Technical Field

The present disclosure relates to ropes and more particularly to coverbraided ropes and especially to methods for forming spliced connections in coverbraided ropes.

Background Art

Tightly coverbraided ropes are well known as the most easy to handle, most abrasion resistant and least likely to tangle rope type for many applications. These applications include but are not limited to synthetic warps and towlines, synthetic trawler warps, yachting lines, anchoring lines, deep water mooring lines, deep water oil derrick anchoring lines, seismic lines, paravane and superwide lines, rigging lines, ropes for forming pelagic mesh in pelagic trawls and many other.

Tightly coverbraided ropes also have other benefits including safety when used around persons. For example, a tightly coverbraided rope when properly made usually is able to be easily visually inspected to ascertain that the coverbraided sheath protecting the strength member has not failed and thus the rope should be safe to use.

In the commercial pelagic trawl fishing industry, tightly coverbraided ropes exhibit far superior stiffness and resistance to tangling than any other type of rope. For this reason, they are highly favored for certain portions of pelagic trawl's, especially the pelagic mesh (i.e. mesh having greater than four meters in mesh size) used in forming the front part top and side portions, and often used in forming the front part bottom portion as well. A self spreading coverbraided rope known as

"Helix rope", used in trawls sold by Hampidjan HF of Iceland are one form of coverbraided rope that both are easy to handle and also can be used to maintain open a trawl net, increasing catch efficiency, improving selective fishing and preventing marine mammal drowning.

In use in anchoring lines and mooring lines of all types, and in towing lines including superwides, trawler warps and towing warps of all kinds, and wherever it is desired to substitute steel cable, chain or other ropes with a lighter, long lasting and durable synthetic rope, a rope Manufactured by Hampidjan HF of Iceland and known as Dynex Dux is increasing in popularity among certain customer bases. A problem in using this rope is that, as is the problem with all other tightly coverbraided ropes, the coverbraid is extremely difficult to include into a splice braid zone and to harness most of its strength in the rope. Thus, because the coverbraid is formed of a considerable proportion of the rope's material, the expense incurred in forming the coverbraid is not recovered in the useful strength of the rope, increasing its cost and slowing its acceptance. As one of the benefits of such a rope is greatly increased safety compared to steel wire or in some cases chain, especially because when the steel wire or chain breaks it is known to be crippling and even fatal whereas a Dynex Dux is essentially harmless in the same situation, it is important to increase the use of such rope in place of these more dangerous alternatives.

It is very difficult to splice tightly coverbraided (herein including "overbraided") ropes. This is due to the fact that good quality coverbraided ropes have very tight covers (i.e. "braided sheaths"). That is, the braided sheaths are very tightly braided around a core that itself is a strength member. Due to the tightness of the braiding it is not economically feasible to separate the sheath from the core a sufficient amount needed to permit passing a terminal end of the rope through the cover and especially through the core, as is needed to form a maximally strong splice, without weakening or breaking the braided sheath. To overcome these difficulties in the commercial pelagic trawl net industry, for several years some net makers have resorted to clamping the coverbraided ropes used to form pelagic trawl mesh. However, the clamps pose other problems such as excessive wear of the trawls when the relatively hard clamp abrades the relatively softer rope. Furthermore, clamps often much reduce the longevity of a rope, i.e. the strength retention over time. Users of coverbraided ropes as towing warps, seismic lines, yachting lines and anchoring lines of all types have resorted to discarding a portion of the coverbraid in the vicinity of any splice braid zone where an eye is formed and merely forming a splice in the strength member without including the coverbraid.

Consequently, due to the above problems in the art, coverbraided ropes are expensive compared to the strength harnessed from the material used in forming them. When the coverbraided rope is subjected to water flow about itself, the additional bulk caused by the coverbraid without an efficacious harness of strength from the material forming the coverbraid means a high and wasteful drag in water. However, the coverbraid is necessary for the reasons described supra. That is, it is not a good alternative to use a rope without a protective and stiffening coverbraid for the applications described supra such as warps, towlines, trawler warps, superwide and paravane lines, seismic lines, anchoring lines, deep water oil derrick anchoring lines, yachting ropes, ropes for pelagic trawl mesh and many others. Thus, where the drag in water of the bulky coverbraid that does not well contribute to rope strength is problematic, end users are forced to use steel wire or chain. As mentioned supra, steel wire or chain themselves have the disadvantage of being unsafe, as well as other disadvantages including requiring larger and more expensive support structures when steel wire or chain is used in many applications including but not limited to deep water oil derrick mooring applications, yachting applications, trawling applications, towing warp including trawling warp applications, seismic applications and other. In trawling applications, helix ropes in particular have lost favor among trawl makers, despite their other advantages. In the case of helix ropes, because one of these other advantages is that helix ropes are the most environmentally friendly rope for use in forming a pelagic trawl net, and permit forming a most environmentally friendly trawl net that minimizes incidental catch and does not collapse and drown marine mammals, it is a great loss to fishery resources and marine mammal conservation that helix ropes have lost favor among pelagic trawl fishermen.

Among users of other types of coverbraided ropes, concern exists that as the coverbraid cannot be truly included in a splice in such a fashion that it contributes to the strength of the rope' s terminal connections, that the ropes are rather expensive compared to the strength provided.

Consequently, the use of less safe but less expensive alternatives continues to plague the workforce in many industries.

Thus, it can readily be appreciated that a long felt need exists in the industry for a construction and method that permits splicing coverbraided ropes and especially tightly coverbraided ropes in such a way that the spliced rope retains more strength than a knotted variant of such rope.

DEFINITIONS "Core Rope": means a portion of rope, twine, other cordage or flexible linear element that is intended to be enclosed within a sheath or other protective layer, or that already is enclosed within a sheath or other protective layer. "Helix Rope" means a coverbraided rope and especially a tightly coverbraided rope where several distinct strands form the coverbraid and where at least one of those several distinct strands is sufficiently larger in width and/or diameter than the other strands that that the rope acquires a definite lay direction that is either Right handed or Left handed, with a spiral, or helixing shape, and also that cambered sections are formed by the relief caused by such larger width and/or diameter strand's inclusion in the braided sheath.

"Sling": means a portion of rope, twine, other cordage or flexible linear element having an eye at each end, or having at least one eye at one end. For example, a "sling of helix rope" or a "helix rope sling" can be a portion of helix rope having an eye at each end.

Disclosure

It is an object of the present disclosure to provide a method for splicing coverbraided ropes including all types of synthetic and mainly synthetic towing warps, trawling warps, superwides and paravane lines, seismic lines, anchoring lines of all types, yachting ropes, rigging ropes, deep water oil derrick and other oil derrick anchoring and mooring lines, ropes for forming pelagic trawl mesh, helix ropes and other where such method provides for greater strength than knotted coverbraided ropes including than knotted helix ropes.

It is another object of the present disclosure to provide a method for splicing coverbraided ropes including all the types of synthetic and mainly synthetic ropes and lines mentioned supra where such method provides for reduced wear and greater longevity than knotted coverbraided ropes including than knotted helix ropes.

Disclosed is a method for forming a strong spliced eye connection in coverbraided ropes including in tightly coverbraided ropes including all the types of synthetic and mainly synthetic ropes and lines mentioned supra where a removable void spacer is used to create a tunnel into which a section of the same coverbraid sheath enclosing a strength member core but formed either with or without the strength member core rope inside of it is able to be positioned in between the strength member core and the coverbraid sheath enclosing the strength member core in the vicinity of the spliced eye's splice braid zone, thereby forming a spliced eye connection and thus accomplishing the objects of the present disclosure.

Also disclosed is a method for forming a strong spliced eye connection in coverbraided ropes including in tightly coverbraided ropes where a removable void spacer is used to create a tunnel into which a section of the same coverbraid sheath enclosing a strength member core but formed either with or without the strength member core rope inside of it is able to be positioned within the strands of the strength member core, such as within the longitudinal center of a hollow braided strength member core, where the strength member core also is or becomes enclosed with the coverbraid sheath in the vicinity of the spliced eye's splice braid zone, thereby forming a spliced eye connection and thus accomplishing the objects of the present disclosure.

Due to the spliced tightly coverbraided rope of the present disclosure harnessing much, most or all of the strength of the coverbraid in the ultimate break strength of the rope, the diameter of a rope needed for any application is reduced, thereby reducing costs of the rope, reducing drag in water and thus costs to use the rope including fuel consumption costs in towing applications and including structural costs in both mooring, anchoring, oil derrick mooring, towing and trawling applications, including superstructure costs associated with deploying, floating and storing steel wire and chain anchoring and mooring lines, steel wire towing warps and trawling warps and much more vs. storing synthetic and mainly synthetic versions of such lines and warps. The lowered costs of acquisition and use promote acquisition and use of the spliced coverbraided rope of the present disclosure, thereby permitting increasing safety of work persons and as also permitting bettering environmental interaction of commercial fishing gear, especially by promoting the use of helix rope in pelagic trawls as helix rope formed pelagic trawls have the least environmental impact of any fishing trawl.

Possessing the preceding advantages, the method and process for forming spliced coverbraided ropes of the present disclosure answers needs long felt in the industry.

These and other features, objects and advantages are likely to be understood or apparent to those of ordinary skill in the art from the following detailed description of the preferred embodiment as illustrated in the various drawing figures.

Brief Description of the Drawings

Figs. 1 shows steps of the method of the present disclosure for forming slings of the present disclosure including helix rope slings of the present disclosure where the drawings are not cluttered by reference numerals.

Fig. 2 is an alternate view of Fig. 1 wherein reference numerals are included.

Best Mode for Carrying Out the Disclosure The present disclosure teaches a method where an elongated object is inserted into a core rope intended for use as a core for a tightly coverbraided rope including for a helix rope, where the elongated object is passed through the body of the core rope several times at an intended splice braid zone, or alternatively at least one time and left buried within and lying coaxial with the long dimension of the hollow braided core rope at the intended splice braid zone, and subsequently a cover is tightly braided around both the core rope as well as the elongated object in such a fashion as to form a tightly coverbraided rope including a helix rope. Alternative to being passed through the body of the core rope, the elongated object may be laid alongside the core rope at the splice braid zone. Then, a distal end of the tightly coverbraided rope is cut and attached to the proximal end of the elongated object. Lastly, the elongated object is pulled out (withdrawn) from within the braided sheath and core in a direction that draws the distal end of the coverbraided rope into a space within the core rope and braided sheath, or between the core rope and braided sheath, that previously was occupied by the elongated object.

In one of the present disclosures preferred embodiments, the elongated object is generally tubular with blunt ends. Preferably also the blunt ends of the elongated object have a long dimension that is not parallel to the long dimension of the main body of the elongated object. This is to ensure that the elongated object's ends remain outside the braided sheath. That is, the shape of the elongated object's ends are constructed and configured so as to permit the strands coming together at the braid point or otherwise to slide off of the ends of such ends, as well as to prevent cutting of the strands forming the braided sheath. In another preferred embodiment, the elongated object is a hollow steel pipe with a steel wire formed loop at one end and a steel eye at the other end. The removable, elongated object is also known herein as a "removable void spacer" or as a "void spacer", the terms being interchangeable. .

In another embodiment of the present disclosure eyes are spliced at the ends of sections of core rope, resulting in several slings of core rope, i.e. "core rope slings". Then, using sections of a thinnest twine economically possible to use for any particular purpose, two or more core rope slings are connected one to another by attaching the thinnest possible twine to a first core rope sling at a meeting of a splice braid zone and an open eye of such first core rope sling and attaching the other end of such thinnest possible twine to another core rope sling also at a meeting of the splice braid zone and eye where such eye is most proximal the first core rope sling. The result in a linear element formed of several interconnected core rope slings. The length of the thinnest possible twine between interconnected eyes of subsequent core rope slings is about twice the length of any splice braid zone. Then the removable void spacers are laid alongside at least one of and preferably all of the splice braid zones and retained in place either by taping, other mechanical means, or by hand. Then the in between open eyes portion of the sling formed of a core rope including the splice braid zones having the removable void spacers situated alongside of themselves are coverbraided using a conventional braiding machine that can be paused and restarted at the will of an operator. As any eye approaches the braid point, the operator pauses the machine, withdraws the eye from the interior zone of the converging braid strands, retains the eye without such interior zone of converging braid strands and re starts the braiding machine. The sheath forming the coverbraid thus also is formed over the sections of thinnest possible twine connecting the eyes of subsequent core rope slings one to another, but not over the eyes. Then, interconnected eyes are affixed to a ram having a hook at each end, each hook grabbing one of the eyes, and the ram's length shortened so as to draw the eyes more tightly together and relieve some of the tension on the section of hollow braided sheath enclosing the thinnest possible twine connecting the eyes of subsequent core rpe slings. Then, the braided sheath enclosing the thinnest possible twine is severed into two generally equal halves. Then, each severed half of braided sheath is passed through its corresponding open eye, bent back upon itself and attached to the proximal end of the removable void spacer that is situated alongside the splice braid zone corresponding to such open and there retained by mechanical means or by hand. Then, using mechanical means such as pneumatic or hydraulic retractable rams, or by hand, the removable void spacer is withdrawn from the portions of coverbraided sheath enclosing it and in a direction that draws the distal end of the attached portion of hollow braided sheath into the braided sheath encompassing the core rope and/or into both the braided sheath encompassing the core rope as well as the core rope itself, so that as a result the distal end of the portion of such hollow braided sheath and a portion of the such hollow braided sheath adjacent to such distal end come to occupy a space in between the core rope and the braided sheath, and or come to occupy a space within the core rope and also within the braided sheath encompassing the core rope that previously was occupied by the removable void spacer.

By loading the linear element formed of several interconnected core rope slings onto a spool, and using such spool as a feed out spool for the braiding machine in conjunction with a feed out wheel, and taking up the interconnected linear elements ultimately over a take up wheel and onto a take up spool, a space in the production line is able to be made to enact the operations of withdrawing the removable void spacers and associated actions, thereby permitting a continuous flow production process. When the coverbraid is being formed about the splice braid zones the braid angle is adjusted using well known methods for adjusting braid angles with braiding machines so as to ensure that none of the core rope sling's material is visible to the unaided eye through the completed coverbraided sheath. Similarly for the coverbraided sheath over any portion of the core ropes.

Detailed Description of the present disclosure

First Production Process and Product

The following steps are carried out in order to practice one of the methods of the present disclosure :

In reference to Fig.1 :

Step One: a length of core rope is provided.

Step Two: a removable void spacer is passed through the core rope at a zone that corresponds to any intended splice braid zone for any intended sling being formed by the method of the present disclosure. The removable void spacer is passed through the core rope a number of times that corresponds to any intended number of "tucks" (including "passes" and "pass throughs") it is intended for the splice to have. There may be as little as one pass through, as mentioned above.

Step Three: the core rope is made snug around the removable void spacer (this step is optional, but preferred.)

Step Four: the length of core rope with attached removable void spacers is passed through a braiding machine so that a braided sheath is progressively braided about the combination of the core rope and included removable void spacers from one end to another end of the length of core rope.

The coverbraid may be formed of uniform strands. Or, in order to form a helix rope, one of the strands forming the coverbraid is sleeted to be larger than the other strands forming the coverbraid, said other strands being uniform.

Step Five: the length of coverbraided rope is severed near the end of each void spacer that is proximal the intended location of any eye intended to be formed.

Step Six: the severed ends of coverbraided rope are attached to respective proximal ends of each void spacer.

Step Seven: the void spacer(s) with attached cut end of coverbraided rope is/are withdrawn from the coverbraided rope in a direction that draws the severed end of the coverbraided rope into a position previously occupied by the void spacer.

As a result, a spliced eye is formed into a portion coverbraided rope, said spliced eye having strength greater than a mesh knot.

As a result also, a spliced sling of coverbraided rope is formed.

To make several coverbraided rope slings at once: preferably, several void spacers are placed into a continuous length of core rope, each void spacer being placed at a position that corresponds to an intended location of an intended splice braid zone in each final intended sling of coverbraided rope. Then, the continuous length of core rope is coverbraided. Then, the pertinent subsequent steps of the method of the present disclosure are carried out, resulting in any desired quantity of coverbraided rope slings.

The method of the present disclosure includes forming portions of a trawl using slings of helix rope of the present disclosure formed by the method of the present disclosure.

In further detail, in referenced to Fig. 2, which is an alternate view of Fig. 1 where reference numerals now are included: Step One: (providing a length of core rope):

A length of core rope is provided. This may be done by laying on a table a length of core rope (2) that is attached at one end to a feed out spool and attached at another end to a pay out spool, on which such spools further length of the core rope preferably are situated.

Step Two: (passing each void spacer into the core rope a certain number of "tucks" at predetermined locations):

A "void spacer" (4) is passed through the core rope at a region in the core rope that corresponds to any intended splice braid zone (6) for any intended sling being formed by the method of the present disclosure . The void spacer is passed through the core rope a number of times that corresponds to any intended number of "tucks" (8) (including "passes" and "pass throughs") it is intended for the splice to have. At least two tucks is preferred, with four tucks being shown.

Positioning void spacers in order to form a sling: between any void spacer and any next void spacer is either:

(i) a length of core rope intended to form the core of a portion of the coverbraided rope forming the between-eye portion of the sling, as indicated by "core rope between eye portion (5)"; and

(ii) a length of core rope intended to form the core of a portion of coverbraided rope that is intended to form the "tucks" or "passes" of the splice, as indicated by "core rope tuck zone" (7).

The void spacers each can be a hollow tube such as a rigid steel pipe, or can be a flexible rubber hose of adequate diameter, or can be a Teflon coated solid rubber object. It is anticipated that flexible void spacers that do not resist deforming to an extend that allows the length of core rope with included void spacers to be spooled and unspooled to facilitate further steps is preferred for the instant described fabrication embodiment of the present disclosure.

To further discuss preferred constructions and configurations of the void spacers: a void spacer may have its terminal ends (10) bent at ninety degrees or otherwise not parallel to the axis or long dimension of the main length (12) of the void spacer, with such terminal ends' long dimensions preferably both aimed in a similar yet "mirror image" orientation. Preferably, the void spacer's terminal ends are dull and tapered and/or rounded, even spike shaped with a dulled tip. The end of the void spacer that the cut end of the coverbraided rope is intended to be inserted within or otherwise attached to may be a tapered wedge shape adapted to receive a sharp, wedge cut portion of coverbraided rope that is affixed to the void spacer's respective end such as by taping. Or, the terminal ends of the void spacer may be hollow with a cavity of sufficient depth to receive a cut end of the coverbraided rope and frictionally retain if for the subsequent step of drawing the cut end through that portion of the coverbraided rope occupied by the void spacer, and can be similar to the pointed tip of a dull hypodermic syringe. The terminal end of the void spacer not proximal the portion of the core rope that is intended to correspond to the cut part of the coverbraided rope to be formed by the coverbraiding process is itself not necessarily hollow, but is constructed and configured in such as way as to remain outside the braided sheath and permit easy removal from the braided sheath, for example has an aperture located in the region of point 13 (see Step Six) that can be grabbed with a hook or gaff.

Step Three: the core rope is made snug around the void spacer (this step is optional, but preferred.) Step Four: (overbraiding the combination of core rope and void spacers to form a length of coverbraided rope containing void spacers at pre-determined locations):

The length of core rope with attached void spacers is passed through a braiding machine so that a braided sheath 398 is progressively braided about the combination of the core rope and included void spacers from one end to another end of the length of core rope. Thus is formed a length of coverbraided rope encapsulating portions of the void spacers attached to and passing through the core rope. In further detail: as the braiding machines carriers are situating strands forming the coverbraid sheath around the void spacer's terminal ends, it is insured, either by hand or by a vibrating mechanical brush or the like, that such terminal ends are not covered by the final braided sheath but rather that they protrude without it;

Step Five: The length of coverbraided rope is severed near the terminal end of each void spacer that is most proximal the intended location of any eye intended to be formed, thus forming coverbraided rope severed ends (14) near void spacer proximal ends (16).

Usually, this includes cutting the coverbraided rope between void spacers in the middle of the shortest length of coverbraided rope between void spacers, that itself usually is portion of the coverbraided rope have zone 7.

Step Six: the coverbraided rope severed ends are attached to respective void spacer proximal ends (attaching the severed ends of coverbraided rope to respective proximal ends of each void spacer): This may be accomplished by inserting the cut end of coverbraided rope into a hollow end of the void spacer nearest the intended location of an eye, and frictionally retained therein by pressure of the material of the sheath being compacted into the hollow interior of the void spacer. A shim may be inserted if additional friction is desired to permit the operation of step nine. The severed ends may be wrapped tightly with tape and then cut into a spiked, wedged and tapered shape to facilitate such insertion and retention. Or, such shaped end of coverbraided rope may be mated to a wedge shaped tapered terminal end of the void spacer, and held thereon by tape. Or, the severed end of the coverbraided rope may otherwise be attached to such terminal end of the void spacer, such as by being frayed and then bent about an aperture or loop of steel wire at such terminal end of the removable void spacer and held in place by hand while a mechanical means withdraws the removable void spacer. In order to permit withdrawing the removable void spacer, the a portion of the eye being formed that is further from the cut end being attached to the removable void spacer must be held in place, and a a purchase must be obtained on a portion of the core rope between eye portion during withdrawal of the removable void spacer.

Step Seven: each removable void spacer with attached coverbraided rope severed end is withdrawn from the coverbraided rope in a direction that draws the severed end of the coverbraided rope through that portion of the core rope and braided sheath that was previously occupied by the removable void spacer, i.e. into the intended and preferably through the intended splice braid zone of the core rope.

As a result, a portion of coverbraided rope intended to form the splice braid, named "intended splice braid coverbraided rope portion" and indicated by reference numeral 18, is drawn into and situated within a portion of the core rope corresponding to zone 6 and also a portion of the braided sheath enveloping zone 6, especially into a position that previously was occupied by the removable void spacer.

Preferably, the terminal end of the removable void spacer farthest from the cut end of the coverbraided rope has an aperture that can be temporarily attached to by a hook or gaff, facilitating withdrawing the removable void spacer from the coverbraided rope with sufficient force to also draw the cut end of coverbraided rope into the portion of the body of the coverbraided rope that was occupied by the removable void spacer.

The removable void spacer should have a diameter that permits easy sliding of the cut end of the coverbraided rope into the body of the coverbraided rope, while also not creating so much slack in the sheath of the coverbraided rope that the sheath fails to tightly grab the inserted portion of coverbraided rope and the core under pressure in such a fashion as to provide maximal strength to the splice.

As a result, a spliced eye (20) is formed into a portion coverbraided rope, said spliced eye having strength greater than a mesh knot.

As a result also, a sling coverbraided rope sling (22) is formed.

To form a trawl of the present disclosure : the method of the present disclosure includes the subsequent step of forming portions of a trawl with the coverbraided rope slings of the present disclosure .

Alternative Production Processes and Product Embodiments

While the above taught Processes form a very strong splice, in some cases due to economic considerations other production processes may be preferred. In certain applications, it may be desirable that the removable void spacers may be situated alongside the core rope, rather than being passed through it. Then, the combination of removable void spacers situated alongside the core rope and the provided portion of core rope are coverbraided to form a coverbraided rope. Then, the coverbraided rope severed ends are attached to the respective terminal ends of the removable void spacers as described above, and pulled into the rope by withdrawing the removable void spacers in the direction as described above.

In certain other applications, a sling is formed into a length of core rope, then removable void spacers are situated besides the length of core rope in predetermined locations, either by being positioned alongside the length of core rope in such locations, or by being passed through as taught above in the preferred method. Then, the combination of removable void spacers situated besides the length of core rope and the core rope are coverbraided to form a braided sheath around the removable void spacers and core rope as taught above for the preferred method. Then, portions of the braided sheath extending beyond each eye previously spliced into the core rope are severed and subsequently attached to the respective terminal ends of the removable void spacers as taught above in the preferred method. Then, the removable void spacers are withdrawn from within the braided sheath and/or from within the combination of the braided sheath and core rope if the removable void spacers were passed through the core rope, in the direction as taught above for the preferred method. Resultantly, portions of the braided sheath come to occupy positions relative to the core rope that previously was and/or were occupied by the removable void spacers, resulting in a sling of coverbraided rope. By attaching end to end several slings formed of core rope prior to the coverbraiding step, such as by a length of twine or loop of other material connecting eyes of differing slings so as to form a series of slings connected end-to-end and then passing such connected series of slings through a braiding machine, and then carrying out subsequent steps of the present disclosure, several slings of coverbraided rope can be formed at once.

Industrial Applicability: The method of the present disclosure for forming slings of coverbraided rope or for forming spliced eyes into portions of coverbraided rope can be used to form a sling of other coverbraided rope, including helix rope as well as all types of ropes and lines mentioned supra, and to form a spliced eye into portions of other coverbraided rope, including helix rope as well as all types of ropes and lines mentioned supra. The slings of coverbraided rope thus formed, or the spliced eye included in a portion of coverbraided rope thus formed, can be used to form portions of a trawl, a towing warp using spliced eyes, such as a seismic towing warp, any and all types of ropes and lines mentioned supra or any other. Thus, the terms "helix rope" and "coverbraided rope" as used in the steps taught herein for carrying out the method of the present disclosure that is taught herein are interchangeable.

The method of the present disclosure also can be used to form end to end splices, or other types of splices besides spliced eyes.

In order to use the helix rope slings of the present disclosure to form a lowered drag self spreading trawl it is needed to:

(a) form as much of the pelagic mesh of the trawl as possible from the helix rope of the present disclosure; and

(b) position the helix rope of the present disclosure in such a fashion that it has a particular orientation relative to the exterior of the trawl and also relative to the long dimension of the trawl. More particularly, the helix rope of the present disclosure is used to form mesh bars and/or mesh legs of the trawl where helix ropes 35 having either right handed or left handed lay orientations for the helixing strand are selected and positioned so that when viewed from external at least the top and sides of the trawl, and in the instances of a pure midwater trawl that shall not be fished in bottom contact when viewed from all sides of the trawl, with the mesh legs and/or mesh bars at intended angles of attack and intended percentages of mesh opening, the cambered sections of that portion of each helix rope that is external the trawl are able to generate lift vectors having greater magnitudes normalized to the long dimension of the trawl and directed away from the interior of the trawl compared to the lift vector magnitudes directed toward the long axis of the trawl and able to be generated by those cambered sections that are on the portions of the helix ropes internal the trawl. In other words, those cambered sections on the portion of the helix ropes that are internal the trawl are more parallel to the intended oncoming water flow and/or to the planned long dimension of the trawl than are the cambered sections of each helix rope that are internal the trawl. Another way of describing such orientation for helix ropes of the present disclosure to best be used to form a lowered drag self spreading trawl is that when viewed from a position both external the trawl as well as looking from the mouth of the trawl toward the aft of the trawl, those helix ropes 35 having right handed lays for their helix strand have their leading edges being the left side of each such helix rope, while those helix ropes 35 having left handed lays for their helix strand have their leading edges being the right side of such helix ropes.

Other uses for helix ropes of the present disclosure include forming lowered drag pelagic trawls where the lay orientation and/or orientation of the cambered sections of the helix ropes of the present disclosure is not controlled so as to result in a self spreading trawl. One fashion of forming such a lowered drag trawl of the present disclosure is to form all or as much as possible of the pelagic mesh of a trawl from helix ropes 35 where all such helix ropes have the same lay direction for their helixing strand.

Further Alternative Splicing Embodiments of the Present Disclosure

In order to minimize drag of pelagic trawls formed of helix ropes of the present disclosure, it is best to form slings of helix rope and connect those to form the pelagic mesh. Especially, such slings are used to form the legs and/or mesh bars of the pelagic mesh. A sling is a section of a rope having an eye at both ends, although in some instances an eye could be at only one end. To achieve the minimized drag it is needed to maximize the strength of the eye, and this is accomplished by forming an eye with a spliced connection where such spliced connection is made in such a fashion as to conserve more of the helix rope's breaking strength than is able to be conserved by the use of knots practical for use in pelagic trawls (i.e. knots not so bulky as to result in a high drag trawl, or in an easily abraded trawl). The following methods of the present disclosure are useful for forming spliced slings. The term "spliced sling" for purposes of the following portion of the instant disclosure shall mean a portion of a helix rope of the present disclosure having a spliced eye located at one or both ends of itself. First Spliced Helix Rope Sling Production Method

Step One: a predetermined length of strength member core is selected (the predetermined length of strength member core hereinafter referred to as the "core rope"). The core rope preferably is a hollow braided rope. The core rope may have no impregnation material, or may have less than 55% by weight of the maximum amount of any type of impregnation material that it is capable of absorbing, or it may be fully impregnated. Minimal drag properties in pelagic trawl applications have surprisingly and contrary to the state of the art been found when the core rope has no impregnation material to an amount of impregnation material that is less than 73% by weight of the maximum amount of an impregnation material that the core rope is cable of absorbing, and especially less than 55% by weight of such impregnation material as mentioned supra. However, when the core rope is intended for other applications, as the present disclosure's splicing method may be used to form ropes for other applications, including seismic applications, paravane lines, seismic lines, yachting lines, rigging lines, anchoring lines, deep water oil rig mooring lines, towing warps and trawler towing warps and and any other uses for rope, cable or chain, and also such as when the core rope is made from a UHMWPE, a maximal amount of a suitable impregnation material has been found to be advantageous.

Step Two: an eye is spliced at one end of the length of the core rope, and preferably an eye is spliced at both ends of the length of the core rope, forming a core rope sling. The preferred splice method is to insert the cut end of the core rope into the hollow body of the hollow braided core rope by opening up the braid of the core rope and passing the cut end and the part of the core rope intended to form the inserted portion of core rope forming part of the splice braid zone into the body of the core rope intended to form the external portion of the core rope forming part of the splice braid zone, and then either leaving the cut end of the core rope enclosed within the hollow body of the core rope in the intended splice braid zone or pulling the cut end of the core rope out of the body of the core rope at a point that is at an end of the splice braid zone that is farthest from the eye formed by this process.

Step Three: several core rope slings are attached to one another in order to form a linear element formed of a series of such core rope slings. The various core rope slings are attached to one another to form such linear element by connecting subsequent (and/or intended to be subsequent) core rope slings eye to eye with sections of twine, the twine forming such sections of twine hereinafter also known as "connecting twine". An intermediate length of connecting twine is left in between the interconnected eyes of each subsequent core rope sling so that such intermediate length of connecting twine is about from five centimeters to 200 centimeters in length, or even more, depending upon the ultimate length of the splice braid zone to be coverbraided. This intermediate length of connecting twine equals approximately double the length of any core rope sling's splice braid zone, or is even about double such length plus an additional five to twenty centimeters.

Step Four: the interconnected core rope slings are wound upon a reel and/or spool that shall be used with or in conjunction with a feed out spool and/or a feed out wheel of a conventional braiding machine designed and configured to form braided sheaths about lengths of rope and/or other linear elements. Care is taken to impart minimal and preferably no rotation to the core rope slings so as to avoid imparting torque to the final finished product. In all cases care is taken to ensure that the core rope slings remain torque free, i.e. lacking a tendency to rotate about their longitudinal axis when tension is applied to the core rope sling and/or to the finished product. Step Five: a length of twine is passed over the take up wheel and affixed to the take up spool at one end, such length of twine hereinafter also known as the "take up twine". At another location on the length of take up twine that corresponds to a location intended for the braid point the various strands and the helix strand, i.e. the strands forming the braided sheath, also are attached to the take up twine. Care is taken to ensure that sufficient length of the take up twine remains upstream of the braid point to permit future knotting and connecting as is described further below, and that such upstream portion of the take up twine is retained outside of the converging braid strands in order to preclude it becoming covered by or enclosed within a hollow braided sheath that is intended to be formed, such withdrawn portion of the take up twine also to be known hereinafter as the "withdrawn portion of take up twine".

Step Six: the operation of the braiding machine is started causing a hollow braided sheath formed of the strands and any helixing strand to be formed, if one is to be formed, such as when forming a helix rope sling with the process of the present disclosure.

Step Seven: after a predetermined length of the hollow braided sheath is formed, such predetermined length corresponding to about twice the length of the splice braid zone of any eye of any core rope sling being used as a strength member core, plus an additional about ten to twenty centimeters to be used for future steps, the braiding machines operations are paused.

Step Eight: an eye of a first core rope sling that also is an eye forming the distal end of the linear element formed of several interconnected core rope slings and at least a corresponding splice braid zone of the same first core rope sling's eye are inserted into the interior zone of the converging strands forming the hollow braided sheath, and then the eye is withdrawn from within the interior zone of the converging strands forming the hollow braided sheath by passing it through the converging strands forming the hollow braided sheath proximal where such strands enter the braid point.

Step Nine: the withdrawn eye is extended and collapsed, i.e. not opened, and is laid alongside the section of hollow braided sheath formed as a result of the above steps so that the base of the eye, i.e. that portion of the open eye most proximal the splice braid zone, is near the braid point, and the furthest portion of the eye from the base of the eye is further downstream from the braid point.

Step Ten: The action of the braiding machine is started briefly so as to make preferably one wrap, and up to two, three or four wraps of the strands forming the braided sheath about the splice braid zone adjacent the withdrawn eye, then the action of the braiding machine is again paused.

Step Eleven: The withdrawn portion of take up twine is passed through the withdrawn eye of the first core rope sling and knotted back on itself so as to affix the withdrawn eye of the first core rope sling to the withdrawn portion of take up twine, thus attaching the withdrawn eye to the take up wheel thereby allowing to impart traction to the withdrawn eye and thus to the entire core rope sling and any other core rope slings connected to it.

Step Twelve: the hollow braided sheath is severed just upstream of the point where the withdrawn length of twine attaches to the hollow braided sheath.

Step Thirteen: While the braiding action of the braiding machine is retained as paused, the take up spool is energized so as to advance downstream the hollow braided sheath and the braid point, thus tightening the withdrawn portion of take up twine connecting the hollow braided sheath and the withdrawn eye.

Step Fourteen: the upstream severed length of hollow braided sheath is now bent back (i.e. "doubled back") and passed through the withdrawn eye and then passed into the interior zone of the converging strands forming the hollow braided sheath and then laid alongside the splice braid zone corresponding to the withdrawn eye.

Step Fifteen: the take up wheel is now, if necessary, reversed from its take up direction to a pay out direction so as to cause the braid tension to become reduced and also so as to cause the braid angle to become more obtuse, until the braid angle is nearer to eighty-nine degrees than it is to seventy degrees when measured between the braid ring and a converging strand used in forming the hollow braided sheath, with a braid angle of about eighty to eighty-seven degrees being also useful, with the result that the core rope sling's material is not visible to an unaided eye after the braided sheath 398 has been formed about the splice braid zone of the core rope sling.

Step Sixteen: the action of the braiding machine is then commenced again, including that the take up spool again commences to rotate in a "take up" direction, causing the braided sheath 398 to form about the splice braid zone corresponding to the withdrawn eye.

Step Seventeen: when the braid point is proximal the point of the splice braid zone that is furthest from the withdrawn eye, the action of the braiding machine is again paused.

Step Eighteen: the take up spool is advanced while the action of the braiding machine remains paused, so as to increase the braid tension and also so as to create a less obtuse (i.e. more acute) braid angle, with the result that the core rope sling's material is not visible after the braided sheath 398 has been formed about a portion of the core rope sling not having a splice braid zone. Step Nineteen: the action of the braiding machine is again started and continued to operate so as to cause the braided sheath 398 to form about the length of core rope sling up to the point that a portion of the next splice braid zone arrives at the braid point.

Step Twenty: the action of the braiding machine is again paused, and the take up spool is again reversed, again reducing the braid tension and again causing the braid angle to become more obtuse, again so as to achieve the result that no portion of the material forming the core rope sling is visible to the unaided eye after the braided sheath 398 has been formed about the splice braid zone of the core rope sling.

Step Twenty-One: a "removable void spacer" is provided. The void spacer may have its terminal ends bent at ninety degrees or otherwise not parallel to the axis of the main length of the void spacer, with such terminal ends' long dimensions preferably both aimed in a similar orientation. A preferable removable void spacer is formed of a hollow steel tube such as a hollow steel pipe having a steel eye welded at one end of the pipe and having a high quality steel cable of suitable diameter doubled over and inserted into the other end of the steel pipe and held in place by solidifying a molten bead weld inside the end of the pipe. The result of such a construction method for a removable void spacer is a removable void spacer designed and configured so as to result in a hollow steel pipe having a loop of high grade steel wire protruding at one end and having a steel eye affixed to its other end, such as may be a link of steel chain welded to such other end of the hollow steel pipe. Such preferable removable void spacer shall be known as "the preferred removable void spacer".).

Step Twenty-Two: a preferred void spacer is situated alongside the splice braid zone that is most proximal the braid point in such a fashion that the steel eye of the preferred void spacer as well as some length of the steel pipe of the preferred void spacer is lying alongside the braided sheath 398 while the majority of the preferred void spacer's steel pipe is lying alongside the core rope sling's still uncovered splice braid zone in such a fashion that the steel pipe ends and the steel wire loop commences where the exposed splice braid zone meets its open spliced eye. To effectively so position the preferred void spacer, it is needed to first insert the preferred void spacer into the interior zone of the converging braid strands, and then to withdraw that portion of it that is to lie alongside the braided sheath 398 by passing the steel eye of the preferred void spacer through the converging strands forming the braided sheath proximal where such strands enter the braid point.

Step Twenty-Three: the take up wheel is now again reversed from its take up direction to rather a pay out direction so as to cause the braid tension to become reduced and also so as to cause the braid angle to become more obtuse, until the braid angle is nearer to eighty-nine degrees than it is to seventy degrees when measured between the braid ring and a converging strand used in forming the hollow braided sheath, with a braid angle of about eighty to eighty-seven degrees being also useful, with the result that the core rope sling's material is not visible to an unaided eye after the braided sheath 398 has been formed about the splice braid zone of the core rope sling.

Step Twenty-Four: the action of the braiding machine is then commenced again, causing the braided sheath 398 to form about the splice braid zone.

Step Twenty-Five: the action of the braiding machine is again commenced including that the take up spool again commences to rotate in a "take up" direction until the braided sheath 398 is formed to about the location where the splice braid zone meets its open eye.

Step Twenty-Six: The braiding machine's operations are again paused.

Step Twenty-Seven: a connecting line connecting the two open eyes most proximal the braiding point is severed, and that open eye having its splice braid already covered by the braided sheath 398 is withdrawn from within the interior zone of the converging braid strands in a similar manner as described supra for withdrawing an open eye from within such interior zone of converging braid strands, and the other eye is retained on a hook that is provided underneath the braid point.

Step Twenty-Eight: The braiding machines action is again started so as to cause more hollow braided sheath to be formed downstream of the withdrawn eye, the length of hollow braided sheath to be formed again corresponding to about two times the length of the splice braid zones present on the core rope slings plus an additional about twenty centimeters of length.

Step Twenty-Nine: when about half the intended overall length of the hollow braided sheath being formed in the above step is completely formed, the braiding machine is again paused and a section of twine is attached at the braid point to the strands forming the hollow braided sheath, said section of twine being about twice the length of a splice braid zone to be coverbraided, and said section of twine being retained outside of the converging braid strands. This section of twine is hereinafter also known as the "next eye connecting twine".

Step Thirty: the braiding machine is again started and operated until the intended length of the hollow braided sheath is formed.

Step Thirty-One: The eye of the core rope sling that has been retained on a hook underneath the braid point is now inserted into the interior zone of the converging braid strands, and then withdrawing from such interior zone of converging braid strands in the fashion as described above for withdrawing eyes from such interior zone of converging braid strands, while the splice braid zone corresponding to this eye is retained within the interior zone of the converging braid strands so that it can be coverbraided. This eye is then attached to the next eye connecting twine.

Step Thirty-Two: The length of hollow braided sheath is severed about in half.

Step Thirty-Three: While the braiding action of the braiding machine is retained as paused, the take up spool is energized so as to advance downstream the hollow braided sheath and the braid point, thus tightening the eye connecting twine that connects the hollow braided sheath and the withdrawn eye.

Step Thirty-Four: the downstream severed end of the braided sheath is inserted into the open portion of the steel wire loop forming the terminal end of that void spacer nearest the end of that eye already having had its splice braid zone coverbraided and also having the preferred void spacer situated proximal its splice braid zone. The severed end may be frayed prior to being so inserted. Then the severed end is bend back, that is doubled over the steel wire loop, and held in place by hand by being squeezed together with the other portion of the hollow braided sheath near the steel wire loop. The severed ends may be wrapped tightly with tape and then cut into a spiked, tapered shape to facilitate such insertion and retention.

Step Thirty-Five: the preferred void spacer is pulled out (i.e. is withdrawing) from between the sheath and the core rope, in a direction that draws the severed end of the braided sheath into within the braided sheath and causes it to occupy a position between the braided sheath and the core rope's splice braid zone that previously was occupied by the preferred void spacer. A hydraulic or pneumatic ram is useful for so withdrawing the preferred void spacer. Optionally, a lubricant may be added to assist in drawing the severed hollow braided sheath into position. Such lubricant also may be used to lubricate the preferred void spacer prior to its use. Such lubricant is especially useful should the braided sheath be formed of highly inelastic materials such as UHMWPE and others. This step may be made either when the portion of splice braid zone with the preferred void spacer is upstream of or downstream of the take up wheel, so long as tension is maintained on the coverbraided core rope sling so as to permit withdrawing the preferred void spacer. The take up wheel may be cushioned or padded to permit the preferred void spacer to pass over it under tension without damaging either the product being formed of the machinery.

To produce further and subsequent spliced eye helix rope slings of the present disclosure, the actions, steps, methods and processes described in Steps Fourteen and onward are now repeated in the order and sequence as described hereinabove in order to produce the next spliced eye helix rope sling of the present disclosure. Then, the Steps Fourteen and onward may again be repeated, each time they are repeated another helix rope sling of the present disclosure being formed, until the linear element formed from the interconnected core rope slings is consumed. Then, Steps One and onward are repeated in order to form more helix rope slings of the present disclosure as desired.

Preferably, prior to splicing the eyes into any section of core rope so as to form a core rope sling, a very abrasion resistant, very durable sheath is slid upon the core rope and maintained in a region corresponding to any intended open eye to be formed, thereby resulting in a sheathed eye. The best construction for such a sheath is a hollow braided construction that has been made rigid by use adhesives and by forming a hollow braid of very tight wraps about a rod or rope that is then removed from such hollow braid where such rope or rope has a diameter that is sufficiently larger than the diameter of the core rope to be sheathed so that it is not difficult to pass the body of the core rope into the sheath. The rigidity imparted to any eye by such sheath greatly facilitates handling of the eyes in the production process of the present disclosure.

It is important that the braid angle and the elasticity of fibers forming both the braided sheath and forming the strength member of either the helix rope or of the spliced eye helix rope sling of the present disclosure, or of any other rope or of any other sling of the present disclosure, are selected so that the braided sheath and the strength member core or their equivalents both experience total failure at the same elongation of the final produced helix rope or its counterparts. For example, when less elastic fibers form the braided sheath, and more elastic fibers form the strength member core rope, the strength member core rope's strands are of a less obtuse braid angle than are the strands forming the braided sheath.

Further Industrial Applicability

A helix rope sling of present disclosure as formed by the process taught hereinabove is useful for forming self spreading lowered drag trawls of lowered noise and also for forming lowered drag trawls of lowered noise. However, when the helixing strand is omitted from the production process and replaced with another strand so as to form a braided sheath of uniform strands, the remainder of the process taught hereinabove for producing spliced eye helix rope slings is then useful for producing spliced eye slings of coverbraided rope for any other application. When such coverbraided rope is to be used as yachting rope, seismic rope, superwides, towing warps, trawling warps, anchor lines, deep water oil derrick mooring lines, rigging lines and any other uses for rope, cable or chain, often it is advantageous to have a thermoplastic core within the rope. In such instances of having the thermoplastic core within the rope, that portion of the thermoplastic core corresponding to those portions of the core rope to be used in forming the splice braid zone and optionally as well any open eye preferably is removed prior to the splice being formed. Then, the core rope sling having the thermoplastic core is coverbraided so as to form a tightly coverbraided spliced eye sling having a thermoplastic core. It is to be noted that the thermoplastic core is itself contained within a sheath the stops molten and especially semi liquid phases of the thermoplastic core from exiting the rope during extreme pressure. A preferred production process of the present disclosure for producing ultra high strength light weight spliced coverbraided ropes is as follows:

Further Alternative Production Processes and Product

First: a thermoplastic core is provided, with or without lead inside the core for weight, and with or without inside the core insulated conductors designed and configured to tolerate being permanently stretched as needed to survive the production process now being disclosed. Polyethylene is a good material for most thermoplastic cores for this process.

Second: the thermoplastic core is enclosed within a sheath that is able to stop molten phases of the thermoplastic core from exiting the sheath or that is able to mainly stop molten phases of the thermoplastic core from exiting the sheath. Such a sheath can be formed of very densely and tightly braided polyester fibers or other fibers having a higher softening point than the softening point of the thermoplastic core.

Third: a strength member is formed about the combination of the thermoplastic core and the sheath enclosing the thermoplastic core. Preferred materials for forming the strength member are fibers formed of materials that are able to be creeped. For example, fibers of UHMWPE, such as Dyneema®. Creeped as used in this disclosure means that the fibers are able to be permanently elongated a certain percentage of their initial length under a certain tension and at a certain temperature, especially a temperature just lower than a phase change temperature of the material forming the fibers, without compromising the fibers integrity and long term usefulness, and preferably also without compromising the fibers strength. A preferred construction for forming the strength member is a braided construction and especially a hollow braided construction.

Fourth: an eye is spliced into one or both ends of the strength member, with a portion of the thermoplastic core corresponding to any intended splice braid zone being removed from the intended splice braid zone prior to completion of the splicing process and the sheath enclosing the thermoplastic core being tied off and knotted so as to become sealed, rather than left cut open, thereby stopping flow of future molten phases of the thermoplastic core from exiting the sheath. The result is an alternative core rope sling.

Fifth: the alternative core rope sling is transformed into an alternative coverbraided spliced eye sling using the process of the present disclosure for forming spliced eye helix rope slings, except that the use of a helixing strand preferably is omitted and in its place a strand is used so that all strands in the braided sheath are similar, and also except that the alternative core rope sling is used in place of a core rope sling. A preferred material for forming strands forming the coverbraid is a material such as Dyneema or other UHMWPE. A settable adhesive substance, or a substance capable of being phase changed into an adhesive substance, where such adhesive substances have an elasticity of at least 10% at between zero degrees centigrade and negative fifteen degrees centigrade, and more preferably an elasticity of at least 50% at such temperatures, and more preferably an elasticity up to and even exceeding 500% at such temperatures and at temperatures that exceed sixty degrees centigrade preferably is situated about the outside of the strength member core, i.e. about the outside of the alternative core rope sling, just prior to the convergence of strands forming the coverbraided sheath about the outside of the alternative core rope sling. That is, just prior to the formation of any sheath about the alternative core rope sling.

Sixth: excess of such adhesive substances are removed from the outside of the braided sheath.

Seven: the alternative coverbraided spliced eye sling formed in the above step and of the combination of the alternative strength member and the sheath enclosed thermoplastic core are next subject to a tension that preferably is lesser than 50% of the break strength of the alternative strength member, and more preferably is less than 30% of such break strength, and yet more preferably is less than 20% of such break strength, and yet more preferably is less than 15% of such break strength, and yet again more preferably is less than 10% of such break strength, and even yet again is more preferably less than 7% of such break strength, even more preferably is less than 5% of such break strength, with about 3% of such break strength being preferred and with lesser than 3% being useful

Eighth: The combination of the tensioned alternative strength member and the sheath enclosed thermoplastic core are next subjected to a heat that is regulated and applied in such a fashion so as to cause all or at least the majority of the fibers forming the strength member core to approach near to, but to remain at lower than, their phase change temperature, while simultaneously causing the thermoplastic core to change to a molten phase. It is worth noting that the disclosed steps of first applying the disclosed tension to the alternative strength member, whether or not it is already used in forming either or both the alternative core rope sling or the alternative coverbraided spliced eye sling, and then subsequently applying the disclosed heat to at least the alternative strength member, again whether or not it is already used in forming either or both the alternative core rope sling or the alternative coverbraided spliced eye sling, is contrary to the state of the art.

Ninth: the tension and temperature are maintained until a desired amount of elongation of the strength member core can be detected, and preferably until it is detected.

Tenth: While the tension is maintained on the strength member, whether or not it is already used in forming either or both the alternative core rope sling or the alternative coverbraided spliced eye sling, and thus by extension also on the sheath enclosed thermoplastic core as well as on anything enclosed within the alternative strength member, the combination of any or all of the alternative coverbraided spliced eye sling; the alternative strength member and the sheath enclosed thermoplastic core and anything else contained within the strength member is cooled until the thermoplastic core has reach a solid phase, resulting in a high strength light weight synthetic rope sling useful for all the above mentioned uses.

Preferably, prior to splicing the eyes into the alternative core rope in order to form the alternative core rope sling, a very abrasion resistant, very durable sheath is slid upon the alternative core rope and maintained in a region corresponding to any intended open eye to be formed, thereby resulting in a sheathed eye. The best construction for such a sheath is a hollow braided construction that has been made rigid by use adhesives and by forming a hollow braid of very tight wraps about a rod or rope that is then removed from such hollow braid where such rope or rope has a diameter that is sufficiently larger than the diameter of the alternative core rope to be sheathed so that it is not difficult to pass the body of the alternative core rope into the sheath. The rigidity imparted to any eye by such sheath greatly facilitates handling of the eyes in the production process of the present disclosure. Additional Further Alternative Production Processes and Product

While the immediately above Alternative Production Process is useful for forming many ropes and high strength light weight spliced eye synthetic slings, in some cases it may be desired to form a high strength light weight synthetic rope without eyes, or it may be desired to form any of such products without a coverbraid. The following modification of the above taught production process is yet another alternative production process of the present disclosure for producing further alternative products of the present disclosure:

Firstly: a thermoplastic core is provided, with or without lead inside the core for weight, and with or without inside the core insulated conductors designed and configured to tolerate being permanently stretched as needed to survive the production process now being disclosed. Polyethylene is a good material for most thermoplastic cores for this process.

Secondly: the thermoplastic core is enclosed within a sheath that is able to stop molten phases of the thermoplastic core from exiting the sheath or that is able to mainly stop molten phases of the thermoplastic core from exiting the sheath. Such a sheath can be formed of very densely and tightly braided polyester fibers or other fibers having a higher softening point than the softening point of the thermoplastic core.

Thirdly: a strength member is formed about the combination of the thermoplastic core and the sheath enclosing the thermoplastic core. Preferred materials for forming the strength member are fibers formed of materials that are able to be creeped. For example, fibers of UHMWPE, such as Dyneema®. Creeped as used in this disclosure means that the fibers are able to be permanently elongated a certain percentage of their initial length under a certain tension and at a certain temperature, especially a temperature just lower than a phase change temperature of the material forming the fibers, without compromising the fibers integrity and long term usefulness, and preferably also without compromising the fibers strength. A preferred construction for forming the strength member is a braided construction and especially a hollow braided construction. The combination of the formed strength member formed about the combination of the thermoplastic core and the sheath enclosing the thermoplastic core is hereinafter also referred to as the "alternative core rope".

Fourth: Optionally, an eye is spliced into one or both ends of the alternative core rope, with a portion of the thermoplastic core corresponding to any intended splice braid zone being removed from the intended splice braid zone prior to completion of the splicing process and the sheath enclosing the thermoplastic core being tied off and knotted so as to become sealed, rather than left cut open, thereby stopping flow of future molten phases of the thermoplastic core from exiting the sheath. The result is an alternative core rope sling. Whether or not an eye is spliced in order to form the alternative core rope sling, or should the alternative core rope be left without spliced eyes, the sheath enclosing the thermoplastic core is tied off and knotted so as to become sealed, rather than left cut open, thereby stopping flow of future molten phases of the thermoplastic core from exiting the sheath.

Fifth: the alternative core rope formed in the above steps and that is of the combination of the strength member and the sheath enclosed thermoplastic core are next subject to a tension that preferably is lesser than 50% of the break strength of its strength member, and more preferably is less than 30% of such break strength, and yet more preferably is less than 20% of such break strength, and yet more preferably is less than 15% of such break strength, and yet again more preferably is less than 10% of such break strength, and even yet again is more preferably less than 7% of such break strength, even more preferably is less than 5% of such break strength, with about 3% of such break strength being preferred and with lesser than 3% being useful.

Eighth: The tensioned alternative core rope that is the combination of the tensioned strength member and the sheath enclosed thermoplastic core are next subjected to a heat that is regulated and applied in such a fashion so as to cause all or at least the majority of the fibers forming the alternative core rope's strength member to approach near to, but to remain at lower than, their phase change temperature, while simultaneously causing the thermoplastic core to change to a molten phase. It is worth noting that the disclosed steps of first applying the disclosed tension to the alternative core rope and or to the alternative core rope's strength member, whether or not it has a thermoplastic core, is contrary to the state of the art.

Ninth: the tension and temperature are maintained until a desired amount of elongation of the alternative core rope's strength member core can be detected, and preferably until it is detected.

Tenth: While the tension is maintained on the alternative core rope, whether or not it is already used in forming the alternative core rope sling, and thus by extension also on the sheath enclosed thermoplastic core as well as on anything enclosed within the strength member of the alternative core rope, the combination of any or all of the alternative core rope' s strength member, the alternative core rope, the alternative core rope sling and the sheath enclosed thermoplastic core and anything else contained within the alternative core rope's strength member is cooled. If a thermoplastic core is used, the cooling is continued until the thermoplastic core has reach a solid phase, resulting in a high strength light weight synthetic rope and/or a high strength light weight synthetic rope sling useful for all the above mentioned uses.

Preferably, prior to splicing any eyes into the alternative strength member core, the same very abrasion resistant, very durable sheath is constructed, configured and used as mentioned above to both stiffen and protect the resultant eyes.

Although the present disclosure has been described in terms of the presently preferred embodiment, it is to be understood that such disclosure is purely illustrative and is not to be interpreted as limiting. Consequently, without departing from the spirit and scope of the disclosure, various alterations, modifications and/or alternative applications of the disclosure shall, no doubt, be suggested to those skilled in the art upon having read the preceding disclosure. Accordingly, it is intended that the following claims be interpreted as encompassing all alterations, modifications or alternative applications as fall within the true spirit and scope of the disclosure.