenziadazole), PEN (Polyethylene Naphthalate), Glass, Basalt, Metals and metal alloys, PVC (Polyvinyl Chloride), PVDC (Polyvinylidene Chloride), Polyurethane-polyurea, Polyvinyl Alcohol, PPS (Polyphylene Sulfide); and   the step of providing the lubricity material comprises the step of selecting at least one material from the group of materials consisting of Wax, Hydrogenated polyolefins, Silicones, Fluorocarbons, Graphite, Molybdenum Disulfide, Tungsten disulfide, Polyalpha-olefin (PAO), Synthetic esters, Polyalkylene glycols (PAG), Phosphate esters, Alkylated napthalenes (AN), Hexagonal boron nitride, Silicate esters, Glycerin, Polyvinyl alcohol (PVA), and Cellulose ether.   
     
     
         15 . A method of forming a rope structure, comprising the steps of:
 providing a base fiber material;   providing an lubricity material;   forming a plurality of fiber structures each comprising a base matrix formed of the base fiber material and at least one lubricity portion formed of the lubricity material such that the lubricity material defines a lubricity of at least a portion of the base matrix;   combining the fiber structures to form a plurality of yarns; and   combining the plurality of yarns to form the rope structure.   
     
     
         16 . A method as recited in  claim 15 , in which the step of forming the base matrix comprises one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process. 
     
     
         17 . A method as recited in  claim 15 , in which the step of forming the fiber structure comprises the step of combining the base fiber material and the additive fiber material when forming the base matrix. 
     
     
         18 . A method as recited in  claim 15 , in which the step of forming the fiber structure comprises the steps of:
 forming the base matrix using one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process; and   applying the lubricity material to the base matrix.   
     
     
         19 . A method as recited in  claim 15 , in which the step of forming the fiber structure comprises the steps of:
 forming the base matrix using one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process; and   forming a coating comprising the lubricity material on the base matrix.   
     
     
         20 . A method as recited in  claim 15 , in which the step of forming the fiber structure comprises the steps of:
 forming the base matrix using one of an extrusion process, a dry spin process, a wet spin process, and a gel spin process; and   forming a resin matrix such that the resin matrix adheres the lubricity material to the base matrix.   
     
     
         21 . A method as recited in  claim 15 , in which:
 the step of the providing the base fiber material comprises the step of selecting at least one material from the group of materials consisting of Nylon, Polyester, High Modulus Polypropylene (HMPP), Olefin, Polyolefin, High Modulus Polyethylene (HMPE), Polyacrylonitrile, Carbon, Aramid, PBO (Poly(p-phenylene-2,6-benzobisoxazole), LCP (Liquid Crystal Polymer), PIPD (Poly[2,6-diimidazo(4,5-b:4′,5′-e)pyridinylene-1,4(2,5-dihydroxy)phenylen]), PBI (Polybenziadazole), PEN (Polyethylene Naphthalate), Glass, Basalt, Metals and metal alloys, PVC (Polyvinyl Chloride), PVDC (Polyvinylidene Chloride), Polyurethane-polyurea, Polyvinyl Alcohol, PPS (Polyphylene Sulfide); and   the step of providing the lubricity material comprises the step of selecting at least one material from the group of materials consisting of Wax, Hydrogenated polyolefins, Silicones, Fluorocarbons, Graphite, Molybdenum Disulfide, Tungsten disulfide, Polyalpha-olefin (PAO), Synthetic esters, Polyalkylene glycols (PAG), Phosphate esters, Alkylated napthalenes (AN), Hexagonal boron nitride, Silicate esters, Glycerin, Polyvinyl alcohol (PVA), and Cellulose ether.