Methods of Forming Wrapped Yarns and Ropes Having Predetermined Surface Characteristics

Abstract

A plurality of first fibers and a plurality of second fibers are provided. A coefficient of friction of the second fibers is greater than a coefficient of friction of the first fibers. Abrasion resistance characteristics of the second fibers are greater than abrasion resistance properties of the first fibers. A gripping ability of the second fibers is greater than a gripping ability of the first fibers. The first fibers and the second fibers are passed through a convergence duct such that the first fibers pick up the second fibers. A false twist is imparted to the combination of the plurality of first fibers and the plurality of second fibers. The false twist is removed from the combination of the plurality of first fibers and the plurality of second fibers to form the blended yarn.

What is claimed is: 
     
         1 . A method of forming a blended yarn comprising the steps of:
 providing a plurality of first fibers, where the first fibers are sized to extend along a length of the blended yarn; and   providing a plurality of second fibers, where
 the second fibers are sized to extend only partly along a length of the blended yarn, 
 a coefficient of friction of the second fibers is greater than a coefficient of friction of the first fibers, 
 abrasion resistance characteristics of the second fibers are greater than abrasion resistance properties of the first fibers, and 
 a gripping ability of the second fibers is greater than a gripping ability of the first fibers; 
   forming a combination of the plurality of first fibers and the plurality of second fibers by passing the plurality of first fibers and the plurality of second fibers through a convergence duct such that the first fibers pick up the second fibers;   imparting a false twist to the combination of the plurality of first fibers and the plurality of second fibers by passing the combination of the plurality of first fibers and the plurality of second fibers through a false-twisting device;   removing the false twist from the combination of the plurality of first fibers and the plurality of second fibers to form the blended yarn.   
     
     
         2 . A method as recited in  claim 1 , in which at least a portion of the second fibers are engaged with and extend from the plurality of first fibers to define surface characteristics of the blended yarn. 
     
     
         3 . A method as recited in  claim 1 , in which step of forming the combination of the plurality of first fibers and the plurality of second fibers comprises the step of arranging the second fibers to at least partly surround the first fibers. 
     
     
         4 . A method as recited in  claim 1 , in which step of forming the combination of the plurality of first fibers and the plurality of second fibers comprises the step of forming a core comprising the first fibers, where the second fibers surround the first fibers. 
     
     
         5 . A method as recited in  claim 1 , in which the second fibers comprise at least one fiber selected from the group of fibers consisting of polyester, nylon, Aramid, LCP, and HMPE fibers. 
     
     
         6 . A method as recited in  claim 1 , in which the second fibers are polyester fibers. 
     
     
         7 . A method as recited in  claim 6 , in which the blended yarn comprises about sixty to eighty percent by weight of the first fibers and about twenty to forty percent by weight of the second fibers. 
     
     
         8 . A method as recited in  claim 1 , in which the second fibers are LCP and Aramid fibers. 
     
     
         9 . A method as recited in  claim 8 , in which the blended yarn comprises about fifteen to thirty-five percent by weight of the first fibers and about sixty-five to eighty five percent by weight of the second fibers. 
     
     
         10 . A method as recited in  claim 1 , in which the first fibers are HMPE fibers. 
     
     
         11 . A method as recited in  claim 1 , further comprising the step of forming a braided rope formed from a plurality of blended yarns. 
     
     
         12 . A method as recited in  claim 11 , in which the step of forming the braided rope further comprises the step of forming a core and a jacket. 
     
     
         13 . A method as recited in  claim 11 , in which the step of forming the braided rope further comprises the step of forming a double braided rope. 
     
     
         14 . A method as recited in  claim 1 , further comprising the steps of:
 combining a plurality of the blended yarns to form a plurality of strands; and   combining the plurality of strands are combined to form a rope.   
     
     
         15 . A method of forming a rope comprising the steps of:
 providing a first set of first fibers;   providing a second set of second fibers;   combining the first and second sets of fibers to form a plurality of wrapped yarns such that
 the first set of the first fibers forms a core that is substantially surrounded by the second set, 
 the first fibers substantially determine the load bearing characteristics of the rope, and 
 the second fibers substantially determine abrasion resistance properties and gripping ability of the rope; and 
   applying a tension load on the rope such that
 the tension loads on the rope are primarily borne by the first fibers, and 
 the second fibers substantially determine friction, abrasion resistance, and gripping ability of the rope. 
   
     
     
         16 . A method as recited in  claim 15 , in which the second fibers at least partly surround the first fibers. 
     
     
         17 . A method as recited in  claim 15 , in which the first fibers are formed of HMPE and the second fibers are formed of polyester. 
     
     
         18 . A method of forming a blended yarn comprising the steps of:
 selecting a plurality of first fibers and a plurality of second fibers such that
 a coefficient of friction of the second fibers is greater than a coefficient of friction of the first fibers, 
 abrasion resistance characteristics of the second fibers are greater than abrasion resistance properties of the first fibers, and 
 a gripping ability of the second fibers is greater than a gripping ability of the first fibers; 
   combining the plurality of second fibers with the plurality of first fibers using a false-twisting process such that
 the first fibers extend along the length of the blended yarn and the second fibers do not extend along the length of the blended yarn, and 
 at least a portion of the second fibers are engaged with and extend from the plurality of first fibers effectively to define surface characteristics of the blended yarn; and 
   applying a tension load to the blended yarn such that
 the tension loads on the blended yarn are primarily borne by the first fibers, and 
 the second fibers substantially determine friction, abrasion resistance, and gripping ability of the blended yarn. 
   
     
     
         19 . A method as recited in  claim 18 , in which the second fibers at least partly surround the first fibers. 
     
     
         20 . A method as recited in  claim 18 , in which at least a plurality of the first fibers are continuous and at least a plurality of the second fibers are discontinuous.