WO2004079085A1

WO2004079085A1 - Metal rope

Info

Publication number: WO2004079085A1
Application number: PCT/EP2003/050145
Authority: WO
Inventors: Jan Calleeuw; Daniël DAUWE
Original assignee: N.V. Bekaert S.A.
Priority date: 2002-05-13
Filing date: 2003-05-06
Publication date: 2004-09-16
Also published as: AU2003303746A1

Abstract

A metal rope (10) comprises wires (16, 18). The wires (16, 18) have a surface of stainless steel. A number of wires (18) are exposed to the surface of the rope (10). The number of wires that is exposed to the surface of the rope is equal to m. Some wires of these m wires exposed to the surface of the rope are coated with a transparent polymer. The number of wires coated is equal to n, whereby 1≤ n < m. The transparent polymer (22) is selected from the group consisting of thermoplastic polymers, polyimides, polyamides and polyphtalamides, or a copolymer thereof. The invention further relates to a structure, such as a woven (144) or knitted structure (150) comprising a metal rope according to the invention. The metal rope (10) can be used in architectural, building and decorative applications.

Description

METAL ROPE

Field of the invention.

The present invention relates to a metal rope comprising wires having a surface of stainless steel, e.g. stainless steel wires. At least one of the wires that are exposed to the surface of the rope is coated with a transparent polymer.

The present invention also relates to a fabric comprising a decorative metal rope and to the use of such a metal rope in architectural and decorative applications.

Background of the invention.

Metal ropes comprising stainless steel wires are known in the art. They are frequently used in applications where a good anti-corrosion protection is important.

On the other hand, decorative and colorful ropes are known. Such ropes are for example made of plain carbon steel wires coated with a zinc coating and on top of this zinc coating a polymer coating to which coloring pigments are added. However, such ropes are expensive as all filaments of the rope have to be coated individually.

Summary of the invention.

It is an object of the present invention to provide a metal rope having an attractive esthetic aspect. It is another object to provide a metal rope that can be manufactured at low cost.

It is another object to provide a structure such as a woven or knitted structure comprising such a metal rope.

According to a first aspect of the present invention there is provided a metal rope with wires having a surface of stainless steel. Some of these wires are exposed to the surface of the rope, other wires are located at the center of the rope and are not exposed to the surface of the rope. The number of wires that is exposed to the surface of the rope is equal to m. Some wires of these m wires exposed to the surface of the rope are coated with a transparent polymer. The number of wires coated is equal to n, whereby 1 < n < m.

The transparent polymer is preferably selected from the group consisting of thermoplastic polyesters, polyimides, polyamides and polyphtalamides, or a copolymer thereof.

A wire exposed to the surface of the rope coated with a transparent polymer is hereafter referred to as "colored wire".

A wire with a surface of stainless steel can be a common stainless steel wire or can be a wire with a metal core, e.g. a core of plain carbon steel with an external layer of cladded stainless steel.

Preferably, a thermoplastic polyester is used as polymer. Thermoplastic polyester has the advantage of giving a good adhesion with the stainless steel wire and of having a low degree of moisture absorption. The good adhesion level is obtained without pickling treatment on the stainless steel wire so that the initial bright aspect of the stainless steel wire is not reduced. The low degree of absorption further guarantees that this bright aspect is kept for a long time.

This thermoplastic polyester is preferably selected from the group consisting of polyethylene terephtalate, polybutylene terephtalate, polyethylene naphtenate or any copolymer comprising polyethylene terephtalate, polybutylene terephtalate or polyethylene naphtenate.

According to a preferred embodiment of the invention, the transparent polymer comprises a transparent organic coloring agent, which can be added to the polymer in the form of small grains in a carrier of a similar or same polymer. This embodiment offers the advantage of various colors depending upon the concentration and type of coloring agent : metallic like colors and fluorescent colors may be applied to the stainless steel wire in this way. The coloring agent together with the transparency of the polymer and the bright aspect of the stainless steel wires give to the wire a typical metallic look. In some embodiments, an additional polymer coating is applied on the colored wire. This additional polymer coating comprises for example a thermoplastic polyester coating or a polyurethane coating. The additional polymer coating may be transparent or colored.

The rope according to the invention may be a single-strand rope, i.e. a rope comprising only one strand, or a multi-strand rope, i.e. a rope comprising more than one strand.

The rope can be further embedded in a coating of a polymer coating. This polymer coating may for example be applied on the rope by an extrusion process. The polymer coating comprises for example a thermoplastic polyester coating or a polyurethane coating. The polymer coating may be transparent or colored.

One advantage of embedding a rope according to the present invention in a polymer coating is that the friction of the rope may be reduced. Another reason to apply a polymer coating to a rope according to the present invention is to keep the rope, and more particularly the cavities created between the wires or the strands of the rope, free of dust particles.

According to a second aspect of the present invention, a fabric is provided comprising a metal rope according to the first aspect of the invention. This fabric may be a woven structure or a knitted structure.

In case of a woven structure, the metal rope according to the present invention may form the warp, or the weft or both the warp and the weft. Other embodiments of woven structures comprise ropes comprising colored wires of a certain color in the warp direction and ropes comprising colored wires of another color in the weft direction. Further embodiments of woven fabrics comprise a pattern made by using metal ropes according to the present invention. A metal rope according to the invention can be used in the structural field, i.e. in the building and architectural field. A metal rope according to the invention is also suitable to be used as a decorative rope.

Within the building and architectural field several applications are possible.

A first application is the use of the metal rope as stay rope or stay strand for suspension bridges with a high span length of support. Here the individual steel wires of the metal rope often have diameters exceeding

4.0 mm. Metal ropes for this application often comprise more than one strand of twisted wires.

A second application is the use of the metal rope as stay rope or stay strand for roof support or for outside wall support. Roofs for sport stadium, sport halls, airport buildings, exposition halls can be suspended on such metal ropes. The possible application of various colors is also more important in this second application than in the first application.

A third application is the use of the metal rope for stays and supports of antennas and masts.

Also within the decorative field various applications are possible. A rope according to the present invention can for example be used in jewelry rope, necklaces, bracelets, buckles and other fashion articles. The metal rope according to the invention can be applied for the suspension of lighting apparatus, for the building of stands at expositions and exhibitions, for the interior and exterior design of shops, suspension or lifting of objects in theaters. In the decorative field, the wire diameter is usually much smaller than the wire diameter of ropes used in the architectural field.

The second aspect of the present invention, the fabric comprising the colored wire rope, may also have various building and decorative applications. The fabric may be used as a railing or balustrade for terraces, balconies, stairs and bridges. The fabric may function as a ceiling in public buildings. Furthermore, the fabric may be used as a decorative woven structure for inner or outer walls or for curtains. The fabric can even be used in furniture, for example as the seat or the back of chairs such as garden chairs.

Brief description of the drawings.

The invention will now be described into more detail with reference to the accompanying drawings wherein

FIGURE 1 shows a cross-section of a multi-strand metal rope according to the invention;

FIGURE 2 shows a cross-section of a first embodiment of a colored wire of a metal rope according to the invention; FIGURE 3 shows a cross-section of a second embodiment of a colored wire of a metal rope according to the invention; - FIGURE 4a en FIGURE 4b show the cross-section of a single- strand metal rope according to the invention; FIGURE 5 illustrates a longitudinal view of an end of a metal rope according to the invention; FIGURE 6 illustrates an application of a metal rope according to the invention in the decorative field;

FIGURES 7, 8 and 9 are lop views of woven structures according to the second aspect of the present invention; FIGURES 10, 11a and 11 b and 12 are cross-sectional views of woven structures according to the second aspect of the present invention;

FIGURE 13 is a top view of a knitted structure according to the second aspect of the present invention.

Description of the preferred embodiments of the invention. FIGURE 1 shows a cross-section of a metal rope 10 according to the first aspect of the present invention. The metal rope 10 is a multi-strand rope. A core strand 12 is surrounded by six layer strands 14. The core strand 12 comprises seven stainless steel wires 16. Each layer strand 14 comprises seven stainless steel wires. The six wires 18 are each individually exposed to the surface of the wire rope 10 due to the twisting of the strand 14. At least one of these six wires 18, wire 19, is provided with a transparent polyester coating to which a transparent organic coloring agent has been added. As the wires 19 are twisted in the strands of the rope they are giving the rope a unique eye-pleasant appearance.

In an alternative embodiment only one strand of the multi-strand rope comprises a colored wire.

By varying the number of wires 19 in a strand, by varying the colors of the wires 19, by making combinations of different colors in one strand or in different strands, ... a great number of different ropes can be obtained.

FIGURE 2 shows a cross-section of a first embodiment of a colored wire

19 with a full stainless steel core 20. The stainless steel core 20 is provided with a polyester coating 22.

FIGURE 3 shows a cross-section of a second embodiment of a colored wire 19. This wire may have a core of plain carbon steel 24. The core

24 is cladded with a stainless steel 26. The cladded wire is then provided with a polyester coating 22.

Wire rope 10 of FIGURE 1 has a 7x7 construction. Other embodiments and constructions of ropes are possible.

Another interesting multi-strand construction is for example a 7 x 19 construction.

Interesting constructions of single-strand ropes are : 1 +6 or 7x1

1+6+12 or 19x1

The diameter of the rope may range between broad limits such as from 0.50 mm to 180.0 mm, e.g. from 0.50 mm to 60.0 mm, and depends largely upon the application, the greater diameters being used in the architectural and building field.

FIGURE 4a shows a cross-section of a single-strand construction of a metal rope 10 according to the invention. Such a construction is also called a spiral strand. It consists of up to eleven layers of stainless steel wires. The wires 16, which are not exposed to the surface, are left blank. One of the wires 18 which are exposed to the surface of the rope is provided with a transparent polyester coating to which a transparent organic coloring agent has been added. The colored wire is indicated with number 19. As the colored wire 19 is present in the rope as a spiral, this colored wire is giving the rope a unique eye-pleasant appearance.

In an alternative embodiment a number of wires 18 exposed to the surface of the rope are replaced with a colored wire. For example every sixth wire exposed to the surface of the rope is a colored wire. The different colored wires may have the same color or may have different colors.

The diameter of the individual wires may vary between 0.30 mm and 8.0 mm, e.g. between 0.40 mm and 5.0 mm.

The thickness of the polyester coating on the final steel wire 18 may range from 20 micrometer (μm) to 150 μm. The minimum values are imposed by reason of providing a sufficient abrasion resistance. The maximum values are imposed by reasons of cost and by reasons of maintaining a sufficient level of transparency.

Typical stainless steel compositions for the stainless steel are according to norms AISI 302, AISI 304 and AISI 316.

The polyester coating is preferably applied to the individual wires by means of an extrusion process. FIGURE 4b shows the cross-section of the single-strand rope of figure 4a on which an additional polymer coating 40 is applied.

FIGURE 5 illustrates an end of a metal rope 10 according to the invention. The end of the metal rope is clamped into an end piece 30 in the form of a fork to enable to attach the metal rope 10 to a construction, roof, wall etc...

FIGURE 6 illustrates an application of a metal rope 10 within the decorative field. The metal rope 10 forms the essential part of a stand 31. Tension sleeves 32 tension and fix the wire rope 10 to the base floor. The wire rope is guided over a guiding wheel 34 fixed to a wall. Distant keepers 36 take care that an appropriate distance is kept between two parts of the wire rope 10. A rack bottom plate 38 rests on supports 40, which are attached to the metal rope 10.

FIGURES 7 to 13 all illustrate woven structures 144 according to the second aspect of the present invention.

In FIGURE 7 steel cords 10 form the warp whereas synthetic yarns 146 such as aramide form the weft. At least one of the steel cords comprise a rope 19 according to the present invention.

A nylon filament 148, such as nylon 940/2/2 binds the warp to the weft. By using different colored wires or by increasing the number of colored wires a great number of fabrics can be obtained.

In FIGURE 8 steel cords 10 form the weft whereas synthetic yarns 146 form the warp. A number of the steel cords comprises ropes according to the present invention.

In FIGURE 9 steel cords 10 both form the weft and the warp. A nylon filament 148 holds both weft and warp together. In FIGURE 9 both the weft and the warp are straight steel cords 10. An alternative embodiment, however, may be provided by having the weft cord 10 altematingly go up and under the warp cord 10. At least one of the steel cords of the warp and/or of the weft is replaced by a rope according to the present invention.

In the woven structure 144 of FIGURE 10 steel cords 10 form the weft and nylon filaments 148 form the warp in an alternating zigzag way : a first nylon filament 148 goes over and under and over the steel cords 10, a second nylon filament 148 goes under and over and under the steel cords 10, etc... At least one of the steel cords 10 is replaced by a rope according to the present invention.

In the woven structure 144 of FIGURE 11a and 11b steel cords 10 form also the weft and nylon filaments 148 also form the warp in an alternating zigzag way, but here the nylon filament 148 goes over two steel cords 10, and subsequently under two steel cords 10 etc ... in other words, the pitch of the warp nylon filaments is four steel cords instead of two. At least one of the steel cords is replaced by a rope according to the present invention.

FIGURE 12 shows the cross-section of a so-called solid woven structure 144 which exists as such for reinforcement of conveyor belts. Such a solid woven structure has two layers of ropes 10 as warp, and three layers of synthetic filaments 146 or steel cords as weft. The ropes are for example steel cords. The warp and weft layers are bound by means of nylon filaments 148. At least one of the ropes 10 comprise a metal rope according to the present invention.

FIGURE 13 shows a fabric comprising a knitted structure 150 of ropes 10. At least one of the ropes is a rope as subject of the invention.

In a special embodiment, a pattern is knitted into the structure 150 by using ropes having different colored wires.

Claims

CLA1MS

1. A metal rope comprising wires, said wires having a surface of stainless steel, m wires of said wires are exposed to the surface of the rope, a number of wires of said m wires exposed to the surface of the rope being coated with a transparent polymer, said number being equal to n, n being at least 1 and being smaller than m, said polymer being selected from the group consisting of thermoplastic polyesters, polyimides, polyamides and polyphtalamides, or a copolymer thereof.

2. A metal rope as claimed in claim 1 , wherein said wires are stainless steel wires.

3. A metal rope as claimed in claim 1 , wherein said wires have a metal core with an external layer of cladded stainless steel.

4. A metal rope as claimed in any one of the preceding claims wherein said thermoplastic polyester is selected from the group consisting of polyethylene terephtalate, polybutylene terephtalate, polyethylene naphtenate or any copolymer comprising polyethylene terephtalate, polybutylene terephtalate or polyethylene naphtenate.

5. A metal rope as claimed in any one of the preceding claims wherein said polymer comprises a transparent organic coloring agent.

6. A fabric comprising at least one metal rope as claimed in any one of claims 1 to 5.

7. A fabric according to claim 6, wherein said fabric is a woven structure.

8. A fabric according to claim 7, wherein said woven structure comprises a weft and a warp, either the weft or the warp or both are formed by said metal rope.

9. A fabric according to claim 6, wherein said fabric is a knitted structure.

10. Use of a metal rope as claimed in any one of claims 1 to 5 as architectural rope.

11. Use of a metal rope as claimed in any one of claims 1 to 5 as decorative rope.