Composite rope structures and systems and methods for fabricating cured composite rope structures

1 . A method of fabricating a composite rope structure comprising the steps of:

fabricating at a first location impregnated yarns comprising fibers within a resin matrix;

transporting the impregnated yarns from the first location to a second location;

dispensing the impregnated yarns at the second location; and

curing the resin matrix of the dispensed impregnated yarns at the second location to obtain the composite rope structure.

2 . A method as recited in claim 1 , further comprising the steps of combining the impregnated yarns at the first location to obtain uncured strands, where the step of transporting the impregnated yarns comprises the step of transporting the uncured strands from the first location to the second location.

3 . A method as recited in claim 2 , further comprising the steps of combining the uncured strands at the first location to obtain an uncured rope structure, where the step of transporting the impregnated yarns comprises the step of transporting the uncured rope structure from the first location to the second location.

4 . A method as recited in claim 1 , further comprising the step of twisting the fibers within the resin matrix of the impregnated yarns.

5 . A method as recited in claim 1 , further comprising the step of heating the impregnated yarns.

6 . A method as recited in claim 4 , further comprising the step of heating the impregnated yarns to facilitate twisting of the fibers within the resin matrix.

7 . A method as recited in claim 2 , further comprising the step of heating the impregnated yarns to facilitate combination of the impregnated yarns into the uncured strands.

8 . A method as recited in claim 3 , further comprising the steps of:

heating the impregnated yarns to facilitate combination of the impregnated yarns into uncured strands;

heating the uncured strands to facilitate combination of the uncured strands into the uncured rope structure.

9 . A method as recited in claim 1 , further comprising the step of applying a release agent to the uncured yarn.

10 . A method as recited in claim 2 , further comprising the steps of:

applying a release agent to the impregnated yarn; and

applying a release agent to the uncured strands.

11 . A method as recited in claim 1 , in which the step of curing the uncured rope structure comprises the step of heating the uncured rope structure.

12 . A method as recited in claim 1 , further comprising the step of shaping the uncured rope structure.

13 . A method as recited in claim 1 , further comprising the step of collecting the impregnated yarns on at least one yarn bobbin.

14 . A method as recited in claim 2 , further comprising the steps of:

collecting the impregnated yarns on at least one yarn bobbin; and

collecting the uncured strands on at least one strand bobbin.

15 . A method as recited in claim 3 , further comprising the steps of:

collecting the impregnated yarns on at least one yarn bobbin;

collecting the uncured strands on at least one strand bobbin; and

collecting the uncured rope structure on at least one rope bobbin.

16 . A method as recited in claim 15 , in which the step of transporting the impregnated yarn from the first location to a second location comprises the step of transporting the uncured rope structure collected on the at least one rope bobbin from the first location to the second location.

17 . A method of fabricating a composite rope structure comprising the steps of:

fabricating at a first location impregnated yarns comprising fibers within a resin matrix;

collecting the impregnated yarns on a plurality of yarn bobbins;

combining the impregnated yarns on the plurality of yarn bobbins at the first location to obtain uncured strands;

collecting the uncured strands on a plurality of strand bobbins;

combining the uncured strands on the plurality of yarn bobbins at the first location to obtain an uncured rope structure;

collecting the uncured rope structure on a rope bobbin;

transporting the uncured rope structure collected on the rope bobbin from the first location to a second location;

dispensing the uncured rope structure at the second location by removing the uncured rope structure from the rope bobbin; and

curing the resin matrix at the second location to obtain the composite rope structure.

18 . A method as recited in claim 17 , further comprising the steps of:

heating the impregnated yarns to soften the resin matrix of the impregnated yarns;

twisting the fibers within the softened resin matrix of the impregnated yarns;

heating the impregnated yarns to facilitate combination of the impregnated yarns into the uncured strands;

heating the uncured strands to facilitate combination of the uncured strands into the uncured rope structure.

19 . A method as recited in claim 2 , further comprising the steps of:

applying a release agent to the impregnated yarns; and

applying a release agent to the uncured strands.

20 . A method as recited in claim 17 , in which the step of curing the uncured rope structure comprises the step of heating the uncured rope structure.

21 . A method as recited in claim 17 , further comprising the step of shaping the uncured rope structure.

22 . A system for fabricating a composite rope structure, the fabricating system comprising:

a twisting system for twisting fibers within a resin matrix to obtain impregnated and twisted yarns;

a first release agent stage for applying release agent to the impregnated and twisted yarns;

a first combining system for combining impregnated and twisted yarns to obtain uncured strands;

a second release agent stage for applying release agent to the uncured strands; and

a second combining system for combining the uncured strands to obtain uncured composite rope.

23 . A fabricating system as recited in claim 22 , in which the twisting system comprises:

a first bobbin for storing untwisted impregnated yarns;

a heating stage for heating the untwisted impregnated yarns; and

a yarn bobbin for collecting the impregnated and twisted yarns, where the yarn bobbin rotates about a twist axis of rotation to twist the fibers within the resin matrix.

24 . A fabricating system as recited in claim 22 , in which the first combining system comprises:

a plurality of yarn bobbins;

a heating element;

a first shaping die; and

a strand bobbin; wherein

the plurality of yarn bobbins are rotated about a first system axis to combine the plurality of impregnated yarns into the uncured strands;

the first shaping die shapes the uncured strands; and

the strand bobbin collects the uncured strands.

25 . A fabricating system as recited in claim 22 , in which the second combining system comprises:

a plurality of strand bobbins;

a heating element;

a second shaping die; and

a rope bobbin; wherein

the plurality of strand bobbins are rotated about a second system axis to combine the plurality of uncured strands into the uncured rope structure;

the second shaping die shapes the uncured rope structure; and

the rope bobbin collects the uncured rope structure.

26 . A system for deploying a composite rope structure, the deploying system comprising:

a rope bobbin for supporting an uncured rope structure comprising fibers and a resin matrix;

a heating element; and

a shaping die; wherein

the heating element heats the uncured rope structure such that the uncured resin matrix cures; and

the shaping die engages the uncured rope structure to maintain the uncured rope structure in a desired geometry as the resin matrix cures.

27 . A deploying system as recited in claim 26 , further comprising:

at least one infeed roller arranged to support the uncured rope structure extending from the rope bobbin to the heating element;

at least one intermediate roller arranged to support the uncured rope structure extending from the heating element to the shaping die; and

at least one outfeed roller arranged to support the uncured rope structure exiting the shaping die.

28 . A system for fabricating and deploying a composite rope structure, the fabricating and deploying system comprising:

a fabricating system at a first location, the fabricating system comprising

a twisting system for twisting fibers within a resin matrix to obtain impregnated yarns,

a first combining system for combining impregnated yarns to obtain uncured strands, and

a second combining system for combining the uncured strands to obtain uncured composite rope; and

a deploying system at a second location, the deploying system comprising

a rope bobbin for supporting an uncured rope structure comprising fibers and a resin matrix,

a heating element, and

a shaping die, wherein

the heating element heats the uncured rope structure such that the uncured resin matrix cures, and

the shaping die engages the uncured rope structure to maintain the uncured rope structure in a desired geometry as the resin matrix cures.