Complete Guide About Bungee Cords

A rope having two or more elastic strands covered in woven fabric is called a Bungee Cord. There are hooks on both ends of it. Elastic cord and shock cord are other names for bungee cords.

Typically, a cloth sheath surrounds the elastic material, which is usually rubber. The bungee cord is used in a variety of applications due to its elastic nature. It is widely used to secure luggage on the vehicle's exterior.

Manufacturing:

The bungee cord's elastic strands are comprised of rubber, which can be natural, synthetic, or a combination of both. Everything is contingent on the use of a bungee cord. Any material, such as polypropylene, cotton, or nylon, can be used for the outside woven sheath. These materials help to protect the outer sheath and give the rope greater elasticity.

Bungee Cord Manufacturing Raw Materials

Rubber, either synthetic or natural, is the raw material used to make bungee cords. Natural rubber, commonly known as latex rubber, is a suitable choice because of its high tensile strength and flexibility. It is also capable of returning to its former shape. Natural rubber is an ideal material for bungee cords due to these qualities. Latex rubber is only moderately resistant to sunlight and air. This means that UV light can harm natural rubber.

On the other hand, synthetic rubber displays superior resistance to sunshine and air. But synthetic rubber, such as neoprene, demonstrates less tensile strength and flexibility than natural rubber. Due to these factors, natural rubber is used most of the time for military demands. Natural rubber is also used for bungee jumping.

The coat of the bungee cord is a fabric covering that is made of cotton or nylon yarn. This yarn is braided in construction. The coating of fabric is diverse, and it is related to the rope’s intended usage. The bungee cords that are used professionally have a single layer of nylon coating. A single layer of nylon affords higher resistance to abrasions and also has excellent tensile strength. However, if the bungee cord is used for military purposes and bungee jumping, then it has two layers of cotton covering. Some carefully constructed bungee ropes have a natural rubber covering, and this is braided in construction.

Bungee Cord Design

The application of bungee rope determines its design. A diameter of 0.25 inch to 0.62 inch is available for normal commercial bungee rope. A diameter of 0.25 inch to 0.87 inch is offered for military use. The diameter of the bungee cord used for leaping is 0.62 inches.

Bungee Cord Stretch

Bungee cords are made to stretch to precise lengths with varying degrees of elongation. The length of unstretched bungee rope is used to calculate bungee rope elongation. A bungee cord, for example, is considered to have 100% elongation if it can extend to twice its original length. You can also use bungee cord to tie Tarpaulin.

Bungee Rope Manufacturing Process

The following steps are involved in the bungee cord manufacturing process:

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Rubber Ribbon Extrusion

The extraction of natural or synthetic rubber is the first step in the manufacturing process. After that, the rubber is formed into long ribbons. The rubber ribbon has a thickness of 0.09 to 0.12 inches, a width of 0.25 inches, and a length of up to 100 feet. After that, the rubber is fed into the extruder, which is a heated cylinder. The extruder has two ends; the rubber moves under pressure from one end of the cylinder and is forced out through the other small hole of the extruder. The hole through which the pressed rubber is forced out is of the desired shape. The cooling process is then completed, and the rubber is shipped to the manufacturers.

Making Rubber Ribbons

The number of strands and ribbons used in the cord determines the tensile strength and diameter of the bungee rope. These strands are evenly unwound from the coils for the braiding process. There is a chance that the strands will stick together due to the hot weather. These rubber strands are coated with finely powdered talc or soapstone to avoid such situations. This coating process is continuous and concludes with the unwinding process.

Braiding the Cover

The braiding of the rubber strands is the next step. This procedure is carried out on a machine known as a braider. The braider is manually loaded with the free ends of the rubber strands. When these rubber strands enter the braider, they are gently squeezed with the help of rollers and other devices. Another roller or take-up reel on the output end pulls the strands through the machine.

The rubber strands are kept taut and slightly stretched by varying the speed and pressure. This stretch and tension assist in reducing the diameter of the rubber strands and allowing the fabric covering to be wound tightly. The braider weaves yarn onto the stretched rubber strand and covers it as it passes through the machine. When the cord is fully extended, the covering must be tightly woven so that no dirt can enter the yarn gaps. If two or more yarn coverings are required, they are applied one after the other. The outer yarn covering can be coloured or color-coded to the client's specifications.

Connecting End Fittings

The manufacturer has not attached the Bungee Cords end fittings. The end fittings are completed in accordance with the specifications. Bungee cords, which are used to secure luggage and equipment, are first cut to the required length. After being cut, the cord is doubled and coiled with a stiff wire. A wire coiler machine does this coiling. After coiling, a J-shaped hook is attached to the end to secure it. A stretched cord is wound tightly by a strong and waxed string known as whipping for bungee cord that is used for jumping. The bungee cord ends are wrapped around a non-metallic eye. Another option is to sew the cord to the woven fabric webbing.

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