Rope structure with improved bending fatigue and abrasion resistance characteristics

1. A rope structure adapted to engage an intermediate structure while loads are applied to ends of the rope structure, comprising:

a primary strength component comprising a plurality of fibers adapted to bear the loads applied to the ends of the rope structure;

a coating comprising

a lubricant portion, and

a binder portion, where the binder portion is applied to the primary strength portion to form a matrix that at least partly surrounds at least some of the fibers to support the lubricant portion relative to at least some of the fibers; whereby

the matrix supports the lubricant portion such that the lubricant portion

reduces friction between at least some of the plurality of fibers, and

reduces friction between at least some of the plurality of fibers and the intermediate structure.

2. A rope structure as recited in claim 1 , in which coating material is applied to the primary strength component in liquid form and allowed to dry to form the coating.

3. A rope structure as recited in claim 2 , in which the liquid form of the coating material comprises substantially between 5% and 40% by weight of the lubricant portion.

4. A rope structure as recited in claim 2 , in which the liquid form of the coating material comprises substantially between 32% and 37% by weight of the lubricant portion.

5. A rope structure as recited in claim 2 , in which the liquid form of the coating material comprises approximately 35% by weight of the lubricant portion.

6. A rope structure as recited in claim 1 , in which the lubricant portion comprises one or more of PTFE and silicon oil.

7. A rope structure as recited in claim 6 , in which the lubricant portion is in powder form.

8. A rope structure as recited in claim 6 , in which an average size of the PTFE is within approximately 0.01 microns to 2.00 microns.

9. A rope structure as recited in claim 6 , in which an average size of the PTFE is within approximately 0.10 microns to 0.50 microns.

10. A rope structure as recited in claim 6 , in which an average size of the PTFE is approximately 0.22 microns.

11. A rope structure as recited in claim 1 , in which the binder portion adheres to at least some of the fibers.

12. A rope structure as recited in claim 1 , in which the coating comprises a polyurethane dispersion.

13. A method of forming a rope structure adapted to engage an intermediate structure while loads are applied to ends of the rope structure, comprising the steps of:

providing a plurality of fibers;

combining the plurality of fibers to form a primary strength component adapted to bear the loads applied to the ends of the rope structure;

providing a coating material in liquid form comprising a lubricant portion and a binder portion;

applying the coating material in liquid form to the primary strength component;

allowing the coating material in liquid form to dry on the primary strength member such that the binder portion forms a matrix that at least partly surrounds at least some of the fibers to support lubricant portion relative to at least some of the fibers such that the lubricant portion reduces friction between at least some of the plurality of fibers and between at least some of the plurality of fibers and the intermediate structure.

14. A method as recited in claim 13 , in which the step of providing the liquid form of the coating material comprises the step of providing substantially between 5% and 40% by weight of the lubricant portion.

15. A method as recited in claim 13 , in which the step of providing the liquid form of the coating material comprises the step of providing PTFE to form the lubricant portion.

16. A method as recited in claim 15 , in which an average particle size of the PTFE is within approximately 0.01 microns to 2.00 microns.

17. A method as recited in claim 13 , in which the step of providing the liquid form of the coating material comprises the step of providing a binder portion that adheres at least some of the fibers and holds the lubricant portion in place.

18. A method as recited in claim 13 , in which the step of providing the liquid form of the coating material comprises the step of providing a binder portion comprising a polyurethane dispersion.

19. A rope structure adapted to engage an intermediate structure while loads are applied to ends of the rope structure, comprising:

a primary strength component comprising a plurality of fibers adapted to bear the loads applied to the ends of the rope structure, where the plurality of fibers are combined to form plurality of yarns, the plurality of yarns are combined to form a plurality of strands, and the plurality of strands are combined to form the primary strength component;

a coating comprising PTFE particles suspended within a matrix formed of binder material such that the binder fixes the PTFE particles relative to at least some of the fibers such that the PTFE particles reduce friction between at least some of the plurality of fibers and between at least some of the plurality of fibers and the intermediate structure.

20. A rope structure as recited in claim 19 , in which:

the coating is formed by applying coating material in a liquid form to the primary strength component;

the liquid form of the coating material comprises substantially between 5% and 40% by weight of the lubricant portion; and

an average size of the PTFE is within approximately 0.01 microns to 2.00 microns.