EQUIPMENT PROTECTION SLEEVES

Abstract

Protective polymer covers for metal equipment are disclosed. The metal equipment is generally used with wire ropes, and the protective polymer covers provide a smooth protrusion free surface which is suitable for contact with a synthetic line. The protective polymer covers are shaped to conform to an outer peripheral surface of the metal equipment, and include at least one cover section having at least one means for connection at each of a first end portion and a second end portion. The protective polymer covers are composed of a thermosetting cast polyurethane having a Shore D hardness of greater than about 60 or a Shore A hardness of greater than about 85.

Claims

1. A releasably attachable durable polymer cover for a metal structure which is used for rope contact, the cover comprising: at least one cover section composed of a thermosetting cast polyurethane having a Shore D hardness of greater than about 60 or a Shore A hardness of greater than about 85, the at least one cover section comprising a first end portion, a second end portion, a first axial end, and a second axial end; and a means for releasable attachment of the at least one cover section around the metal structure, wherein the means for releasable attachment is positioned at or proximal to the first end portion and the second end portion of the at least one cover section, wherein the durable polymer cover is shaped to conform to an outer peripheral surface of the metal structure such that a space between any portion of an inner surface of the durable polymer cover and the outer peripheral surface of the metal structure is not greater than 0.2 inches when the durable polymer cover is installed on the metal structure, and wherein the durable polymer cover provides a smooth outer surface around the metal structure which lacks protrusions and is suitable for contact with a synthetic line.

2. The durable polymer cover of claim 1, wherein the space between any portion of the inner surface of the durable polymer cover and the outer peripheral surface of the metal structure is not greater than 0.1 inches when the durable polymer cover is installed on the metal structure.

3. The durable polymer cover of claim 1, wherein the at least one cover section comprises at least one recessed channel at each of the first end portion and the second end portion which is configured and sized to receive the means for releasable attachment.

4. The durable polymer cover of claim 3, wherein the at least one recessed channel at each of the first end portion and the second end portion comprises: a top recessed channel positioned at or proximal to the top axial end of each of the first end portion and the second end portion of the at least one cover section; and a bottom recessed channel positioned at or proximal to the bottom axial end of each of the first end portion and the second end portion of the at least one cover section.

5. The durable polymer cover of claim 3, wherein the means for releasable attachment comprises a nut and bolt set, a screw, a tap-in pin, or a combination thereof.

6. The durable polymer cover of claim 1, wherein the means for releasable attachment comprises a ladder clip system, a ball and socket system, a cam lock system, at least one set of internally positioned high strength magnets, or a combination thereof.

7. The durable polymer cover of claim 1, further comprising: a secondary attachment means comprising a hook and loop closure, an adhesive tape, an adhesive, at least one set of internally positioned high strength magnets, or a combination thereof, wherein the secondary attachment means is positioned at or proximal to the first end portion and the second end portion of the at least one cover section, on the inner surface of the durable polymer cover, or both.

8. The durable polymer cover of claim 1, wherein the thermosetting cast polyurethane is formed by reaction of a polytetramethylene ether glycol with an isocyanate.

9. The durable polymer cover of claim 1, wherein the at least one cover section comprises at least one row of inset teeth at each of the first end portion and the second end portion, wherein the means for releasable attachment comprises contact between the at least one row of inset teeth on the first end portion and the at least one row of inset teeth on the second end portion, wherein the second end portion is on a same cover section as the first end portion or on an adjacent cover section.

10. The durable polymer cover of claim 1, wherein the first end portion has at least one projection configured to fit within at least one indent on the second end portion, wherein the second end portion is on a same cover section as the first end portion or on an adjacent cover section.

11. The durable polymer cover of claim 1, wherein the metal structure is selected from the group comprising bollards, chocks, roller chocks, cleats, kevels, capstans, winches, sheaves, buttons, bits, double bits, H-bits, side bits, fairleads, fairlead rollers, pilings, dauphins, mooring rings, deck perimeters and dock perimeters.

12. The durable polymer cover of claim 1, wherein one or both of the first axial end and the second axial end comprises a lip that restricts rotational movement of the durable polymer cover about the metal structure when the durable polymer cover is installed on the metal structure.

13. A releasably attachable durable polymer cover for a metal structure on a marine deck or dock, the cover comprising: two cover sections composed of a thermosetting cast polyurethane having a Shore D hardness of greater than about 60 or a Shore A hardness of greater than about 85, the at least one cover section comprising a first end portion, a second end portion, a first axial end, a second axial end, and at least one countersunk channel; and at least one means for releasable attachment of each of the two cover sections directly to the metal structure through the at least one countersunk channel, wherein the durable polymer cover is shaped to conform to an outer peripheral surface of the metal structure such that a space between any portion of an inner surface of the durable polymer cover and the outer peripheral surface of the metal structure is not greater than 0.1 inches when the durable polymer cover is installed on the metal structure, and wherein the durable polymer cover provides a smooth outer surface around the metal structure which lacks protrusions and is suitable for contact with a synthetic line.

14. The durable polymer cover of claim 13, wherein the means for releasable attachment comprises a screw, a tap-in pin, or a combination thereof.

15. The durable polymer cover of claim 13, further comprising: a secondary attachment means comprising a hook and loop closure, an adhesive tape, an adhesive, at least one set of internally positioned high strength magnets, or a combination thereof, wherein the secondary attachment means is positioned at or proximal to the first end portion and the second end portion of the at least one cover section, on the inner surface of the durable polymer cover, or both.

16. A device for rope contact on a marine deck or dock, the device comprising a metal structure attachable to the marine deck or dock which is configured to hold or secure a wire rope, and the durable polymer cover of claim 1, wherein the durable polymer cover provides a smooth outer surface around the metal structure which lacks protrusions and is suitable for contact with a synthetic line.

17. A protective cover for a cleat or kevel, the cover comprising: two sections shaped to conform to an outer peripheral surface of the cleat or kevel such that a space between any portion of an inner surface of the protective cover and the outer peripheral surface of the cleat or kevel is not greater than 0.2 inches, wherein each section is composed of a thermosetting cast polyurethane having a Shore D hardness of greater than about 60 or a Shore A hardness of greater than about 85, wherein each section comprises: a base portion, a top portion, at least one center column portion connecting the base portion and the top portion, and a lateral edge; and means for releasable attachment of the two sections in face-to-face relation, wherein the means for releasable attachment is positioned at or proximal to the lateral edge of each section, wherein the protective cover provides a smooth outer surface lacking protrusions which is suitable for contact with a synthetic line.

18. The protective cover of claim 17, wherein the space between any portion of the inner surface of the durable polymer cover and the outer peripheral surface of the metal structure is not greater than 0.1 inches.

19. The protective cover of claim 17, wherein the means for releasable attachment comprises a nut and bolt set, a screw, a tap-in pin, a ladder clip system, a ball and socket system, a cam lock system, at least one set of internally positioned high strength magnets, or a combination thereof.

20. The durable polymer cover of claim 17, further comprising: a secondary attachment means comprising a hook and loop closure, an adhesive tape, an adhesive, at least one set of internally positioned high strength magnets, or a combination thereof, wherein the secondary attachment means is positioned at or proximal to lateral edge of one or both of the two cover sections, on the inner surface of the durable polymer cover, or both.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Aspects, features, benefits and advantages of the embodiments herein will be apparent with regard to the following description, appended claims, and accompanying drawings. In the following figures, like numerals represent like features in the various views. It is to be noted that features and components in these drawings, illustrating the views of embodiments of the present invention, unless stated to be otherwise, are not necessarily drawn to scale.

[0026] FIGS. 1A-1C illustrate perspective views of a button partially covered by a single cover section of a durable polymer cover in accordance with certain aspects of the present invention;

[0027] FIG. 1D illustrates a close-up view of a portion of the cover section shown in FIG. 1C pointing out the connection point between two portions of the protective cover in accordance with certain aspects of the present invention;

[0028] FIGS. 2A-2B illustrate perspective views of a button partially covered by a single cover section of a durable polymer cover in accordance with certain aspects of the present invention;

[0029] FIG. 2C illustrates a close-up view of a portion of the cover section shown in FIG. 2B pointing out the connection point between two portions of the protective cover in accordance with certain aspects of the present invention;

[0030] FIGS. 3A-3C illustrate perspective views of a double bit where one bit is covered by a durable polymer cover, and the other bit is partially covered by a single cover section of the durable polymer cover in accordance with certain aspects of the present invention;

[0031] FIG. 3D illustrates a cross-sectional view taken through line 3D-3D of the double bit partially covered by the cover section shown in FIG. 3C;

[0032] FIG. 3E is an end view of the boat double bit covered by the durable polymer cover shown in FIG. 3C;

[0033] FIG. 3F illustrates a close-up view of a portion of the protective cover shown in FIG. 3D pointing out the connection point between two portions of the protective cover in accordance with certain aspects of the present invention;

[0034] FIG. 4 illustrates a perspective view of a double bit partially covered by an alternative embodiment of a durable polymer cover in accordance with certain aspects of the present invention;

[0035] FIG. 5 illustrates an exploded view of an alternative embodiment of a durable polymer cover prior to installation on a double bit in accordance with certain aspects of the present invention;

[0036] FIGS. 6A-6D illustrate perspective views of a kevel partially covered by a single cover section of a durable polymer cover in accordance with certain aspects of the present invention;

[0037] FIG. 6E illustrates a partial view of a connection point between two portions of the protective cover shown in FIGS. 6A-6D in accordance with certain aspects of the present invention;

[0038] FIG. 6F illustrates a close-up view of a portion of the protective cover shown in FIG. 6E pointing out the connection point between two portions of the protective cover in accordance with certain aspects of the present invention;

[0039] FIG. 7 illustrates an exploded view of an alternative embodiment of a durable polymer cover prior to installation on a kevel in accordance with certain aspects of the present invention;

[0040] FIG. 8 illustrates a top view of a durable polymer cover comprising three sections in accordance with certain aspects of the present invention;

[0041] FIG. 9 illustrates a close-up view of the connection point between two portions of the protective cover shown in FIG. 8 in accordance with certain aspects of the present invention;

[0042] FIG. 10 illustrates a perspective view of a corner or edge protective cover in accordance with certain aspects of the present invention;

[0043] FIG. 11 illustrates a perspective view of a corner or edge protective cover in accordance with certain aspects of the present invention;

[0044] FIGS. 12A-12B illustrate perspective views of a durable protective cover in accordance with certain aspects of the present invention;

[0045] FIG. 13 illustrates a perspective view of a durable polymer cover in accordance with certain aspects of the present invention;

[0046] FIG. 14 illustrates an exploded view of a durable polymer cover prior to installation on a button in accordance with certain aspects of the present invention;

[0047] FIG. 15 illustrates a perspective view of the durable polymer cover shown in FIG. 14 installed on a button;

[0048] FIG. 16 illustrates a cross-sectional view taken through line 16-16 of the button covered by the durable polymer cover shown in FIG. 15;

[0049] FIG. 17 illustrates a view of a radial end of a cover section showing a cam and lock system releasable attachment means in accordance with certain aspects certain aspects of the present invention;

[0050] FIG. 18 illustrates a view of a radial end of a cover section showing a ball and socket releasable attachment means in accordance with certain aspects certain aspects of the present invention;

[0051] FIG. 19 illustrates a view of a radial end of a cover section showing magnets as a releasable attachment means in accordance with certain aspects certain aspects of the present invention;

[0052] FIG. 20 illustrates a view of a radial end of a cover section showing a tap in pin as a releasable attachment means in accordance with certain aspects certain aspects of the present invention; and

[0053] FIG. 21 illustrates a view of a radial end of a cover section showing a tooth and ladder back system as a releasable attachment means in accordance with certain aspects certain aspects of the present invention.

DETAILED DESCRIPTION

[0054] In the following description, the presently disclosed invention is set forth in the context of various alternative embodiments and implementations involving durable polymer covers which provide a non-abrasive surface suitable for contact with synthetic line. These covers are designed to encase the rope contacting surfaces of various types of metal equipment. As such, these covers may be used to encase or cover any type of metal equipment or fitting which is normally used with wire rope, and provide a low coefficient of friction cover which is smooth and protrusion free and thus reduces wear on the synthetic line and protects the line from damage.

[0055] Various aspects of the durable polymer covers may be illustrated by describing components that are coupled, attached, and/or joined together. As used herein, the terms coupled, attached, and/or joined are interchangeably used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being directly coupled, directly attached, and/or directly joined to another component, there are no intervening elements shown in said examples.

[0056] Various aspects of the durable polymer covers may be illustrated with reference to one or more exemplary implementations. As used herein, the term exemplary means serving as an example, instance, or illustration, and should not necessarily be construed as preferred or advantageous over other variations of the devices, systems, or methods disclosed herein. Optional or optionally means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. In addition, the word comprising as used herein means including, but not limited to.

[0057] Relative terms such as lower or bottom and upper or top may be used herein to describe one element's relationship to another element illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of aspects of the durable polymer covers in addition to the orientation depicted in the drawings. By way of example, if aspects of the durable polymer covers shown in the drawings are turned over, elements described as being on the bottom side of the other elements would then be oriented on the top side of the other elements as shown in the relevant drawing. The term bottom can therefore encompass both an orientation of bottom and top depending on the particular orientation of the drawing.

[0058] Other than in the operating examples, or where otherwise indicated, all numbers expressing quantities, ratios, ranges, etc. used herein are to be understood as modified in all instances by the term about even though the term about may not expressly appear with the value, amount or range.

[0059] It must also be noted that as used herein and in the appended claims, the singular forms a, an, and the include the plural reference unless the context clearly dictates otherwise. Thus, for example, reference to any of a sleeve, a cover, a bolt may be taken to be a reference to one or more of each and equivalents thereof, and so forth. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art.

[0060] The presently disclosed invention includes protective covers for various types of equipment, including at least marine deck or dock equipment such as cleats, chocks, bits, buttons, kevels, capstans, winches, sheaves, fairleads, and bollards. The following definitions are provided for clarity only, and are not meant to be limiting of the presently disclosed invention. For example, while a winch is indicated here as a type of marine deck or dock equipment, such may be found on land vehicles, rescue vehicles, or in other types of industry, such as the logging industry.

[0061] As used herein, the term cleat may be taken to mean a type of fixture found on docks and vessels, typically shaped like a very wide and short capital letter T. Closed types of cleats may have a solid base while open types may have two closely spaced legs in the center. In use, a line with a loop on the end can be passed through the legs and secured over the top portion (top of the T).

[0062] As used herein, the term chock may be taken to mean a type of fixture typically found on a vessel which is designed to hold a line rather than using it as a tie point. A chock may be found near a cleat and generally is used to keep the line in position so it does not move laterally and chafe or abrade. Chocks are generally designed as flattened loops that have a narrow opening at the top to accept and remove the line.

[0063] As used herein, the term bit may be taken to mean a type of fixture which is a solid column (square or cylindrical) having a cross bar that is of a lesser diameter and which forms a lowercase letter t. While bits are mostly found on vessels near the bow and stern, they may be used on docks. If there is a need to use something taller than a cleat in order to accept large diameter lines.

[0064] As used herein, the term button may be taken to mean a type of fixture which is a solid cylindrical column and which may be used to thread cable between boats or barges and/or a dock. As used herein, the term bollard may be taken to mean a type of fixture which is a solid cylindrical column and which may be used to thread cable between boats or barges and/or a dock. Bollards are typically larger than buttons and are most commonly found on docks and large ships.

[0065] As used herein, the term capstan may be taken to mean a type of fixture which is a revolving drum, with a vertical axis, that is used for heaving in lines. As used herein, the term winch may be taken to mean a type of fixture which is a revolving drum, with a horizontal axis, that is used for heaving in lines. As used herein, the term sheave may be taken to refer to a pulley wheel that turns inside a block, and which contacts the rope. As used herein, the term fairlead may be taken to mean a type of fixture which is used to guide a line, rope or cable around an object, either out of the way or to stop it from moving laterally. Typically, a fairlead will be a ring or hook. A fairlead may be a separate piece of hardware, or it could be a channel in the structure of the deck or dock.

[0066] A typical wire rope is about 1 inch by 65 feet and weighs over 120 pounds. Replacing that rope with a synthetic line reduces the weight to a little over 15 pounds, or about 87% lighter than the wire rope. Further, in addition to being lighter, that same synthetic line is also 14% stronger (1 inch wire breaking strength=103,400 lbs. of line pull; 1 inch synthetic breaking strength=120,000 lbs. of line pull). Synthetic line has no memory so there is no stored energy (e.g. no violent backlash when broken under high loads), it floats in water, and greatly reduces the tripping hazards on barge decks. Additionally, synthetic line will not accumulate the burrs that wire rope does, and thus eliminates the danger of lacerations a worker faces when handling with wire rope.

[0067] Synthetic line is also more efficient than wire rope. Only one person is needed for winch operation (eliminating the need for two or more people to operate), making and breaking connections can be done more quickly without sacrificing safety, and the take up of slack and final tensioning on any tensioning device is easier and faster. Thus, the use of synthetic line represents a huge improvement in both the ease and efficiency of operation and safety for the worker.

[0068] While synthetic line has many advantages over wire rope, it has not been globally adopted. Often, this is due to a prohibitive expense associated with replacing the current equipment so that it may be used with synthetic line. For example, in the marine industry, current boat-to-barge, barge-to-barge, and mooring connections all utilize fittings intended to be used with wire rope. These fittings are most commonly made of cast steel that rusts and contains burrs and sharp edged grooves, all of which create an abrasive surface which is non-conducive to use with synthetic line. The protective covers of the presently disclosed invention solve this problem by providing smooth, durable polymer covers for the standard metal equipment normally used for contact by wire rope. These covers offer a low coefficient of friction surface that is protrusion free and thus reduces or eliminates the wear and tear on synthetic lines.

[0069] The covers may be installed and uninstalled with ease and in certain cases may be portable. The covers may be composed of durable polymers which provide a smooth, protrusion free and/or low friction surface which is abrasion resistant. The durable polymers may include at least nylon, polyester, polyether, polycarbonate, polystyrene, polyurethane, specially blended urethane polymers, polyethylene, polytetrafluorethylene, high molecular weight polyethylene, ultra-high molecular weight polyethylene, hard rubber combined with other materials, or combinations thereof. In general, any durable polymer having a Shore D hardness of greater than about 60 or a Shore A hardness of greater than about 85 may be used to form the durable polymer covers of the presently disclosed invention. The exact polymer selected may depend on the size of the durable polymer cover, the environment in which it will be used, and the specific type of work and work load to which it will be subjected.

[0070] In certain embodiments, the durable polymer material may be thermosetting cast polyurethane having a Shore D hardness of about 65 or a Shore A hardness of about 95. In certain embodiments, the polymeric material may be polyurethane formed from the polyol polytetramethylene ether glycol (PTMEG) and an isocyanate.

[0071] These durable polymers may create a low coefficient of friction cover that may fit over existing fittings or equipment which was intended for use with wire rope, and thus provide the user with the ability to use synthetic lines without harming the line. Further, these covers may still be strong enough to withstand the rigors of wire rope in the event a user chooses to employ such.

[0072] The durable polymer covers of the presently disclosed invention may be used to cover any type of equipment or fitting normally used with wire rope. Examples of such equipment include marine equipment, such as a deck or dock structures normally used for wire rope contact. Non-limiting examples of such deck or dock structures include at least bollards, chocks, roller chocks, cleats, kevels, capstans, winches, sheaves, buttons, bits, double bits, H-bits, side bits, fairleads, fairlead rollers, deck or dock perimeters, pilings, dauphins, and mooring rings. The covers may also be used to cover equipment used for towing, such as the winches and rigging found in a tow truck or vehicle, or for rigging, such as the rigging used by window washers and painters. Further, other industries may find these covers useful, such as the logging industry which has recently begun to switch from wire rope to synthetic line.

[0073] The durable polymer covers are lightweight, weather resistant and may only require simple tools for installation and/or removal, such as for the removal and re-installation required for deck fitting inspection or replacement. According to certain aspects of the present invention, the durable polymer covers may be installed and/or removed without tools, such as by hand.

[0074] The durable polymer covers of the presently disclosed invention may comprise means for attaching the covers about a peripheral surface of the various types of equipment. Such means may include at least adhesives, hook and loop closures, magnets, various types of tape, complementary teeth at opposing end, screws, or nuts and bolts. Each of these attachment means may be used individually or in combination, and may be used to attach the cover to the equipment, such as by screwing the cover directly to the equipment, and/or may be used to attach cover sections to each other around the equipment. For example, the cover for a winch may comprise a single section having complimentary projections/indents at opposing ends and magnets embedded within the single section. The magnets may hold the section onto the equipment and the complimentary projections/indents at the opposing ends may be fitted together to secure the section to itself thus forming a cover. The ends may be further secured using an adhesive.

[0075] Referring now to the drawings, embodiments of the durable polymer covers of the presently disclosed invention are shown in FIGS. 1-16. FIG. 1A illustrates a perspective view of a 6 inch marine button generally designated by reference number 100 partially covered by a cover section generally designated by reference number 110A, wherein the cover section 110A provides a smooth surface which is suitable for contact by a synthetic line 2. As shown in FIG. 1A, the durable polymer covers may comprise two cover sections (showing only one section in FIGS. 1A-1C), wherein each section comprises a top portion 112, a base portion 116, and a center column portion 114 which connects the top portion and the base portion. Each cover section 110A may further comprise a first end portion and a second end portion, as is shown in FIG. 1B. Screws or nuts and bolts may be used to connect the cover sections along facing ends. An indent 118 may be provided to assist in insertion of the screw or nut and bolt set used to connect the cover sections along facing ends, as well as a predrilled channel, which is shown as 120 in FIG. 1B.

[0076] FIG. 1C illustrates a side view of the button 100 partially covered by a cover section 110A, and further pointing out placement of the connection means 122 through the predrilled channels. FIG. 1D illustrates a close-up view of the connection means from FIG. 1C, which shows a possible placement position for the nut and bolt set 122 within the cover section. The distance a between the edge of the connection means 122 and side of the cover section which faces the peripheral surface of the marine button may be large enough to maintain structural integrity and strength for the cover section and may depend on at least the overall size of the equipment to be covered and the material of the durable polymer cover.

[0077] In the various embodiments of the durable polymer covers disclosed herein, possible connection means include screws and/or nuts and bolts which may be used to secure the various cover sections to one another and/or to the rope contacting surface. The screws or nuts and bolts may be formed of any material known in the art. In preferred embodiments, these parts may be formed from non-corrosive materials such as, for example, stainless steel, nylon, or other plastics or polymers. Other connections means are also possible in place of, or in addition to, screws and/or nuts and bolts, several of which are described herein below.

[0078] With continued reference to FIG. 1D, the connection means 122 may be a nut and bolt, as shown. The bolt may be a socket head cap screw having an outer head diameter which is the same as the matching nut. As such, the indent which accepts the nut and bolt 122 may be the same on both sides/ends of the cover section. This may reduce production costs for the cover sections and make installation easier as each section may be identical. Further, in certain embodiments, the indent may be hexagonal in shape and may provide a tight fit for a comparably sized nut. This may make installation of the connection means quicker and easier because only a single tool would be required to install the bolt side (via the socket head cap) of the connection means.

[0079] FIGS. 2A-2B illustrate perspective views of a 10 inch marine button generally designated by reference number 200 partially covered by a cover section. With reference to FIG. 2A, the durable polymer covers may comprise two cover sections (showing only one section in FIG. 2A), wherein each section comprises a top portion 212, a base portion 216, and a center column portion 214 which connects the top portion and the base portion. Each cover section may further comprise a first end portion and a second end portion having predrilled channels (220a, 220b). Screws or nuts and bolts which may be used to connect the cover sections along facing ends may be inserted through these channels. An indent 218 may be provided to assist in insertion of the screw or nut and bolt set used to connect the cover sections.

[0080] FIG. 2B illustrates a side view of the button 200 partially covered by a cover section 210A, and further points out placement of the connection means (222a, 222b) through the predrilled channels. FIG. 2C illustrates a close-up view of the connection means from FIG. 2B, which shows a possible placement position for a nut and bolt set (222a, 222b) within the cover section. As with the embodiment shown in FIG. 1D, the distance b between the edge of the connection means 222 and side of the cover section which faces the peripheral surface of the marine button may be large enough to maintain structural integrity and strength for the cover section and may depend on at least the overall size of the equipment to be covered and the material of the durable polymer cover.

[0081] Further, and with continued reference to FIG. 2C, the bolts may be socket head cap screws having outer head diameters which are the same as the matching nuts. As such, the indents which accept the nut and bolt sets (222a, 222b) may be the same on both sides/ends of the cover section. As discussed above, this may reduce production costs for the cover sections and make installation of the durable polymer covers easier as each section may be identical.

[0082] While the embodiment of the durable polymer cover shown in FIGS. 1A-1D contains only a single means for releasable attachment, or connection means (120, 122), and the embodiment shown in FIGS. 2A-2C contains two means for releasable attachment, or connection means (220a, 220b, 222a, 222b), various other numbers of connection means and types of connection means are envisioned and are within the scope of the presently disclosed invention (see for example FIGS. 4 and 5). Further, various types of connections means may be combined. For example, as shown in FIGS. 8 and 9, each cover section may comprise at least one row of inset teeth (840) at each of the first end portion and the second end portion. Contact between the at least one row of teeth on the first end portion of the first cover section (810A) and the at least one row of teeth on the second end portion of an adjacent cover section (810B) may lock the two cover sections together. In certain embodiments, each cover section may further comprise at least one channel 818 at each of the first end portion and the second end portion which is configured and sized to receive a screw or nut and bolt 822 (see FIG. 9), as was shown in the embodiments of FIGS. 1A-1D.

[0083] Additionally, while the embodiments of the durable polymer cover shown in each of FIGS. 1-4, 6, 7, 12, and 14-16 comprise two sections or portions, other configurations are within the scope of the presently disclosed invention. For example, the embodiment shown in FIGS. 5 and 8 comprises three cover sections (810A, 810B, 810C), while the embodiment shown in FIGS. 10, 11 and 13 comprise only one cover section.

[0084] In various embodiments of the durable polymer cover, each cover section may further comprise at least one magnet which is configured to contact the peripheral surface of the equipment to be covered. The magnet may be embedded within the durable polymer cover, or may be positioned on an inner surface of the durable polymer cover which is adjacent to the peripheral surface of the equipment. The magnet may aid in placing and/or holding the cover on the peripheral surface of the equipment during installation.

[0085] Shown in FIG. 12A is an embodiment of a durable polymer cover comprising at least two cover sections (shown in FIG. 12A is one cover section 1210), wherein each cover section has an upper rim portion 1212, a center column portion 1214, and a bottom portion 1214. In the embodiment shown, the bottom portion 1216 extends outward and upward from the vertical axis of the cover, and thus provides a trough in which the synthetic line may reside. Further, the at least two cover sections may be attached to the rope contacting surface by magnets 1250, which are shown to be on an inner surface the cover section 1210 that would be adjacent to the peripheral surface of the rope contacting structure. These magnets may be positioned on an inner surface of each cover section in slots, or may be embedded within the cover sections, as is shown in FIG. 12B (1212 and 1216 are shown for reference).

[0086] The magnets included in the durable polymer cover shown in FIGS. 12A and 12B may be the only means needed for attaching the durable polymer cover to the rope contacting surface on the marine dock or deck. Installation may be as simple as placing the cover sections around the rope contacting surface of the marine equipment. In this way, the durable polymer cover may be installed or removed rapidly and with ease and may be used as a portable part of the dock or deck equipment. Thus, a boat which uses synthetic line may make connections to a dock or another vessel having only steel mooring equipment by simply installing the durable polymer cover around the mooring equipment in order to protect their synthetic line, or by removing the durable polymer cover from their own deck equipment so that wire rope may be used.

[0087] In other embodiments, each cover section may further comprise at least one magnet at one end portion and a magnetically responsive material at the other end portion configured to make contact with the magnet on an end portion of an adjacent section (see for example magnets 1910 in FIG. 19). These later magnets may aid in placing and holding cover sections together before the attachment means (screws or nuts and bolts) can be introduced. In certain embodiments, the magnets may be used without any other attachment means (screws or nuts and bolts) to attach the cover sections around the rope contacting surface of the metal equipment.

[0088] These magnets may be hard or permanent magnets which are placed at specific positions, as described above, or may be magnetic polymers, which may be placed at any position along the cover section such as, for example, an inner or end portion layer. Magnetic polymer materials are advantageous as they can be easily and cheaply formed into complex shapes, and can be corrosion resistant and low friction. Exemplary materials include Dupont Teflon, hard rubber, or nylon mixed with atomized ferromagnetic material. Other similar cheap polymers include epoxy and polyester resins. The use of such magnetic polymers avoids the use of traditional ferrite block and metal parts, which are heavy and costly to cut and shape, especially when the shape may be curved.

[0089] In certain embodiments, portions of the ends of each durable polymer cover may further comprise ultra-high bond (UHB) or very high bond (VHB) tape, such as 3M VHB tape, which may aid in placing and holding cover sections together before the attachment means (screws or nuts and bolts) can be introduced. Such tape may also be placed on any portion of an interior surface of each cover section which is adjacent to the peripheral surface of the equipment. As such, the tape may aid in placing and/or holding the cover section(s) on the peripheral surface of the equipment during installation.

[0090] In various embodiments of the durable polymer cover, each cover section may further comprise at least one section of hook and loop fastener, such as Velcro, which is configured to contact a complimentary section of hook and loop fastener placed on the peripheral surface of the equipment. As with the tapes and magnets discussed above, these fasteners may aid in placing and/or holding the durable polymer cover on the peripheral surface of the equipment during installation. Further, and as discussed above for the tape and magnets, each section may comprise one section of Velcro or hook and loop fastener at an end portion which is configured to contact a complimentary section of Velcro or hook and loop fastener placed at the other end portion. In this way, adjacent facing ends of the cover sections may be brought together and held in place while a secondary connection means is inserted. The hook and loop fastener may be used alone as the only connection means, or may be used in combination with one or more of any of the other connection means disclosed herein.

[0091] Additional connection means include at least glues or adhesives, which may be placed on the inner surface of the cover sections and/or on the end portions (as described above for the magnets and the hook and loop fasteners).

[0092] FIGS. 3A-3C illustrate perspective views of a marine double bit partially covered by a durable polymer cover according to embodiments of the presently disclosed invention. Each column (300A or 300B) of the double bit may be covered by at least two cover sections, wherein the durable polymer cover provides a smooth surface which is suitable for contact by a synthetic line 2. Each cover section may comprise a top portion 312, a base portion 316, and a center column portion 314 which connects the top portion and the base portion. Each cover section may also comprise a means for connecting the cover sections at the top and/or bottom of the durable polymer cover. Shown in FIG. 3A is a connecting notch 318 positioned on facing sides of the top portion 312 of each cover section.

[0093] As shown in FIG. 3B, the durable polymer cover which covers each column (300A or 300B) of the double bit may comprise two cover sections, wherein each cover section may comprise a top portion (312a, 312b), a base portion (316a, 316b) and a center column portion (314a, 314b) which connects the top and base portions. In certain embodiments, the base portion (316a, 316b) of each cover section may extend outward and may cover the base region of the double bit, or a lip. This not only aids in further protecting surfaces which may come into contact with the rope, but may also act to stop rotation of the cover on the bit. A predrilled channel 336 may extend through the base portion 316 of each cover section and may provide a means for connecting the at least two cover sections around each column (300A or 300B) using a screw or nut and bolt set.

[0094] Shown in FIG. 3C is a projection 330 which extends from an end portion of one cover section and which is configured to fit within an indent on an end portion of an adjacent cover section (shown as 332 in FIG. 3D). Diameters c and d are also shown and may depend on at least the size of the equipment and the materials of the cover sections.

[0095] FIG. 3D shows a cross-sectional view of the double bit partially covered by the durable polymer cover taken along line 3D-3D of FIG. 3C. The top portion 312, center column portion 314, and base portion 316 are shown, as well as pre-drilled channels positioned in the base portions having connection means (screw or nut and bolt) inserted therein (328a, 328b). Screws or nut and bolt sets may be used to secure the cover sections around each column of the double bit. Diameters e, f and g are shown in FIG. 3E and may depend on at least the size of the equipment and/or the materials of the durable polymer cover. FIG. 3F illustrates a close-up view of the connection means from FIG. 3D, which shows a possible placement position for the nut and bolt set (320) within the top portion of the cover section.

[0096] An alternate embodiment of a durable polymer cover for a double bit is shown in FIG. 4. As shown, the durable polymer cover may have a vertical axis which is aligned with the vertical axis of each column (400A, 400B) of the double bit. The cover for each bit may comprise at least two cover sections, where each cover section may be screwed or bolted to an adjacent cover section, and may cover at least a portion of a column (400A, 400B). Each cover section may comprise a top rim portion (412a, 412b), a center column portion (414a, 414b), and a bottom portion (416a, 416b). Further, each cover section may also comprise a first vertical end portion and a second vertical end portion. In certain embodiments of the durable polymer cover, each cover section may further comprise at least one connecting notch 418 on an exterior side which allows for easy insertion of a screw or nut and bolt set 422.

[0097] Another alternate embodiment of a durable polymer cover for a double bit is shown in FIG. 5. This embodiment may comprise at least two cover sections each having a center column portion (514a, 514b) and a bottom rim portion (516a, 516b), and a cap portion (512). Each cover section may be screwed or bolted (screws 522) to an adjacent cover section and/or directly into the bit. Additionally, the cap section 512 may be screwed or bolted to an adjacent cover section and/or directly into the bit. Additional portions of covering material may be added at positions which may be contacted by the synthetic line. As shown in FIG. 5, the additional material 530 may be at an edge of the double bit which contacts the synthetic line such as, for example, on an outer edge of the double bit.

[0098] The presently disclosed invention may also include rope contacting structures useable on marine docks or decks. As shown in FIG. 5, the presently disclosed invention may include a double bit which comprises two columnar bit structures having predrilled channels at various positions which may be configured to accept screws or nut and bolt sets (522). In various embodiments, the double bit may be composed of durable structural materials such as polymers or may be composed of materials more commonly known in the art such as steel or iron. The double bit may also comprise projections 540 which would keep a durable polymer cover from rotating about the bit once installed.

[0099] FIGS. 6A-6C illustrate perspective views of a marine kevel 600 partially covered by a durable polymer cover according to embodiments of the presently disclosed invention. As shown, the kevel may be covered by at least two cover sections (a single section 610 is shown). Each cover section 610 may cover half of the kevel as taken along a vertical plane through the longitudinal center of the kevel. Each cover section may comprise a top portion 612, a base portion 616, and at least one center column portion (614a, 614b) which connect the top portion and the base portion. Each cover section may further comprise a lateral end portion which defines an edge or end.

[0100] Each cover section may also comprise a means for connecting the cover sections at the top and/or bottom of the protective cover. Shown in FIG. 6B is a connecting notch 621 having a predrilled channel positioned on facing sides or ends of the bottom portion (616, see FIG. 6C) of each cover section, and pre-drilled channels (619, 620) positioned on facing sides or ends of the top portion (612, see FIG. 6C) of each cover section.

[0101] Also shown in FIGS. 6C and 6D are the diameters h, i, j, and k which indicate the thickness of the cover section at various points. These diameters may be large enough to maintain structural integrity and strength for the cover section and may depend on at least the overall size of the equipment to be covered and the material of the durable polymer cover.

[0102] Shown in FIGS. 6D and 6E is a possible placement for the predrilled channel 620 in the top portion, and the predrilled channel 621 in the bottom portion of a protective cover section. Screws or nut and bolt sets may be used to secure the protective cover sections around the marine kevel. FIG. 6F illustrates an exploded view of one connection means from FIG. 6E, which shows a possible placement position for the nut and bolt set (622) within the top portion of the cover section. As discussed above with reference to FIGS. 1D, 2C, and 3E, the connection means may be a nut and bolt, wherein the bolt may be a socket head cap screw having an outer head diameter which is the same as the matching nut. As such, the indent which accepts the nut and bolt 622 may be the same on both sides/ends of the cover section. This may reduce production costs for the cover sections and make installation easier as each section may be identical. Further, in certain embodiments, the indent may be hexagonal in shape and may provide a tight fit for a comparably sized nut. This may make installation of the connection means quicker and easier because only a single tool would be required to install the bolt side (via the socket head cap).

[0103] An alternate embodiment of a durable polymer cover for a kevel is shown in FIG. 7. As shown, this embodiment may comprise at least two cover sections which may have an upper portion (712a, 712b), at least one center column portion, and a bottom portion (916a). Further, one cover section may be screwed or bolted to an adjacent cover section and/or directly into the kevel. As an example, screws 722 may be placed through predrilled channels 720 in the cover section and 730 in the kevel along an upper portion, a lower portion, or both. In alternative embodiments, the two cover sections may comprise other attachment means such as, for example, magnets, adhesives, tapes (UHB, 3M VHB), or hook and loop closures, on either the lateral an internal surface which is adjacent to the peripheral surface of the cleat or kevel. These attachment means may be used alone, in combination, or in combination with a screw to attach the cover to the cleat or kevel.

[0104] The durable polymer covers of the presently disclosed invention are intended to be used to protect synthetic line from abrasion or damage on structures intended for contact with wire rope. As such, at least one cover section may be placed adjacent to the structure so that a first end portion of the at least one cover section is proximate to a second end portion of either the same cover section or an adjacent cover section. The at least one section may comprise magnets which act to releasable hold the section onto the structure. The at least one section may then be secured around the structure by attaching the first end portion to the proximate second end portion. The attachment may be by any means previously disclosed. In embodiments where the durable polymer cover is portable, no attachment may be needed at the first and second ends and the cover may be held in place by the magnets.

[0105] Shown in FIG. 10 is a protective cover 1010 for a rope contacting surface. The rope contacting surface may be an edge or corner of a marine vessel or dock, and the protective cover 1010 may be shaped to conform to an edge or corner of the marine vessel or dock. In an embodiment, the protective cover 1010 may have an upper portion 1012, and a lower portion 1014 and may be attached to the deck of the marine vessel or to the dock by a hook 1020 formed on the upper portion 1012 of the protective cover. In alternative embodiments, a screw or nut and bolt set may be used to directly attach the protective cover to the deck of the marine vessel or to the dock. As discussed above with reference to the durable polymer covers, the presently disclosed protective cover may further comprise other attachment means, such as adhesives, tapes, hook and loop closures, or magnets.

[0106] Shown in FIG. 11 is an alternative embodiment of a protective cover 1110 for an edge or corner of a marine vessel or an edge or corner of a dock which may come into contact with a synthetic line. The protective cover 1110 may be shaped to conform to an edge or corner of the marine vessel or dock as described above. As such, the protective cover 1110 may have an upper portion 1112 and a lower portion 1114 and may be attached to the deck of the marine vessel or to the dock by a hook 1120. Further, the protective cover may comprise at least one magnet 1150 which is positioned on an inner surface of the cover and which is configured to contact the peripheral surface of the rope contacting structure (corner or edge surfaces).

[0107] Also included in the presently disclosed invention are protective covers for the drums of a winch or capstan. Embodiments previously described and shown to cover buttons and bits may also be used to cover the rope contacting surfaces of a winch or capstan drum. Alternatively, and as shown in FIG. 13, a cover 1310 specifically designed to cover a drum on a winch or capstan is also included in the presently disclosed invention. The cover 1310 may include a cover comprising interlocking teeth 1340. These teeth may have a keystone design (as shown) or may include any other type of projection and indent that may allow adjacent ends of two cover sections, or opposite ends of a single cover section, to be attached and to form a smooth surface over which the synthetic line may pass. In the embodiment shown in FIG. 13, the cover may comprise a single cover section 1310 which may be flexible enough to be formed around the drum and locked thereon using the interlocking teeth 1340. An inner surface of the cover 1310 which is adjacent to the peripheral surface of the drum may further comprise an additional connection means such as, for example, magnets, tapes (UHB, 3M VHB) or hook and loop fasteners.

[0108] Another alternate embodiment of a durable polymer cover for a button is shown in FIGS. 14-16. This embodiment may comprise at least two cover sections (1410a, 1410b) which may be may be screwed or bolted (screws 1422a) to an adjacent cover section using countersunk channels in the cover sections (as detailed above) and/or may be directly attached to the button 1400 by screws 1422 that are received in countersunk channels 1420 in the two cover sections (1410a, 1410b) that are aligned with channels 1430 in the button 1400.

[0109] The presently disclosed invention may also include rope contacting structures useable on marine docks or decks. As shown in FIGS. 14 and 16, the presently disclosed invention may include a button 1400 having predrilled channels 1430 at various positions which may be configured and sized to receive screws 1422. In various embodiments, the button 1400 may be composed of durable structural materials such as polymers or may be composed of materials more commonly known in the art such as steel or iron. The button 1400 may also comprise projections 1440 which would keep a durable polymer cover from rotating about the button 1400 once installed. As shown in FIGS. 14 and 16, the projections 1440 may include an indent 1432 or other feature that may further assist in aligning and restricting rotation of the durable polymer cover on the button 1400.

[0110] With reference to FIGS. 17-18, additional means for releasable attachment are illustrated. FIG. 17 shows a cam and lock system that may be positioned at radial ends (such as the first and second ends, see for example FIG. 1B) or on the lateral edges (such as shown for the kevel cover in FIGS. 6A-6C). The cam and lock system may include a cam 1710 and lock 1720 which connect to provide a means for releasable attachment. Each cover section may comprise one or more cams and a match number of locks (two each are shown in FIG. 17). Each end of the cover section may include only cams or lock, or may include a combination. As shown in FIG. 17, one end includes two cams 1710 and one end includes two locks 1720 so that the cover sections are identical, thus reducing the production costs for the durable polymer cover. As shown in FIG. 18, the means for releasable attachment may include a ball 1810 and socket 1820.

[0111] With reference to FIG. 20, additional means for releasable attachment include tap-in pins 2010, and/or one way rivets. Further, tooth and ladder-back systems, as shown in FIG. 21, which include teeth 2120 on each end that mesh to form a connection are possible. Such may be placed along small portions of the ends, such as shown by the tabs 2110 in FIG. 21, or may be placed along a longer portion of the ends.

[0112] While the durable polymer covers have been described in the context of covering marine deck or dock structures, other embodiments and fields of use are within the scope of the presently disclosed invention. For example, the covers disclosed herein may also be used to cover equipment used for towing, such as the winches and rigging found on a tow truck or vehicle, or for rigging, such as the rigging used by window washers and painters. Further, other industries may use such covers, such as the logging industry which has recently begun to switch from wire rope to synthetic line for cable logging.

[0113] In each of the embodiments shown and discussed herein, the covers may be composed of durable polymers such as, for example, nylon, polyester, polyether, polyurethane, specially blended urethane polymers, polyethylene, polytetrafluorethylene, high molecular weight polyethylene, ultra-high molecular weight polyethylene, or hard rubber combined with other materials. In general, any durable polymer having a Shore D hardness of greater than about 60 or a Shore A hardness of greater than about 85 may be used to form the durable polymer covers of the presently disclosed invention. In certain embodiments, the durable polymer material may be thermosetting cast polyurethane having a Shore D hardness of about 65 or a Shore A hardness of about 95. In certain embodiments, the polymeric material may be polyurethane formed from the polyol polytetramethylene ether glycol (PTMEG) and an isocyanate. Such durable polymers may create a low coefficient of friction surface that reduces the wear and damage to synthetic line yet may be strong enough to withstand the rigors of wire rope in the event a user chooses to use such.

[0114] In certain embodiments, the durable polymeric material may further comprise a backing or embedded material which may reinforce the cover sections. For example, fiberglass fibers may be incorporated as a backing material during the casting process. The fibers may be provided as an open weave or may comprise chopped fibers which are distributed throughout the polymeric material. The added reinforcing materials may be used to help the disclosed covers resist high pressures or localized strains when under load with a synthetic line.

[0115] The choice of the hardness of the polymer material may be dictated by the final use and thickness of the cover. In each of the aforementioned examples (see for example FIGS. 1-3), the cover sections are shown to have varying thicknesses throughout their profile. In certain embodiments, however, each cover section may be formed with a uniform thickness throughout the profile such as, for example, 1 inch. In other embodiments, such as the cover shown in FIG. 13 which comprises only one section, the combination of the choice of durable polymer and cover thickness may provide a durable cover having enough flexibility to be opened around the equipment and closed to form the cover. For example, a polymer material having a Shore D hardness of 65 and a thickness of inch may be useful to provide a winch cover.

[0116] While specific embodiments of the invention have been described in detail, it should be appreciated by those skilled in the art that various modifications and alternations and applications could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements, systems, apparatuses, and methods disclosed are meant to be illustrative only and not limiting as to the scope of the invention.