Patent Publication Number: US-2019177890-A1

Title: Braided textile sleeve with axially collapsible, anti-kinking feature and method of construction thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This U.S. Divisional Application claims the benefit of U.S. Utility patent application Ser. No. 15/348,682, filed Nov. 10, 2016, and U.S. Provisional Application Ser. No. 62/254,800, filed Nov. 13, 2015, both of which are incorporated herein by reference in their entirety. 
    
    
     BACKGROUND OF THE FNVENTION 
     1. Technical Field 
     This invention relates generally to textile sleeves, and more particularly to braided textile sleeves. 
     2. Related Art 
     It is known to protect elongate members in braided textile sleeves against a variety of environmental conditions and affects, or to just contain elongate members in textile sleeves for bundling and routing purposes. In the case of braided sleeves, the braided wall is commonly braided as a circumferentially continuous, seamless wall, sometimes referred to as a ‘closed’ wall. One known advantage of a closed, braided wall construction, in contrast to woven or knit wall constructions, is that the wall can be circumferentially expanded by pushing the opposite ends toward one another during installation to facilitate sliding the wall over an elongated member. However, a known problem with braided sleeves can arise during installation, particularly when trying to install the sleeve over relatively lengthy elongate members, such as wires and tubes, and/or about relatively sharp bends or corners. Commonly, when confronted. with lengthy elongate members and sharp bends, the sleeves tend to flatten on themselves and kink, particularly within the region of a bend, thereby causing the material of the sleeve to bunch-up axially on itself, and thus, the sleeve ceases to continue along the length of the elongate member, thereby complicating the installation process. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the invention, a protective textile sleeve is provided. The sleeve has a tubular wall of braided yarns extending lengthwise along a central longitudinal axis between opposite ends. At least some of the braided yarns including heat-set yarns. The wall has a plurality of annular first regions forming generally convex ridges and a. plurality of annular second regions forming generally concave valleys, The first regions alternate with the second regions along the central longitudinal axis. The first regions including a plurality of twisted yarns forming a plurality of closed loops, wherein at least some of the braided yarns pass through at least some of the closed loops within the first regions. 
     In accordance with another aspect of the invention, the first regions can be provided having a first stiffness and the second regions can be provided having a second stiffness, with the first stiffness being greater than the second stiffness. Accordingly, the relatively increased stiffness first regions resist the wall from being circumferentially compressed and flattened, while the relatively decreased stiffness second regions provide axial flexibility and axial compressibility to facilitate routing the sleeve about bends without kinking. 
     In accordance with another aspect of the invention, the first regions can include heat-set yarns. 
     In accordance with another aspect of the invention, the heat-set-yarns can be provided as monofilaments. 
     In accordance with another aspect of the invention, the second regions can include non-heat-settable yarns. 
     In accordance with another aspect of the invention, the non-heat-settable yarns can be provided as relatively soft multifilaments to enhance the coverage protection offered by the sleeve and to enhance axial compressibility and flexibility of the wall to resist kinking. 
     In accordance with another aspect of the invention, at least some of the heat-set yarns can be braided in bundles, with each of the bundles including a plurality of yarns twisted with one another and forming closed loops, with at least some of the closed loops of one bundle being interlinked with at least some closed loops of another bundle in the first regions. 
     In accordance with another aspect of the invention, the second regions can be formed to include non-heat-set yarns, with the non-heat-set yarns extending through closed loops of the bundles to enhance the structural integrity of the sleeve. 
     In accordance with another aspect of the invention, a plurality of the yarns can be braided to pass through each of the closed loops. 
     In accordance with another aspect of the invention, the first regions can include yarns braided in a first pattern and the second regions can include yarns braided in a second pattern, wherein the first pattern is different from the second pattern, such that the first pattern has an increased stiffness against axial and radial compression relative to the second pattern, which in turn can provide enhanced flexibility. 
     In accordance with another aspect of the invention, the wall can be formed entirely of heat-set monofilaments. 
     In accordance with another aspect of the invention, a method of constructing a tubular protective textile sleeve is provided. The method includes braiding a plurality of yarns with one another to form a tubular wall extending lengthwise along a central longitudinal axis between opposite ends, with at least some of the yarns being provided as heat-settable yarns. Further, compressing the opposite ends of the tubular wall axially toward one another to a compressed state. Next, heat-setting the heat-settable yarns while the wall is in the compressed state to form a plurality of annular first regions and a plurality of annular second regions alternating with one another along the central longitudinal axis, wherein the first regions form generally convex ridges and the second regions form generally concave valleys. 
     In accordance with another aspect of the invention, the method can include braiding the wall on a lace-braiding machine. 
     In accordance with another aspect of the invention, the method can include braiding the wall as a seamless, circumferentially continuous wall. 
     In accordance with another aspect of the invention, the method can include forming the second regions including non-heat-settable yarns. 
     In accordance with another aspect of the invention, the method can include providing the non-heat-settable yarns as multifilaments. 
     In accordance with another aspect of the invention, the method can include providing the heat-settable yarns as monofilaments, 
     In accordance with another aspect of the invention, the method can include braiding at least some of the heat-settable yarns in twisted bundles having loops, and further including interlinking at least some of the loops of one bundle with at least some of the loops of another bundle in the first regions. 
     In accordance with another aspect of the invention, the method can include extending non-heat-settable yarns through at least some of the loops of the bundles. 
     In accordance with another aspect of the invention, the method can include braiding yarns in the first regions in a first pattern and braiding the second yarns in the second regions in a second pattern, the first pattern having an increased axial and radial stiffness relative to the second pattern. 
     In accordance with another aspect of the invention, the method can include braiding the wall entirely of heat-settable yarns. 
     In accordance with another aspect of the invention, the method can include braiding the first regions having a first stiffness and braiding the second regions having a second stiffness, with the first stiffness being greater than the second stiffness, such that the first regions provide the sleeve with enhanced hoop strength and anti-kinking properties and the second regions provide the sleeve with enhance flexibility and coverage, 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other aspects, features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description of presently preferred embodiments and best mode, appended claims and accompanying drawings, in which: 
         FIG. 1  is a schematic perspective view of a tubular braided sleeve constructed in accordance with one aspect of the invention shown disposed about an elongate member to be protected; 
         FIG. 2A  is an enlarged fragmentary view showing the braid pattern of a wall of the sleeve of Figure l in accordance with one aspect of the invention; 
         FIG. 2B  is an enlarged fragmentary view showing the braid pattern of a wall of the sleeve of  FIG. 1  in accordance with another aspect of the invention; 
         FIG. 2C  is an enlarged fragmentary view showing the braid pattern of a wall of the sleeve of  FIG. 1  in accordance with another aspect of the invention; 
         FIG. 2D  is an enlarged fragmentary view showing the braid pattern of a wall of the sleeve of  FIG. 1  in accordance with another aspect of the invention; 
         FIG. 3A  is a fragmentary view of the sleeve of  FIG. 1  constructed via the braid pattern of  FIG. 2A  shown in a braided, pre-compressed, pre-heat-set state; 
         FIG. 3B  is a view of the sleeve of  FIG. 3B  shown in an axially compressed, heat-set state; 
         FIG. 3C  is a view of the sleeve, of  FIG. 3B  shown being routed about a sharp bend without kinking; 
         FIG. 4A  is a fragmentary view of the sleeve of  FIG. 1  constructed via the braid pattern of  FIG. 2D  shown in a braided, pre-compressed, pre-heat-set state; 
         FIG. 4B  is a fragmentary view of the sleeve of  FIG. 4A  shown in an axially compressed state; 
         FIG. 4C  is a fragmentary view of the sleeve of  FIG. 4B  shown in an axially compressed, heat-set state; and 
         FIG. 4D  is a fragmentary view of the sleeve of  FIG. 4C  shown being routed about a sharp bend without kinking. 
     
    
    
     DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS 
     Referring in more detail to the drawings,  FIG. 1  illustrates generally a braided protective textile sleeve, referred to hereafter as sleeve  10 , constructed in accordance with one aspect of the invention. The sleeve  10  has a braided, circumferentially continuous, seamless tubular wall  12  extending lengthwise along a central longitudinal axis  14  between opposite open ends  16 ,  18 . The wall  12  has a plurality of annular first regions  20  and a plurality of annular second regions  22  alternating with one another along the central longitudinal axis  14  to provide the wall  12  with axially collapsible features in the form of a corrugated or convoluted profile. The first regions  20  form generally bulbous, convex ridges having a first axial arid radial stiffness and the second regions  22  form generally contracted, concave valleys having a second axial and radial stiffness, wherein the first stiffness is greater than the second stiffness. As a result of the differing region configurations and stiffness between the first and second regions  20 ,  22 , the wall  12  is able to readily collapse and expand axially while retaining its structural integrity, including outer peripheral shape, during assembly and while in use, thereby making assembly of the sleeve  10  about an elongate member  23  to be received and protected therein easy, even over long elongate members  23  and about meandering paths and corners. 
     The wall  12  is preferably braided on a lace-braiding machine, though other braiding mechanisms are contemplated herein, in accordance with one aspect of the invention, the yarns forming or substantially forming the first regions  20  can be provided as heat-settable yarns  24  (substantially forming is meant to mean that a majority, such as greater than 75% content, by way of example and without limitation, of the yarn is heat-settable yarn  24 ) and the yarns forming or substantially forming the second regions  22  can be provided as non-heat-settable yarns  26  (substantially forming is meant to mean that a majority, such as greater than 75% content, by way of example and without limitation, of the yarn is non-heat-settable yarn  26 ). The heat-settable yarns  24  are preferably provided as monofilaments, while the non-heat-settable yarns are preferably provided as multifilaments, though it is contemplated herein the heat-settable multifilaments and non-heat-settable monofilaments could be used, depending on the application performance requirements. Regardless, the heat-settable yarns  24 , particularly after being heat-set, as discussed below, are relatively stiff and rigid in comparison to the non-heat-settable yarns  26 , while the non-heat-settable yarns  26  are relatively soft and flexible in comparison to the heat-settable yarns  24 . Accordingly, the heat-settable yarns  24  can be provided as a heat-settable monofilament or a heat-settable multifilament, such as from, for example, nylon, polyphenylene sulfide (PPS), polyethyleneterephthalate (PET), or polypropylene (PP), having a diameter between about 0.1-0.40 mm, by way of example and without limitation, or being generally flat, having a thickness between about 0.15-0.25 mm and a width between about 1.0-3.5 mm, by way of example and without limitation. The non-heat-settable yarns  26  can be provided from any suitable non-heat-settable material, including, by way of example and without limitation, a mineral fiber, e.g. basalt, silica, or ceramic or fiberglass, 
     During the braiding process, the heat-settable yarns  24  are braided to form the substantial majority of, or the entirety of the first regions  20 , while non-heat-settable yarns  26  are braided to form the substantial majority of, or the entirety of the second regions  22 . Accordingly, the heat-settable yarns  24  are interlaced with one another to form or substantially form the first regions  20  and the non-heat-settable yarns  26  are interlaced with one another to form or substantially form the second regions  22 . In  FIGS. 2A and 2B , different braid patterns are shown in accordance with different aspects of the invention, while it should be recognized that other braid patterns providing relatively stiff first regions  20  and relatively soft, flexible second regions  22  are contemplated herein. The heat-settable yarns  24  in  FIGS. 2A and 2B  are shown as being braided as twisted bundles  28 , wherein each bundle  28  includes a plurality of heat-settable yarns  24 , shown as a pair of heat-settable yarns  24 , by way of example and without limitation, twisted with one another to form closed loops  30 . At least a portion or the entirety of the closed loops  30  within the first regions  20  are interlinked with one another such that the twisted bundles  28  are locked together. In  FIG. 2A , within the second regions  26 , the non-heat-settable yarns  26  are not only interlaced with one another in generally standard braided fashion, undulating over-and-under one another in alternating relation, by they also extend through closed loops  30  of the twisted bundles  28 , while in  FIG. 2B , the second regions  22  are formed entirely of the non-heat-settable yarns  26 . 
     Upon braiding the wall in accordance with the braid pattern of  FIG. 2A , as shown in  FIG. 3A , with the same process applying to that for the braid pattern of  FIG. 2B , the opposite ends  16 ,  18  of the wall  12  are axially compressed toward one another, wherein during the compressing process, the first regions  20 , being relatively stiff, form radially outwardly extending, bulbous convex ridges  32 , while the second regions  22 , being relatively soft and flexible, collapse radially to form radially inwardly extending, contracted concave valleys  34 . While in the compressed state, the wall  12  is heat-set via application of a suitable degree of heat to cause the heat-settable yarns  24  to take on a heat-set configuration. Upon being heat-set, the wall  12  retains a corrugated or convoluted configuration while in a relaxed, unbiased state, as shown in  FIGS. 3B . It should be recognized the wall  12  can be axially compressed to the desired reduced length, whether fully compressed or partially compressed, and further, the wall  12  can be compressed in sections and heat set prior to cutting the sleeve to its finished length, or the wall  12  can be cut to length, then compressed to the desired length, and then heat-set. While compressing the wall  12 , it is contemplated that the wall  12  can be disposed about a central mandrel to facilitate uniform compression of the wall  12  without buckling. Further, the mandrel could be heated to facilitate heat-setting the wall  12  while in its fully or partially compressed state. 
     Upon being heat-set, the wall  12  retains the radially outwardly extending, relatively stiff first regions  20  and the radially inwardly extending, relatively soft and flexible second regions  22 , and as a result, the sleeve  10  is readily able to be installed over relatively long, meandering elongate members  23 , including around bends and corners, as shown in  FIG. 3 , without kinking or losing its “as constructed” outer peripheral shape, whether circular or non-circular, as viewed in lateral cross-section, 
     In  FIGS. 2C and 2D , different braid patterns of the wall  12  in accordance with further embodiments of the sleeve  10  of  FIG. 1  are shown, wherein the same reference numerals as above are used to indicate like features, while it should be recognized that other braid patterns providing relatively stiff first regions  20  and relatively soft, flexible second regions  22  are contemplated herein. The braid patterns shown in  FIGS. 2C and 2D  include solely heat-settable yarns  24 , wherein the heat-settable yarns  24  are interlaced with themselves in a first standard braid pattern, undulating over-and-under one another in opposite helical S and Z directions throughout the second regions  22 , while the heat-settable yarns  24  are interlaced with each other in a second braid pattern in the first regions  20 , with the second braid pattern being formed by pairs  36  of the heat-settable yarns  24  looping about intermediate heat-settable yarns  24  and each other to change helical directions relative to one another. Accordingly, one of the yarns  24  in the pair of yarns  36  changes from an S or Z helical direction to the opposite S or Z direction with the first region  20 , while the other of the yarns  24  in the pair of yarns  36  changes from an S or Z helical direction to the opposite S or Z direction with the first region  20 , thereby forming closed loops  30 . Extending through the closed loops  30  is a plurality, shown as a pair of heat-settable yarns  24 , by way of example and without limitation, extending opposite helical directions to one another. The main difference between the braid patterns of  FIGS. 2C and 2D  is with regard to the axial length of the second, relatively flexible regions  22 , wherein the second regions  22  of  FIG. 2C  are shown as being the same or substantially the same axial length as the relatively stiff first regions  20 , and in contrast, the second regions  22  of  FIG. 2D  are shown as having an increased axial length relative to the relatively stiff first regions  20 , shown as being about twice as long, by way of example and without limitation, it should be recognized that the first and second regions  20 ,  22  can be braided having any suitable axially extending length, wherein the first and second regions can all be about the same length, or they can vary in length individually or relative to one another over the length of the sleeve  10 , as desired for the intended application. 
     Upon braiding the wall in accordance with the braid patterns of  FIGS. 2C and 2D , as shown in  FIG. 4A  for the braid pattern of  FIG. 2D , though the same process applies to the braid pattern of  FIG. 2C , the opposite ends  16 ,  18  of the wall  12  are axially compressed toward one another, wherein during the compressing process, the first regions  20 , being relatively stiff, form radially outwardly extending, convex ridges  32 , while the second regions  22 , being relatively flexible, form radially inwardly extending, concave valleys  34 , with the wall  12  taking a generally bellowed or convolute shape, as shown in  FIG. 4B . While in the compressed state, the wall  12  is heat-set via application of a suitable degree of heat to cause the heat-settable yarns  24  to take on a heat-set configuration. Upon being heat-set, the wall  12  retains a corrugated or convoluted configuration while in a relaxed, unbiased state, as shown in  FIG. 4C . It should be recognized the wall  12  can be axially compressed to the desired reduced length, whether fully compressed or partially compressed, and further, the wall  12  can be compressed in sections and heat set prior to cutting the sleeve to its finished length, or the wall  12  can be cut to length, then compressed to the desired length, and then heat-set. While compressing the wall  12 , it is contemplated that the wall  12  can be disposed about a central mandrel to facilitate uniform compression of the wall  12  without buckling. Further, the mandrel could be heated to facilitate heat-setting the wall  12  while in its fully or partially compressed state. 
     Upon being heat-set, the wall  12  retains the radially outwardly extending, relatively stiff first regions  20  and the radially inwardly extending, relatively soft and flexible second regions  22 . As a result, the sleeve  10  is readily able to be installed over relatively long, meandering elongate members  23 , including around bends and corners, as shown in  FIG. 4D , without kinking or losing its “as constructed” outer peripheral shape, such as round, by way of example and without limitation. As the sleeve  10  is being routed around bends, the flexible, softer second regions  22  are able to collapse axially, while the first regions  20  maintain the peripheral profile of the wall  12 , whether circular or non-circular, as viewed in lateral cross-section, thereby maintaining or substantially maintaining the “as constructed” outer peripheral shape of the wall  12 . Accordingly, assembly of the sleeve  10  over the length of generally long, meandering elongate members  23  is greatly simplified. 
     Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that the invention may be practiced otherwise than as specifically described, and that the scope of the invention is defined by any ultimately allowed claims.