Method of making sealed wire rope

Claim 1

A method of making a sealed wire rope having a smooth exterior surface and having each strand impregnated with a plastic foam material and substantially separated from adjacent strands by a dense non-foamed plastic material of substantially the same composition as the plastic foam material comprising: (a) impregnating an uncured foamable plastic resin material individually into a plurality of wire strands, (b) closing the uncured foamable plastic resin containing wire strands together into a wire rope in a closing die while injecting an uncured nonfoamable plastic resin material having substantially the same composition as the uncured foamable plastic material into the closing die at a point prior to complete closing of the strands together and in sufficient quantity to substantially completely encapsulate the uncured foamable plastic containing wire strands with uncured nonfoamable plastic resin material, and (c) passing the wire rope together with the uncured foamable and uncured unfoamable plastic resin compositions through a heating device to foam and cure the foamable plastic resin and cure the unfoamable plastic resin.

Claim 2

A method of making a sealed wire rope having a smooth exterior surface and having each strand impregnated with a plastic foam material and substantially separated from adjacent strands by a dense non-foamed plastic material of substantially the same composition as the plastic foam material comprising: (a) impregnating an uncured foamable plastic resin material individually into a plurality of wire strands, (b) closing the uncured foamable plastic resin containing wire strands together into a wire rope in a closing die while injecting an uncured nonfoamable plastic resin material having substantially the same composition as the uncured foamable plastic material into the closing die at a point prior to complete closing of the strands together and in sufficient quantity to substantially completely encapsulate the uncured foamable plastic containing wire strands with uncured nonfoamable plastic resin material, and (c) passing the wire rope together with the uncured foamable and uncured unfoamable plastic resin compositions through a heating device to foam and cure the foamable plastic resin and cure the unfoamable plastic resin.

Claim 6

A method of making a sealed wire strand impregnated with a plastic resin foam material and encapsulated within an outer covering of an unfoamed plastic resin material comprising: (a) passing a plurality of individual wires into a stranding die to form said wires into a wire strand, (b) injecting an uncured foamable plastic resin material into said stranding die at a location such that it contacts the wires prior to the time they contact each other as they pass into and through the stranding die to impregnate the spaces between the wires with the foamable plastic resin material, (c) after the spaces between the wires are impregnated with foamable plasic material maintaining the individual wires together in final wire strand conformation while injecting an uncured unfoamable plastic resin material about the exterior of the wire strand in the stranding die, (d) passing the wire strand through a heating device to heat the wires, foam the foamable plastic resin material and cure the foamable and unfoamable plastic resin material.

Claim 7

A method of making a sealed wire strand impregnated with a plastic resin foam material and encapsulated within an outer covering of an unfoamed plastic resin material comprising: (a) passing a plurality of individual wires into a stranding die to form said wires into a wire strand, (b) injecting an uncured foamable plastic resin material into said stranding die at a location such that it contacts the wires prior to the time they contact each other as they pass into and through the stranding die to impregnate the spaces between the wires with the foamable plastic resin material, (c) after the spaces between the wires are impregnated with foamable plasic material maintaining the individual wires together in final wire strand conformation while injecting an uncured unfoamable plastic resin material about the exterior of the wire strand in the stranding die, (d) passing the wire strand through a heating device to heat the wires, foam the foamable plastic resin material and cure the foamable and unfoamable plastic resin material.

Claim 8

A method of forming a sealed wire rope in which the individual strands are impregnated with a plastic resin foam material and the rope is encapsulated within an outer covering of an unfoamed plastic resin material comprising: (a) impregnating a plurality of wire strands with an uncured unfoamed plastic resin material, (b) stranding the plurality of uncured unfoamed plastic resin impregnated wire strands together to form a wire rope, (c) holding the uncured unfoamed plastic resin impregnated wire strands in intimate contact with each other in a die and injecting an uncured unfoamable plastic resin composition about the strands while they are held in intimate contact, (d) passing the wire rope through a heating device wherein the uncured and unfoamed plastic composition is foamed and cured and the uncured unfoamable plastic composition is cured.

Claim 9

A method of forming a sealed wire rope in which the individual strands are impregnated with a plastic resin foam material and the rope is encapsulated within an outer covering of an unfoamed plastic resin material comprising: (a) impregnating a plurality of wire strands with an uncured unfoamed plastic resin material, (b) stranding the plurality of uncured unfoamed plastic resin impregnated wire strands together to form a wire rope, (c) holding the uncured unfoamed plastic resin impregnated wire strands in intimate contact with each other in a die and injecting an uncured unfoamable plastic resin composition about the strands while they are held in intimate contact, (d) passing the wire rope through a heating device wherein the uncured and unfoamed plastic composition is foamed and cured and the uncured unfoamable plastic composition is cured.