ROPE PRODUCTS, SYSTEMS, METHODS, AND APPLICATIONS

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Application Serial No. 61/993,703, filed May 15, 2014, and U.S. Patent Application Serial No. 14/713,967, filed May 15, 2015, wherein each such document is incorporated herein in its entirety by reference.

BACKGROUND OF THE INVENTION

[0002] Rope products, such as winches and slings, may have numerous applications, and previous types of rope products are known in the art. The present invention relates generally to novel rope products, systems, processes, and related applications.

SUMMARY OF THE INVENTION

[0003] In an embodiment, the invention includes novel rope products, systems, processes, and related applications as disclosed herein. Generally, in one embodiment, the invention includes a rope system. The rope system includes a woven cover having at least one channel and two terminal ends, and the woven cover also includes a plurality of warp threads and a plurality of weft threads and wherein the warp thread and weft threads are interwoven together. The rope system also includes a bundle of fibers that form a continuous loop, and the bundle of fibers is at least partially disposed within the woven cover such that a portion of the bundle of fibers extends beyond the two terminal ends of the woven cover and are exposed as loops.

[0004] In another embodiment, the invention includes a linked rope system. The linked rope system includes (1 ) a fiber material configured in a loop with joined ends to form a first bundle of fiber in a continuous loop, wherein the first bundle of fiber is at least partially encased within a first cover and (2) a second fiber material in a loop with joined ends to form a second bundle of fiber in a continuous loop, wherein the second bundle of fiber is at least partially encased within a second cover. In addition, the first bundle of fiber and the second bundle of fiber are interlinked.

[0005] In yet another embodiment, the present invention includes a method of making a linked rope system. The method includes the steps of looping a first fiber material and joining two terminal ends of the first fiber material to form a first bundle of fiber in a continuous loop, and at least partially enclosing the first bundle of fiber is at least partially encased within a first cover. The method also includes the steps of looping a second fiber material and joining two terminal ends of the first fiber material to form a second bundle of fiber in a continuous loop, and at least partially enclosing the second bundle of fiber is at least partially encased within a second cover. Furthermore, the method includes interlinking the first bundle of fiber that is at least partially encased within a first cover and the second bundle of fiber that is at least partially encased within a second cover.

[0006] The present invention may be better understood by reference to the description and figures that follow. It is to be understood that the invention is not limited in its application to the specific details as set forth in the following description and figures. The invention is capable of other embodiments and of being practiced or carried out in various ways

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] A full and enabling disclosure of the present invention is set forth in the specification, which refers to the appended figures.

[0008] Fig. 1 depicts a rope system pursuant to one embodiment of the present invention;

[0009] Fig. 1A shows a cross-sectional view of the embodiment of Fig. 1 along the line A-A;

[00010] Fig. 2 depicts a rope system pursuant to one embodiment of the present invention;

[00011] Fig. 2A shows a cross-sectional view of the embodiment of Fig. 2 along the line A-A; [00012] Fig. 3 depicts a rope system pursuant to one embodiment of the present invention;

[00013] Fig. 3A shows an end view of the embodiment of Fig. 3;

[00014] Fig. 4 depicts a rope system pursuant to one embodiment of the present invention with a partial cutaway view and with a dashed line representing how a divider may be formed in some embodiments;

[00015] Fig. 4A depicts a further embodiment of the embodiment in Fig. 4 wherein an embodiment of a divider is formed; a rope system pursuant to one embodiment of the present invention;

[00016] Fig. 5 depicts a cover pursuant to one embodiment of the present invention;

[00017] Figs. 5B, and 5C depicts rope systems pursuant to various embodiments of the present invention using the cover embodiment of Fig. 5;

[00018] Figs. 6 and 7depict covers pursuant to certain embodiments of the present invention;

[00019] Figs. 7A, and 7B depict rope systems pursuant to embodiments of the present invention;

[00020] Fig. 8 depicts a rope system pursuant to one embodiment of the present invention;

[00021] Fig. 8A depicts an end view of the embodiment of Fig. 8;

[00022] Fig.9 depicts a rope system pursuant to one embodiment of the present invention;

[00023] Fig. 9A depicts an end view of the embodiment of Fig. 9;

[00024] Fig. 10 depicts a rope system pursuant to one embodiment of the present invention;

[00025] Fig. 10A depicts an end view of the embodiment of Fig. 10

[00026] Figs. 1 1 depicts an end view of the rope system embodiment of Fig. 7B in a folded configuration;

[00027] Fig. 12 depicts an end view of the rope system embodiment of Fig. 7A in a folded configuration;

[00028] Fig. 13 depicts a rope system pursuant to one embodiment of the present invention; [00029] Fig. 13A depicts an end view of the rope system embodiment of Fig. 13 in a folded configuration;

[00030] Figs. 14, 14A, 14B, and 14C depict embodiments of a weldable or seamed cover pursuant to embodiments of the present invention;

[00031] Figs. 15A, 15B, and 15C depict embodiments of covers of the present invention having auditory and/or visual indicators of breakage;

[00032] Fig. 16 depicts a rope system pursuant to one embodiment of the present invention;

[00033] Fig. 17 depicts the rope system of Fig. 16 in an additional configuration;

[00034] Fig. 18 depicts a rope system pursuant to one embodiment of the present invention; and

[00035] Fig. 19 depicts a cover having ribs pursuant to one embodiment of the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[00036] Reference now will be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not a limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment, can be used on another embodiment to yield a still further embodiment.

[00037] Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents. In addition, the use of reference characters with the same two ending digits as other reference characters in the present specification and drawings, without a specific discussion of such structure, is intended to represent the same or analogous structure in different embodiments. Other objects, features and aspects of the present invention are disclosed in or are obvious from the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention. [00038] The present invention includes rope systems. In some embodiments, such rope systems may include a bundle of fibers displaced, partially or fully, within a cover. By way of example and with reference to an illustrative embodiment, Fig. 1 shows rope system 100. Rope system 100 includes a cover 102, which is shown as a woven tubular cover having two open longitudinal ends, and fiber bundle 104. As shown, fiber bundle 104 is comprised of fibers that are continuously wrapped in a loop and then each end of the fibers are joined by a knot (not shown). In this regard, the fibers are a single length and the knot serves as the only connection point. Fig. 1A shows a cross-section of the embodiment of Fig. 1 along the line A-A. As shown, fiber bundle 104 extends beyond each longitudinal end of cover 102 to form loops 105. In this depicted embodiment, fiber bundle 104 may be formed and then inserted into cover 102. In other embodiments, cover 102 may be woven around fiber bundle 104 or, prior to being formed in a tubular shape, cover 102 may be wrapped around fiber bundle 104 and then sealed to form a tubular shape around cover 102. In other embodiments, fiber bundle 104 may be formed by looping fiber bundle 104 within an already-formed cover 102. In still other embodiments, cover 102 may have an alternative shape, such as a flat shape or a square shape.

[00039] In another exemplary embodiment, as shown in Fig. 2 (with a partial cutaway view), rope system 200 includes cover 202, wherein cover 202 is a tube-in-a-tube design having an outer cover 202' and an inner cover 202". Fig. 2A shows a cross- section of the embodiment of Fig. 2 along the lines A-A. As shown, fiber bundle 204 form loops 204' and 204".

[00040] In still another embodiment, as shown in Fig. 3, rope system 300 includes divider 306 disposed within inner cover 302", such that two channels are formed within inner cover 302". As shown, divider is centrally located within inner cover 302, but in other embodiments it may be placed at alternative locations within inner cover 302". Fiber bundle 304 is disposed around divider 306. Fig. 3A shows a cross-section of the embodiment of Fig. 3 along the lines A-A. In this embodiment, fiber bundle may be formed by looping fibers inside inner cover 302" and around divider 306, and then tying the ends of the fibers with a knot. As shown in Figs. 3 and 3A, divider 306 is a separate piece of material joined into 302 to form divider 306. In alternative embodiments, a divider may be formed by joining portions of the inside cover 402" together, such as by weaving, sewing, or otherwise. For example, as shown in Figs. 4 and 4A, cover 400 may have portions of its inner cover 402" joined together (such as joining the points indicated by the dashed line in Fig. 4A) to form a divider.

[00041] By further way of example, in still other embodiments, a divider may be formed by joining separate covers together, such as by weaving or sewing, such that the two joined covers join to form a single cover having two channels separated by a divider, such as shown in Fig. 5, which is an end view of such an illustrative embodiment. In such embodiments, a fiber bundle may be looped continuously through each channel (such as shown schematically in Fig. 5B) or each channel may contain its own continuously-looped fiber bundle (such as shown schematically in Fig. 5C). In similar fashion, any suitable form of divider discussed herein may also be present in the embodiment shown in Fig. 1 or in other embodiments.

[00042] In some embodiments, multiple dividers may be present. By way of example, as shown in Fig. 6, which is an end view of an illustrative cover that may be used in connections with rope system embodiments of the present invention, two dividers may be present such that three channels are formed. As noted above with regard to Figs. 5B and 5C, a fiber bundle may continuously loop in one channel or may continuously extend through two channels or all three channels in the embodiment shown in Fig, 6. Although cover 600 is shown as a single-layer cover, alternative covers may be employed using multiple dividers, including tube-in-tube cover configurations. Similarly, the dividers in the embodiment of Fig. 6 are exemplary and any type of divider may be employed. In other embodiments, more three or more dividers may be included. As shown in Fig. 7, which is an end view of an exemplary cover, three dividers may be employed, which forms four channels. In some such embodiments, as with any embodiments described herein, each divided section may contain a fiber bundle as shown in Fig. 7A or, alternatively, a fiber bundle may be looped around a divider as shown in Fig. 7B (wherein the B suffix added to the reference numerals is merely to differentiate Fig. 7A).

[00043] In some embodiments, such as shown , in Figs. 8 and 8A, fiber bundle 804 may be surrounded by a separate cover 803 that is displaced within, but not adjoined to, cover 802. In still other embodiments, multiple separate covers may be used as shown in Fig. 9. In such embodiments, a fiber bundle may be contained within a single separate cover as shown in Figs. 9 and 9A or may be looped between two or more separate covers as shown in Figs. 10 and 10A. In still other embodiments, separate covers 803 and 903 may optionally have a divider therein, wherein a fiber bundle may be continuously looped in a single channel therein or between one or more channels therein. In some embodiments, the separate cover, such as separate cover 803, may be waterproof or water resistant, and another cover, such as cover 802, may be abrasion resistant.

[00044] In some embodiments, a rope system may be folded into a more compact form. By way of example, Fig. 11 shows rope system 700B of Fig. 7B, which illustrated a cover 702B having three dividers 706B.such that there were four channels. As shown in Fig. 11 , folding rope system 700B over in the latitudinal direction results in the embodiment shown in the end view of Fig. 1 1. In similar fashion, the embodiment of Fig. 7A may be folded to form the folded embodiment shown in the end view depiction of Fig. 12. Finally, in another exemplary embodiment, a rope system may have the configuration shown in Fig. 13 and may be folded as shown in the end view of Fig. 13A. In other embodiments, additional dividers and channels may be present, and folding may be accomplished to form an accordion-like folded rope system.

[00045] In some embodiments, a cover may extend along the entire length or substantially the entire length of a winch or rope system. In other embodiments, a cover may extend to or slightly beyond any hardware at an end of the rope system. As shown in the foregoing illustrative embodiments, a cover may extend over an entire fiber bundle except for the loops of the fiber bundle that extend from each longitudinal end of a cover. In some embodiments, the cover may alternatively extend substantially over the entire fiber bundle except the loops. In other embodiments, a cover may also extend over the loops. In still other embodiments, a cover may surround the loops and have an open portion on the interior of the loop, in which case hardware may still be readily attached within the open portion.

[00046] In the embodiments discussed above, each fiber bundle is formed by continuously wrapping one or more continuous fibers and then joining the free ends. In some embodiments, such free ends of the fiber bundle may be joined by a knot. In other embodiments of the illustrative embodiments herein, such free ends of a fiber bundle may be taped, glued, or joined using any other suitable methods. In some embodiments, the free ends of a fiber bundle ends are not sewn, spliced, clipped, or clamped. Furthermore, a space or gap may exist between the inside of a cover and the fiber bundle, such as shown, by example, in Fig. 1A.

[00047] Covers used in the present invention may be comprised of any suitable material for a particular embodiment. For example, in some embodiments, the fibers of a woven cover may comprise any suitable natural or synthetic material known in the art or combinations thereof. In some embodiments, the fibers comprise meta-, para-aramid fibers, para-aramid fibers, meta-aramid fibers, cotton, rayon, Teflon®-coated fibers, shaped fibers, glass fibers, basalt fibers, carbon fibers, high modulus polyethylene fibers, liquid crystal polymer fibers, hollow fibers, nylon, polyesters, polypropylene, polyethylene, polyphenylene sulfide, polyetheretherketone, polyolefins, high modulus polyethylene (HMPE), amide polymers or copolymers, other aramids, metal yarns, other suitable materials, and combinations thereof. According to some embodiments, such fibers may be heat-shrinkable or have elasticity. By way of example, and without limitation, in some embodiments a cover may include nylon and polyester fibers. In some embodiments, any materials noted herein for a cover may be used for a fiber bundle and any materials noted for a fiber bundle may be used for a cover and vice versa. In addition, any materials used for a cover or a bundle of fibers may be treated or coated to improve the properties of the material for a particular application.

[00048] In some embodiments, materials included in a cover may have one or more of high tensile strength, high thermal resistance, high abrasion resistance, low shrinkage at high temperatures, high fatigue resistance, ultraviolet radiation resistance, high chemical and heat stability, and low moisture regain. In some embodiments, spun or texturized fibers or yarns may be used to limit abrasion. Also, the fibers may be coated with polymers, paraffin waxes, non-paraffin waxes, and/or other substances to improve abrasion, ultraviolet resistance, water and chemical resistance, improve moisture wicking, provide improved heat transfer, fire resistance, and other desirable properties for a particular embodiment. [00049] In some embodiments, a cover used in embodiments of the present invention may be a woven webbing. The term "woven", as used herein, means interlacing individual fibers in a regular order. Any method of weaving known in the art may be utilized in this invention. Similarly, any weave pattern known in the art may be utilized in the webbing including, but not limited to, a plain weave, a twill weave, a satin weave, a tabby weave, a taffeta weave, a matt weave, a basket weave, a rib weave, computer- generated interlacings, and combinations thereof. The fibers of a cover may have any configuration known in the art. For example, the configuration of the fibers may be circular, ovular, elliptical, or flat. Additional configurations of woven material are included in U.S. Patent Application Serial No. 14/078,211 , which is published as U.S. Published Patent Application No. 2014/178,615 and which is incorporated herein in its entirety by reference. In some embodiments, covers may have a construction and/or composition other than a woven construction, such as a film cover, coated fabrics, or combinations of different constructions.

[00050] In addition, in some embodiments, covers of the present invention may include one or more spaced longitudinal ribs, such as shown, by way of example, in Fig. 19. Such ribs, which may have increased longitudinal stiffness, may be spaced equidistantly from one another or may be spaced intermittently. In . some embodiments, the ribs may comprise a woven rope. The ribs may be formed from any suitable material, including materials disclosed to form a cover or a bundle of fibers herein. In some embodiments, ribs may be woven into a cover, whereas in other embodiments they may be attached by any conventional manner. The projection height of the ribs can vary, but may be, in an embodiment, greater than the thickness of the cover. In some embodiments, the projection height may be 5% to 200% greater than the thickness of the cover, including each intermittent value therein. In some embodiments, the projection height may be at least 5% greater than the thickness of the cover. In another embodiment, the projection height 56 for the ribs may be at least 10% greater than the thickness of the cover. In another embodiment, the projection height of the ribs may be at least 20% greater than the thickness of the cover. In yet another embodiment, the projection height may be up to 50% greater than the thickness of the cover and, in still another embodiment, the projection height may be 100% greater than the thickness of the cover. Additional configurations of ribbed covers are disclosed in U.S. Patent Application Serial No. 14/204,758, which is published as U.S. Published Patent Application No. 2014/311 ,61 1 and which is incorporated herein in its entirety by reference.

[00051] By way of example, and without limitation, covers in some embodiments of the present invention may include warp yarns and weft yarns having any suitable denier for a particular application. For example, in some embodiments, warp yarns in the range of about 840 denier to about 2,700 denier may be used. In some embodiments, warp yarns having greater than 2700 denier may be employed, such as in the range of about 2,700 denier to about 5,000 denier. In some embodiments, warp yarns having less than 3,000 denier may be used. In some embodiments fill (or weft) yarn having a denier in the range of about 500 denier to about 1 ,000 denier may be used. With the foregoing exemplary ranges each intermittent value is specifically included.

[00052] For embodiments employing a woven cover, any suitable weaving parameters may be employed. By way of example, a cover may have a tight plain weave, such as in the range of about 4.75 picks per inch to about 50 picks per inch, including each intermittent value therein. In some embodiments, a woven cover may have a pick count of at least about 17.5 picks per inch. In some embodiments, a woven cover may have a plain weave of about 2.5 to about 7.5 picks per inch, including each intermittent value therein. In other embodiments, an outer sleeve may have a pick count of at least about 12.5 picks per inch. In some embodiments, a cover may include an inner cover and an outer cover as previously described, wherein an inner and outer cover may have the same woven configuration or differing woven configurations. For example, in some embodiments an inner cover may have a plain weave configuration and an outer cover may have either a twill weave or a plain weave configuration. For reference, a plain weave may also be referred to as a basket weave.

[00053] In still other embodiments, covers may include non-woven material that is sewn or otherwise connected in a tubular shape. For example, in some embodiments, covers may be sewn, bonded, or otherwise prepared using the same materials as discussed for woven constructions or alternative materials. By way of example, in some embodiments, a cover may be formed using weldable materials. By way of example, a cover of some embodiments may be formed by coating a webbing material, film, fabric, or other material (which may be, by way of example, woven, spun bond nonwoven, nonwoven laminates, films, perforated films, or combinations thereof) with a weldable plastic, such as, for example, polyvinyl chloride or polyurethane. In such weldable embodiments, any suitable weldable materials may be employed, such as films, fibers, or nonwovens coated or uncoated so long as the material can be joined by heat, ultrasonic, radio frequency, welding, or the like.

[00054] By way of example, a rope system with a weldable cover may be formed as shown in the illustrative embodiment of Fig. 14. As shown, material 1401 , which has longitudinal edges 1401', may be laid flat, as shown in Fig. 14, and then it may be folded by joining longitudinal edges 1401' to form a tubular shape, such as that shown in Fig. 14A. Longitudinal edges 1401 ' may be welded to form a seam. Any suitable seam may be used, such as those shown in Figs. 14B and 14C, which illustrate exemplary alternative welded seams 1408' and 1408" from an end view of a tubular cover. In some embodiments, a hook and loop fastener or similar means may be used to join longitudinal edges of a cover. Such welded covers may be used in the manner described herein for any embodiment as a cover for one or more fiber bundles. In addition, such covers with fibers bundle may be used, for example, as a winch rope or, after joining the ends of the tubular cover by any suitable joinder, such as by welding, sewing, heat, ultrasonic, radio frequency, or in any other suitable manner.

[00055] In some embodiments, and as illustrated in Figures 15A, 15B, and 15C, embodiments of the present invention may include auditory and/or visual indicators of breakage prior to a complete break of the rope system. By way of example, covers made of woven material may be used in certain embodiments of the present invention as described above. Such woven covers may include both warp yarns and weft yarns. As provided in some embodiments of the present invention, these materials may provide the warnings necessary for use in embodiments of the present invention. For example, although most ropes are given maximum load requirements, the warp yarns and/or weft yarns may include maximum load weights that are less than the total breaking weight of the entire cover or fiber bundle of a rope system or that are less than the maximum load weight of the entire rope system. For example, in some embodiments, some or all warp yarns and/or weft yarns in a rope may have maximum load weights that are between about 20 and about 80% of the total breaking weight of the entire rope system. In other embodiments, warp yarns and/or weft yarns may include maximum load weights of between about 40 and 60% of the total breaking weight of the entire rope system. In such instances, as the maximum weight is approached, the warp yarns and/or weft yarns will start to break, thereby providing a user with visual and auditory warnings of approaching breakage.

[00056] As shown in Fig. 15A, an exemplary woven rope includes warp yarns 1502 and weft yarns 1504. As shown, Fig. 15B, the rope is subjected to strain, and some of the weft yams 1504 begin to break as shown by broken weft yarns 1504'. In this manner, broken weft yarns 104' may provide an iodination that the total breaking weight of the entire rope is being neared or that a certain threshold of strain or stress has been met. As shown in Fig. 15C, the exemplary rope has undergone additional stress and some of the warp yarns 1502 have broken as shown by broken warp yarns 1502'. These broken warp yarns 1502' may provide an additional indication of a certain threshold being met or neared for the entire rope.

[00057] In some embodiments, additional materials, such as a distinct weft strand or a distinct warp strand of a different material than the other weft and/or warp strands, may be incorporated into a rope to provide an indication of a threshold being met or neared. For example, in one embodiment, such distinct weft strands or a distinct warp strands may be of a weaker material than the remaining weft or warp strands of the rope, such that when the weaker distinct weft strand and/or distinct warp strands are broken an indication is provided. In still other embodiments, an additional material, such as a yarn that does not otherwise serve as a weft strand or warp strand, may be incorporated into a rope to provide an indication of a threshold being met or neared.

[00058] In addition, to provide even greater indications of breakage, some or all weft yarns and warp yarns may be of various colors such that a user may determine when a particular breaking point is reached or is being reached. For example, in some embodiments, some weft yarns may be of a different color, for example red, than the other materials, such as white, utilized in the rope construction. As load conditions are being reached, those red weft yarns, optionally selected to break before the entire rope system reaches a maximum breaking weight, will start to break and will thereby provide the user with a clear indication of possible breakage.

[00059] With regard to fiber bundles employed in embodiments of the present invention, such fiber bundles may include any suitable fibers or any other material suitable for a particular embodiment. By way of example, such fibers and materials may include, without limitation, polyester, nylon, meta- para-aramid fibers, para-aramid fibers, meta-aramid fibers, cotton, rayon, Teflon®-coated fibers, shaped fibers, glass fibers, basalt fibers, carbon fibers, high modulus polyethylene fibers, liquid crystal polymer fibers (such as, by way of example, those available from Vectran Fiber, Inc.), hollow fibers, polypropylene, polyethylene, polyphenylene sulfide, polyetheretherketone, polyolefins, high modulus polypropylene, amide polymers or copolymers, other polyolefins, other aramids, metal yarns, other suitable materials, and combinations thereof. In addition, by way of example, the fiber bundle may have any suitable structure, such as, without limitation, twisted or untwisted continuous filaments, parallel strands, filament bundles comprised of mono-filament yarns, filament bundles comprised of films, twisted rope, braided rope (including, without limitation, solid braided rope and hollow braided rope), liquid crystal polymer rope, woven rope, kernmantle rope, woven ropes with components that may be twisted or braided, braided or twisted ropes using components that are woven or of another format, and combinations thereof. By way of example, and without limitation, such fibers in some embodiments may include twisted, cabled, braided, or woven yarns, or combinations thereof. In some embodiments, spun or texturized fibers or yarns may be used to limit abrasion. According to some embodiments, such fibers may be heat-shrinkable or have elasticity. Also, the fibers may be coated with or otherwise include, such as by using nano- coatings through vapor deposition or other suitable means, with polymers, paraffin waxes, non-paraffin waxes, and/or other substances to improve abrasion, ultraviolet resistance, water and chemical resistance, improve moisture wicking, provide improved heat transfer, fire resistance, and other desirable properties for a particular embodiment. In addition, such materials and/or alternative materials may be used in other non-woven covers that are also within the scope of the present invention. [00060] Any size of fibers may be used as is suitable for a particular embodiment. Furthermore, any fibers employed may be monofilament, multifilament, or tapes. In addition, the size of the bundles shown in the figures herein are exemplary and are not limiting. The fiber within a bundle may also be more tightly packed within a bundle than shown in the depicted embodiment, as well as bound, joined, braided twisted, or otherwise connected if desired. In other embodiments, smaller or larger bundles may be employed. In addition, in some embodiments, multiple bundles may be employed within a single cover and, in some embodiments, even within a single channel within a cover.

[00061] Any suitable denier of fiber may be used. In one embodiment, the fibers of the woven rope may be in the range of about 10,000 denier to about 100,000 denier, including each intermittent value therein. In some embodiments, fibers may have a denier of or greater than about 10,000 denier. In still other embodiments, fibers of or less than about 100,000 denier may be employed.

[00062] Fiber bundles may be wrapped as many times as suitable for any particular embodiment or application. A predetermined length of fiber may be selected based on the ultimate number of wrappings desired and the desired length of the rope system. In some embodiments, an increased number of wrappings may reduce the impact on the connection of the ends of the fiber bundle, such as any impact (such as from tension) at a knot joining the free ends of a fiber bundle. In addition, although ends of a fiber bundle are joined as a knot in the embodiments described above, other suitable connections may be used such as taping, gluing, air splicing, and other suitable connections. In some embodiments, the knot or other connection may be disposed within a cover of a rope system.

[00063] In some embodiments, a fiber bundle may include a fiber optic cable, a sensor wire, and/or other materials, such as for load or temperature sensing. Such materials may be included within a fiber bundle as described above or may be included as a separate fiber bundle.

[00064] In some particular embodiments, rope systems of the present invention may be used as a winch rope. In such embodiments, such as shown in Fig. 16, fiber bundle 1604 is surrounded by cover 1602 except for loops 1605 that extend from cover 1602. Thimble 1615 may be included on one loop 1605 for use in winch applications or other applications. The depicted thimble is exemplary for one embodiment, but any suitable thimble or other hardware may be used. In some embodiments, each loop of that embodiment may include a thimble or other suitable hardware. A metal hook may optionally be attached to one or both ends, either to the fiber bundle loop directly or to a thimble thereon. In some embodiments, one loop at a longitudinal end of the rope system may be attached directly to a winch drum. Winch rope system embodiments may be prepared from any of the embodiments discussed herein.

[00065] In other embodiments, rope systems of the present invention may be used to form or function as a round sling. Round sling embodiments may be prepared from any of the embodiments discussed herein. Such slings may be used to harness or support heavy objects in applications such as, for example, aircraft, rigging, engine, shipbuilding, or other industrial or construction-related tools and parts. In some embodiments, a bundle of fibers may be continuously wound and then partially or wholly encased within a cover, such as by forming or joining a cover around the bundle of fibers. By way of example, and with reference to Fig. 17, loops 1705 of rope system 1700 may be joined together such that the rope system forms a round sling. Any suitable hardware may be used to join loops together to form a round sling, such as metal shackle 1716 shown for exemplary purposes in Fig. 17. In addition, cover 1702 may surround all or a portion of fiber bundles 1704. In some embodiments, cover 1702 may surround all of fiber bundles 1705 except for loops 1705. In still other embodiments, cover 1702 may not cover loops 1705, but after joining loops 1705 together to form a round sling, then cover 1702 may be extended to cover a portion or all of the loops, including or excluding any hardware. In such embodiments, a terminal end at each end of cover 1702 may be connected or joined together to form a continuous cover. Such connection may be done by any suitable means, including fasteners. In some embodiments, such round slings may be joined and connected to create a chain or linked rope system as described below.

[00066] In other embodiments, the present invention further includes a chain or linked rope system. Such linked rope systems may include a plurality of a bundle of fibers in a continuous loop, optionally encased wholly or partially within a cover, interlinked with other bundles of fiber formed in a continuous loop and also optionally encased wholly or partially within a cover. By way of example, Fig. 18 shows a linked rope system 1800. As shown, a bundle fibers 1804 (shown in a partial cutaway view) is encased within a cover 1802, and such a fiber bundle is present (although not shown) within each depicted cover 1802, which has two ends joined by seam S to form a continuous circular cover. The cover and encased bundle of fibers are interlinked with one or more other covers and encased bundle of fibers as depicted.

[00067] Linked rope systems of the present invention may be formed using any suitable procedure for a particular application. For example, as shown with reference to Fig. 18, the bundle of fibers are formed into a continuous loop of fibers by looping a fiber material through an open cover, such as a cover having to open ends (as shown in Fig. 18 for one cover 1804), and then joining two free ends of the fiber material to form a bundle of fibers in a continuous loop. A seam, such as seam S in Fig. 18, may then be formed to join the ends of a cover together to form a circular cover that fully encases the bundle of fibers within that cover. In other embodiments, a bundle of fibers comprising a continuous loop of fibers may be formed and then a cover may be formed or wrapped around that already-formed bundle of fibers, such as by wrapping material to form a cover around the already-formed continuous loop of a bundle of fibers and then sewing a seam to form the cover in a manner similar to that shown in Figs. 14-14C. In still other embodiments, round sling embodiments of the type previously described above with respect to Fig. 17, may be used, wherein loops of a bundle of fibers may be joined, such as by using any suitable hardware, including pins, shackles, thimbles, hooks, and the like made from appropriate materials for a particular application, such as stainless steel, steel, plastic, or composites, to form a link. A plurality of such links may be joined to form a linked rope system. In addition, in some embodiments, links may be connected to other links using hardware or by tying or sewing, as opposed to interlinking. As noted, in some such _, embodiments, a cover may be extended to cover the entire underlying bundle of fibers after connecting the loops of the bundle of fibers. Although the foregoing embodiments are illustrative, in other embodiments a linked rope system may include a plurality of bundles of fibers are interlinked and wherein some or all of the bundle of fibers do not include a cover. [00068] Rope systems of the present invention may be used for any other suitable purpose, such as other types of slings, harnesses, and ropes. Although particular embodiments of the invention have been described using specific terms, devices, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention, which is set forth in the following claims. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein.