Composite rope structures and systems and methods for making composite rope structures

1 . A rope structure comprising:

a plurality of formed composite strands comprising fiber material and matrix material; wherein

the fiber material within the matrix material is twisted; and

the shapes of the plurality of formed composite strands are predetermined to facilitate combination of the plurality of composite strands into the rope structure.

2 . A rope structure as recited in claim 1 , in which the formed composite strands are substantially helical.

3 . A rope structure as recited in claim 1 , in which the shapes of the formed composite strands are predetermined based on geometry of the rope structure.

4 . A rope structure as recited in claim 1 , in which the matrix material of the formed composite strands is cured.

5 . A rope structure as recited in claim 1 , in which the fiber material is made from at least one fiber selected from the group consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers.

6 . A rope structure as recited in claim 1 , in which the matrix material is at least one material selected from the group of materials consisting of thermoplastic polyurethane, polyester, polyethylene, polypropylene, PVC, and nylon.

7 . A rope structure as recited in claim 1 , in which:

the fiber material is at least one fiber selected from the group of fibers consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers; and

the matrix material is at least one material selected from the group of materials consisting of thermoplastic polyurethane, polyester, polyethylene, polypropylene, PVC, and nylon.

8 . A rope structure as recited in claim 1 , in which the formed composite strands comprise a plurality of yarns.

9 . A rope structure as recited in claim 8 , in which the formed composite strands comprise substantially between 70% and 98% by weight of the fiber material.

10 . A rope structure as recited in claim 8 , in which the formed composite strands comprise substantially between 2% and 30% by weight of the matrix material.

11 . A rope structure as recited in claim 8 , in which the formed composite strands comprise:

substantially between 70% and 98% by weight of the fiber material; and

substantially between 2% and 30% by weight of the matrix material.

12 . A rope structure as recited in claim 8 , in which the formed composite strands comprise substantially between 50% and 95% by weight of the fiber material.

13 . A rope structure as recited in claim 8 , in which the formed composite strands comprise substantially between 5% and 50% by weight of the matrix material.

14 . A rope structure as recited in claim 8 , in which the formed composite strands comprise:

substantially between 50% and 95% by weight of the fiber material; and

substantially between 5% and 50% by weight of the matrix material.

15 . A method of forming a rope structure, comprising the steps of:

providing fiber material;

providing matrix material;

arranging the fiber material within the matrix material to obtain blank material;

twisting the fiber material within the matrix material of the blank material to obtain unformed composite strands; and

working the plurality of unformed composite strands to obtain formed composite strands, where each of the formed composite strands has a predetermined shape; and

combining the formed composite strands into the rope structure.

16 . A method as recited in claim 15 , in which the step of working the plurality of the formed composite strands comprises the step of heating the unformed composite strands.

17 . A method as recited in claim 15 , further comprising the step of predetermining the shapes of the formed composite strands based on geometry of the rope structure.

18 . A method as recited in claim 15 , further comprising the step of curing the matrix material of the formed composite strands.

19 . A method as recited in claim 15 , further comprising the steps of:

selecting the fiber material from the group consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers; and

selecting the matrix material from the group of materials consisting of polyurethane, polyester, polyethylene, polypropylene, PVC and nylon.

20 . A rope structure comprising:

a plurality of formed composite strands comprising fiber material and matrix material; wherein

the fiber material within the matrix material is twisted; and

at least one of the formed composite strands is substantially cylindrical;

a plurality of the formed composite strands are substantially helical; and

the substantially helical formed composite strands are formed around the at least one substantially cylindrical formed composite strand to obtain the rope structure.

21 . A rope structure as recited in claim 20 , in which the matrix material of the formed composite strands is cured.

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

the fiber material is at least one fiber selected from the group of fibers consisting of carbon fibers, aramid fibers, polyester fibers, PBO, PBI, basalt, HMPE, and ceramic fibers; and

the matrix material is at least one material selected from the group of materials consisting of thermoplastic polyurethane, polyester, polyethylene, polypropylene, PVC, and nylon.

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

the formed composite strands comprises substantially between 70% and 98% by weight of the fiber material; and

the formed composite strands comprise substantially between 2% and 30% by weight of the matrix material.

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

the formed composite strands comprises substantially between 50% and 95% by weight of the fiber material; and

the formed composite strands comprise substantially between 5% and 50% by weight of the matrix material.