Methods and systems for manufacturing rope

A method for manufacturing rope, comprising:

• receiving a plurality of thermoplastic polymer or resin impregnated rovings;
• combining the plurality of thermoplastic polymer or resin impregnated rovings into a combined roving using a joining module;
• tensioning the combined roving using a dead-head wheel downstream of the joining module, wherein the tensioning is controllable using the dead-head wheel;
• heating the combined roving in an oven;
• removing excess thermoplastic polymer or resin from a surface of the combined roving;
• chilling the combined roving while under tension using a chilling device;
• wherein the tensioning is generated between the oven and the chilling device by using the dead-head wheel downstream of the joining module and upstream of the oven and a puller downstream of the chilling device;
• and
• wherein the removing excess thermoplastic polymer or resin from a surface of the combined roving is executed using a thermoplastic extrusion die, comprising:
• a housing;
• an insert having an inlet through the housing, and a first passage through the insert, the insert formed of an elastomer material and sized and shaped to abut inner walls of the housing;
• and
• a mechanical locking mechanism configured to communicate physical pressure to the insert.

A method for manufacturing rope, comprising:

• receiving a plurality of thermoplastic polymer or resin impregnated rovings;
• combining the plurality of thermoplastic polymer or resin impregnated rovings into a combined roving using a joining module;
• tensioning the combined roving using a dead-head wheel downstream of the joining module at a greater than non-nominal tension;
• heating the combined roving in an oven;
• removing excess thermoplastic polymer or resin from a surface of the combined roving;
• chilling the combined roving while under tension using a chilling device;
• wherein the tensioning is generated between the oven and the chilling device by using the dead-head wheel downstream of the joining module and upstream of the oven and a puller downstream of the chilling device;
• and
• wherein the removing excess thermoplastic polymer or resin from a surface of the combined roving is executed using a thermoplastic extrusion die, comprising:
• a housing;
• an insert having an inlet through the housing, and a first passage through the insert, the insert formed of a plastic material and sized and shaped to abut inner walls of the housing;
• and
• a mechanical locking mechanism configured to communicate physical pressure to the insert.