USOO9506188B2

(12) United States Patent (10) Patent No.: US 9,506,188 B2

Pourladian et al. (45) Date of Patent: Nov. 29, 2016
(54) TORQUE BALANCED HYBRID ROPE (58) Field of Classification Search
CPC ... D07B 1/005: D07B 1/0686: D07B 1/141;
(71) Applicant: WireCo WorldGroup Inc., Kansas D07B 1/144: D07B5/007
City, MO (US) USPC ........................................... 57/222, 237, 238
See application file for complete search history.
(72) Inventors: Bamdad Pourladian, Kansas City, KS (56) References Cited
(US); Gregory John D'Elia, Hatboro,
PA (US) U.S. PATENT DOCUMENTS

(73) Assignee: WIRECO WORLDGROUP, INC., 2,018,230 A * 10/1935 Robertson ....................... 57 222
Prairie Village, KS (US) 3,092,956 A 6/1963 Naysmith
(Continued)
(*) Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35 FOREIGN PATENT DOCUMENTS
U.S.C. 154(b) by 0 days. GB 1391355 4, 1975
(21) Appl. No.: 14/211,237
OTHER PUBLICATIONS
(22) Filed: Mar. 14, 2014
Timothy W. Klein. The Changing Culture of Wire Ropes for Vertical
(65) Prior Publication Data Lift Bridges, Heavy Movable Structures, Inc. Thirteenth Biennial
Symposium, Oct. 25-28, 2010, 10 pages.
US 2014/026O175 A1 Sep. 18, 2014
Primary Examiner — Shaun R Hurley
(74) Attorney, Agent, or Firm — Husch Blackwell LLP
Related U.S. Application Data
(57) ABSTRACT
(60) Provisional application No. 61/785,823, filed on Mar.
14, 2013. A hybrid rope constructed of a plurality of strands, wherein
each strand is constructed of a fiber center, a jacket Sur
(51) Int. C. rounding the fiber center, and a plurality of wires Surround
D07BL/6 (2006.01) ing the jacket. The fiber center can be constructed of one or
D07B I/O (2006.01) more high-strength synthetic fibers or yarns. The jacket can
D07B5/00 (2006.01) be constructed of polypropylene, thermoplastic polyure
thane, high-density polyethylene, linear low-density poly
(Continued) ethylene, nylon or other similar materials. The jacket can
(52) U.S. C. have a braided or woven design and adds a protective layer
CPC ............. D07B I/0686 (2013.01): D07B I/005 between the fiber center and the wires. The wires can be
(2013.01): D07B I/141 (2013.01): D07B constructed of high-strength steel wires, galvanized steel or
5/007 (2013.01): D07B I/08 (2013.01): D07B stainless steel. The fibers or yarns that make of the fiber
220.1/1064 (2013.01): D07B 2.201/2002 center are twisted to lay right and then covered with the
(2013.01): D07B 2201/2019 (2013.01): D07B jacket. The wires then surround the jacket and are twisted to
2201/2074 (2013.01): D07B 2205/205 lay to the left. This creates a torque-balanced condition of
(2013.01): D07B 2205/2014 (2013.01); the hybrid rope.
(Continued) 20 Claims, 5 Drawing Sheets
 US 9,506,188 B2
Page 2

(51) Int. C. 4,365.467 A 12, 1982 Pellow

D07B I/4 (2006.01) 4,807,680 A * 2/1989 Weidenhaupt ........... Dogs
DO7B I/OS (2006.01) 4,878,343 A * 11/1989 Weidenhaupt ........... DO2G 3/48
CPC ................ D07B 2205/2042 (2013.01): D07B 4,887,422 A 12/1989 Klees et al.
2205/2096 (2013.01): D07B 2401/2015 5,797.254. A * 8/1998 Walton ............................ 57 220
(2013.01) 6,334.293 B1 1/2002 Poethke et al.
6,412.264 B1* 7/2002 De Josez et al. ............... 57/217
(56) References Cited 6,563,054 B1* 5/2003 Damien et al. ... 174f120 C
8,079.208 B2 * 12/2011 Volpi .............................. 57 222
U.S. PATENT DOCUMENTS 8,176,718 B2 5/2012 Ridge et al.
8,438,826 B2 * 5/2013 Pourladian et al. ............ 57/237
3,374,619 A 3, 1968 Adams et al. 2010/0162882 A1* 7/2010 Shakespeare ....................... 87.6
3,686,855 A * 8/1972 Falcy et al. ..................... 57 220 2012,0085.077 A1 4/2012 Pourladian et al.
3,705,489 A 12/1972 Smollinger 2012/01599.19 A1* 6, 2012 Gauthier et al. ................ 57 212
4,106,276 A 8/1978 Hosoya
4.321,854 A 3, 1982 Foote et al. * cited by examiner
U.S. Patent Nov. 29, 2016 Sheet 1 of 5 US 9,506,188 B2

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U.S. Patent NOV. 29, 2016 Sheet 2 of 5 US 9,506,188 B2
U.S. Patent Nov. 29, 2016 Sheet 3 of 5 US 9,506,188 B2
U.S. Patent Nov. 29, 2016 Sheet 4 of 5 US 9,506,188 B2

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 US 9,506, 188 B2
1. 2
TORQUE BALANCED HYBRID ROPE cause damage to the equipment being hoisted and Surround
ing property, or potentially many other undesirable and/or
CROSS-REFERENCE TO RELATED dangerous conditions.
APPLICATIONS There is a substantial need in the art for a reduced-weight
torque-balanced rope that (i) provides the strength-to-weight
This Application claims priority to U.S. Provisional Pat ratio of high-strength synthetic rope, (ii) provides the tensile
ent Application Ser. No. 61/785,823, filed on Mar. 14, 2013, strength provided by wire rope or high-strength synthetic
entitled “Torque Balanced Hybrid Rope., the entire disclo rope, (iii) is cut and abrasion resistant, and (iv) has the
sure of which is incorporated herein by reference. 10
desired durability of wire rope for rope or tension members
that are used in running-rope or other applications.
BACKGROUND OF THE INVENTION
SUMMARY
High-strength ropes are used for many commercial and
recreational purposes; many of which require long continu- 15 One embodiment of present invention is directed to a
ous lengths to perform the desired function. For example, reduced-weight torque-balanced rope that (i) provides the
applications such as deep sea moorings, deep shaft hoisting, strength-to-weight ratio of high-strength synthetic rope, (ii)
deep-sea winching, tower cranes, aerial lifting or hoisting, provides the tensile strength provided by wire rope or
and other applications. Many of these applications require a high-strength synthetic rope, (iii) is cut and abrasion resis
substantial length of rope to perform its function, and the 20 tant, and (iv) has the desired durability of wire rope for rope
self-weight of the rope may become excessive and hinder or tension members that are used in running-rope or other
the ability to perform the desired function. Moreover, applications.
because many of these applications involve hoisting or The rope is a hybrid rope constructed of both fiber and
lifting objects, it is desirable for these ropes to be torque wires. A plurality of strands are twisted and then compacted
balanced; that is, the configuration of the lay of the indi- 25 together to construct the hybrid rope. Each strand can be
vidual wires comprising the rope Strands and the twist of the constructed of a fiber center, a jacket Surrounding the fiber
rope strands in order to form the rope are substantially center, and a plurality of wires Surrounding the jacket. The
balanced Such that the rope inherently resists rotating when fiber center can be constructed of one or more high-strength
a tension force is applied. synthetic fibers or yarns. The jacket can be constructed of
If the rope is not torque-balanced, the item being hoisted 30 polypropylene, thermoplastic polyurethane, high-density
or lifted will just rotate in a circle which may introduce polyethylene, linear low-density polyethylene, nylon or
imbalance or other undesirable forces or movements. Many other similar materials. The jacket can have a braided or
of the commercial applications utilize wire rope because it woven design and adds a protective layer between the fiber
provides a high strength and sufficient ductility thereby center and the wires. The wires can be constructed of
allowing for a gradual and visual indication of failure or 35 high-strength steel wires, galvanized steel or stainless steel.
damage prior to actual failure. The ability to detect potential
failures using non-destructive testing is paramount for many The fibers or yarns that make of the fiber center are
of these applications as it allows rope defects to be observed twisted to lay right and then covered with the jacket. The
by operators and inspectors prior to the occurrence of an wires then surround the jacket and are twisted to lay to the
actual failure and thereby prevent accidents. 40 left. This creates a torque-balanced condition of the hybrid
One persistent shortcoming in the art is that the weight of rope.
wire rope limits many applications because the wire rope Other aspects and advantages of the present invention will
itself weighs so much that it significantly works against the be apparent from the following detailed description of the
desired functionality of the application utilizing wire rope. preferred embodiments and the accompanying drawing fig
One option available is to reduce the weight of the rope by 45 U.S.
using lighter-weight, high-strength synthetic fiber ropes.
High-strength synthetic fiber ropes provide a desirable BRIEF DESCRIPTION OF THE SEVERAL
strength-to-weight ratio and may also be torque-balanced or VIEWS OF THE DRAWING
rotation resistant. However, in any running rope applications
wherein the rope has to be spooled on a multilayer drum or 50 The accompanying drawings form a part of the specifi
winch, synthetic ropes tend to perform poorly. Synthetic cation and are to be read in conjunction therewith, in which
fiber ropes often fail in running rope applications because like reference numerals are employed to indicate like or
they lack the abrasion resistance and durability necessary. similar parts in the various views, and wherein:
Further, synthetic fiber rope tends to flatten when it is wound FIG. 1 is a side view of one embodiment of a hybrid rope
under tension and thus, it is not ideal for multi-layer spool- 55 in accordance with the teachings of the present invention;
ing applications. The continual abrasion and flattening out of FIG. 2 is a cross-sectional view of one embodiment of a
wire rope when it is spooled on a drum or winch gradually jacketed fiber center of the hybrid rope of FIG. 1 in
breaks down the fibers thereby gradually reducing the accordance with the teachings of the present invention;
strength of the rope. This reduction in strength is usually not FIG. 3 is a side view of one embodiment of a fiber center
detectable using non-destructive testing thereby leaving the 60 of the hybrid rope of FIG. 1 in accordance with the teachings
condition of the rope unknown at any given time. If the of the present invention;
actual strength of the rope decreases to a point that it is lower FIG. 4 is a sectional view of one embodiment of a braided
than the working stress required for the application, then a jacket in accordance with the teachings of the present
Sudden failure may occur. Since the working stress is invention;
experienced when the rope is hoisting or otherwise being 65 FIG. 5 is a cross-sectional view of one embodiment of a
tensioned, a sudden failure of the wire rope would only single strand of the hybrid rope of FIG. 1 in accordance with
occur when it is loaded and would put workers at risk and/or the teachings of the present invention;
 US 9,506,188 B2
3 4
FIG. 6 is a cross-sectional view of one embodiment of the right or to the left. The entirety of hybrid rope 10 can
four strands used to construct the hybrid rope of FIG. 1 in have a size from about 6 mm to about 76 mm in diameter.
accordance with the teachings of the present invention; As further shown in FIG. 3, fiber center 14 may include
FIG. 7 is a cross-sectional view of one embodiment of the a binder that lays opposite fiber strands 20 as shown. Binder
four strands of FIG. 6 after compaction in accordance with 22 is configured to hold the fiber strands 20 from unwrap
the teachings of the present invention; and ping. Fiber center 14 can have the configuration as shown in
FIG. 8 is a cross-sectional view of one embodiment of a FIG. 5. Alternatively, tape (not shown) could be used instead
single strand of a hybrid rope in accordance with the of fibers for binder 22 or the yarns of fiber center 14. The
teachings of the present invention. tape may be made of, but is not limited to, Teflon(R) made by
10 E.I. du Pont de Nemours and Company, Kevlar R) made by
DETAILED DESCRIPTION OF THE E.I. du Pont de Nemours and Company, UHMPE, Endu
INVENTION max(R) made by Teijin Aramid, or ePTFE. The tape may be
used in addition to or instead of a braided jacket.
The invention will now be described with reference to the As shown if FIG. 2, jacket 16 includes an inner surface 26
drawing figures, in which like reference numerals refer to 15 and an outer Surface 28 that defines a material thickness.
like parts throughout. For purposes of clarity in illustrating Jacket 16 surrounds fiber center 14 substantially along the
the characteristics of the present invention, proportional entire length of fiber center 14 creating a jacketed fiber 24
relationships of the elements have not necessarily been center. Jacket 16 can be polypropylene, thermoplastic poly
maintained in the drawing figures. urethane, high-density polyethylene, linear low-density
The following detailed description of the invention ref polyethylene, nylon, or other like materials. As shown in
erences specific embodiments in which the invention can be FIG. 4, jacket 16 can have a braided or woven design. Jacket
practiced. The embodiments are intended to describe aspects 16 adds a protective layer between fiber center 14 and wires
of the invention in sufficient detail to enable those skilled in 18.
the art to practice the invention. Other embodiments can be As shown in FIG. 5, each strand 12 has a plurality of wires
utilized and changes can be made without departing from the 25 18 wrapped around core 14. As shown in FIG. 5, wires 18
Scope of the present invention. The present invention is may deform into and create an indentation 30 in a portion of
defined by the appended claims and the description is, outer surface 28 of jacket 16 thereby seating wires 18 in
therefore, not to be taken in a limiting sense and shall not jacket 16. One embodiment includes sixteen (16) wires 18
limit the scope of equivalents to which Such claims are wrapped around jacketed fiber center 24. However, any
entitled. 30 number of wires 18 may be used. Wires 18 provide strength
A hybrid rope 10 embodying various features of the and abrasion resistance when combined with jacketed fiber
present invention is shown in FIG. 1. As illustrated in FIG. center 24. Another embodiment includes wires 18 having a
1, the present invention is directed toward hybrid rope 10 diameter from about 0.03 inches to 0.15 inches. However,
comprising a plurality of Strands 12 twisted together. As any wire diameter known in the art is within the scope of the
shown in FIG. 5, each strand 12 comprises a fiber center 14, 35 present invention. The diameter of each wire 18 and the
a jacket 16 Surrounding fiber center 14, and a plurality of outer diameter of the jacketed fiber center 24 will necessar
wires 18 surrounding jacket 16. ily determine the number of wires 18 utilized in hybrid rope
As shown in FIG. 2, fiber center 14 is surrounded by 10 of the present invention and the out-to-out dimension of
jacket 16. As shown in FIG. 3, one embodiment of fiber hybrid rope 10. Wires 18 are generally high-strength steel
center 14 comprises a plurality of fiber strands 20. One 40 wires having an ultimate tensile strength in a range between
embodiment includes fiber center 14 having seven fiber about one thousand seven hundred (1700) MPa and about
strands 20, though any number of fiber strands 20 may be two thousand seven hundred (2700) MPa. Wires 18 may also
used. For example, an embodiment of fiber center 14 may be be galvanized or stainless steel, or any metal or alloy that
comprised of four to twelve (4-12) fiber strands 20 twisted provides desired traits for the environment in which hybrid
at a particular angle and fiber Strands 20 may be one of 45 rope 10 is to be used.
various known diameters, including from about 0.159 inches FIG. 1 shows an embodiment of hybrid rope 10 wherein
to 0.370 inches in diameter. Fiber strands 20 are comprised wires 18 of strand 12 are wrapped around jacketed fiber
of one or a combination of high-strength synthetic fibers or center 24 in a lay left configuration. Further, as shown in
yarns. In one embodiment, each fiber strand 20 is made up FIG. 1, strands 12 are twisted to lay right. The opposing lay
of eleven (11) yarns where each yarn is made up of a 50 of the twist of strands 12 and the lay of wires 18 contribute
plurality of fibers. Any high-strength or high modulus fibers to the torque-balancing or rotation-resistance of hybrid rope
may be used including: aramid fibers, such as Kevlar R made 10. As such, the lay of wires 18 wrapped around fiber center
by E.I. du Pont de Nemours and Company, Twaron(R) made 14 will generally be the opposite of the lay of the strands 20
by Teijin Aramid, or Technora R) made by Teij in Aramid: twisted into hybrid rope 10. Although this is a common lay
liquid-crystal polymer fibers, such as Vectran?R) made by 55 configuration, strands 12 can be twisted to lay left. More
Kuraray Co. Ltd.; ultra-high molecular weight polyethylene; over, the helix angle at which both fiber strands 20 of fiber
poly(p-phenylene-2,6-benzobisoxazole) fibers, such as center 14, wires 18 and strands 12 are wrapped contribute to
Zylon R) made by Toyobo Corporation; or any other high the rotational properties of hybrid rope 10. Wires 18 and
strength or high modulus fiber now known or hereafter Strands 12 may be wrapped at any helix angle now known
developed. 60 and more preferably at 12.5 degrees. Accordingly, the helix
One embodiment of fiber center 14 includes having a angle for each strand 12 and 20, and wire 18 may be
plurality of fiber Strands 20 twisted at a lay angle in a range optimized together to provide the optimal torque-balanced
between about one and about thirty degrees (1-30). One condition. The lay direction and helix angle of fiber strands
embodiment includes fiber strands 20 having a lay angle of 20 in fiber center 14 also contribute to the optimal torque
about two degrees (2). Another embodiment includes fiber 65 balance.
Strands 20 having a lay angle of about twelve and one-half Referring to FIG. 6, illustrates hybrid rope 10 having four
degrees (12.5°). Fiber strands 20 may be configured to lay to Strands 12 and having a closed spiral (or helical) arrange
 US 9,506,188 B2
5 6
ment. Hybrid rope 10 is torque-balanced as described here 3. The hybrid rope of claim 2 wherein said jacket is
inabove. Referring to FIG. 7, one embodiment of hybrid braided over said fiber center.
rope 10 may be compacted as a final manufacturing step 4. The hybrid rope of claim 3 wherein said jacket is made
after Strands 12 are closed and helically arranged to form of one of polypropylene, thermoplastic polyurethane, high
hybrid rope 10. Hybrid rope 10 is compacted resulting in density polyethylene, linear low-density polyethylene, or
each substantially circular strand 12 (as shown in FIG. 6) nylon.
having a “triangular shape wherein the outer surface 32 of 5. The hybrid rope of claim 1 wherein said plurality of
strands 12 include a flattened portion 34 wherein a strand 12 wires fibers is spirally arranged with a helical angle of
engages another Strand 12 (as shown in FIG. 7). Compaction approximately 12.5.
can include swaying or roller die compaction methods. 10 6. The hybrid rope of claim 1 wherein said plurality of
Further, wires 18 may also include another flattened portion fibers is made of one of aramid fibers, liquid-crystal polymer
36 and wherein the outer surface 38 of hybrid rope 10. The fibers, ultra high molecular weight polyethylene fibers,
poly(p-phenylene-2,6-benzobisoxazole) fibers, or high
compacting of hybrid rope 10 allows it to have a substan modulus fibers.
tially uniform outer surface 38 that facilitates wrapping of 7. The hybrid rope of claim 6 wherein said plurality of
hybrid rope 10 on spools or other wrapping device and may 15 fibers is seven.
further contribute to hybrid rope 10 not “flattening out 8. The hybrid rope of claim 1 wherein said plurality of
during spooling under tension. wires is sixteen.
The embodiment of hybrid rope 10 shown in FIGS. 1 9. The hybrid rope of claim 1 wherein said plurality of
through 7 is configured to provide substantially the same Strands is four.
tension load capacity as currently used for 3x19 rope for 10. The hybrid rope of claim 1 further comprising a
similar applications. As such, the outer diameter of hybrid lubricant applied to said fiber centerprior to said fiber center
rope 10 will be substantially equal to the diameter of the being jacketed.
3x19 rope currently known in the art. However, an embodi 11. The hybrid rope of claim 1 wherein said hybrid rope
ment hybrid rope 10 is configured to provide a thirty percent is compacted by a Swaging or roller die compaction process.
(30%) or more reduction in rope weight than standard 3x19 25
12. The hybrid rope of claim 1 wherein said a plurality of
torque balanced wire rope. This embodiment substantially fibers is spirally arranged to the left and said plurality of
matches the out-to-out dimensions of standard 3x19 wire wires is spirally arranged to the left around said plurality of
rope known in the art. fibers and wherein said hybrid rope is twisted to the right.
FIG. 8 illustrates an embodiment where wires 18 have a 13. A torque balanced hybrid rope comprising:
substantially 'D' shaped cross-section wherein the “curved 30
a plurality of Strands having a closed spiral arrangement
side' is in contact with jacket 16 as shown. Alternatively, the with each other, wherein each said Strand includes a
wires can have a variety of shapes, including a “Z” shape. fiber center made up of a plurality of fibers spirally
From the foregoing it will be seen that this invention is arranged to the left with a helical angle of approxi
one well adapted to attain all ends and objects hereinabove mately between 2 and 12.5 degrees, a jacket Surround
set forth together with the other advantages which are 35
ing said fiber center, and a plurality of wires spirally
obvious and which are inherent to the structure. arranged to the left around said plurality of fibers and
It will be understood that certain features and subcombi wherein said hybrid rope is twisted to the right so that
nations are of utility and may be employed without reference said hybrid rope resists rotating when a tension force is
to other features and subcombinations. This is contemplated applied to the rope in a lifting operation.
by and is within the scope of the claims. 40
14. The hybrid rope of claim 13 wherein said jacket is
Since many possible embodiments may be made of the made of one of polypropylene, thermoplastic polyurethane,
invention without departing from the scope thereof, it is to high-density polyethylene, linear low-density polyethylene,
be understood that all matter herein set forth or shown in the or nylon.
accompanying drawings is to be interpreted as illustrative, 15. The hybrid rope of claim 13 wherein said plurality of
and not in a limiting sense. 45
fibers is spirally arranged with a helical angle of approxi
What is claimed is: mately 12.5 degrees.
1. A torque balanced hybrid rope comprising: 16. The hybrid rope of claim 13 wherein said plurality of
a plurality of Strands having a closed spiral arrangement fibers is one of aramid fibers, liquid-crystal polymer fibers,
with each other, wherein each said Strand includes a ultra high molecular weight polyethylene fibers, poly(p-
50 phenylene-2,6-benzobisoxazole) fibers, or high modulus
fiber center comprising a plurality of fibers spirally fibers.
arranged with a helical angle of approximately between
2 and 12.5 degrees and surrounded by a plurality of 17. The hybrid rope of claim 13 wherein said plurality of
fibers is seven.
wires spirally arranged in the same direction as said 18. The hybrid rope of claim 13 wherein said plurality of
plurality of fibers around said fiber center, and wherein 55 Strands is four.
said plurality of strands is twisted in an opposite 19. The hybrid rope of claim 13 further comprising a
direction as said plurality of fibers and said plurality of lubricant applied to said fiber centerprior to said fiber center
wires so that said hybrid rope resists rotating when a being jacketed.
tension force is applied to the rope in a lifting opera
tion. 60
20. The hybrid rope of claim 13 wherein said hybrid rope
2. The hybrid rope of claim 1 further comprising a jacket is compacted by a Swaging or roller die compaction process.
Surrounding said fiber center. k k k k k