Patent Publication Number: US-9416469-B2

Title: Flexible, abrasion resistant woven textile sleeve and method of construction thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application Ser. No. 62/001,439, filed May 21, 2014, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates generally to textile sleeves for protecting elongate members, and more particularly to woven sleeves. 
     2. Related Art 
     It is known to wrap wires and wire harnesses in protective sleeves, such as in automobiles, aircraft or aerospace craft, to provide protection to the wires against abrasion, fluid and thermal affects. In order to achieve the desired protection, the protective sleeve may have multiple layers, with some of the layers being specifically provided for different types of protection. For example, one layer may be provided for water resistance, e.g. a sheet of plastic material, while another layer may be provided for abrasion resistance, and yet another layer may be provided for protection against thermal conditions, e.g. a non-woven layer. Although the aforementioned multilayer sleeves may provide suitable protection against the various environmental conditions, unfortunately they are typically bulky, thereby requiring an increased volume of space, and further, they tend to be relatively heavy and exhibit low flexibility. This can prove detrimental in some applications, particularly applications requiring routing cables or hoses through tight, winding areas, as well as applications having weight restrictions, such as aircraft and aerospace applications, for example. 
     SUMMARY OF THE INVENTION 
     One aspect of the invention provides a woven sleeve for routing and protecting elongate members from exposure to abrasion and other environmental conditions, such as contamination. The sleeve has a flexible, abrasion resistant, self-curling elongate wall constructed from woven monofilament and/or multifilament yarns. The wall has opposite edges extending generally parallel to a central axis of the sleeve, wherein the opposite edges overlap one another. The wall is woven with warp yarns that extend generally parallel to the central axis of the sleeve and fill yarns that extend circumferentially about the sleeve, generally transversely to the central axis. The warp yarns are bundled into individual, discrete groups, with each group including a plurality of yarns in side-by-side relation with one another, wherein each of the yarns within the same discrete group is interlaced over the same side of a common fill yarn. The groups of bundled warp yarns provide enhanced abrasion resistance to abrasion forced applied along the length of the sleeve, while the fill yarns provide the sleeve with enhanced flexibility. 
     In accordance with another aspect of the invention, the discrete bundles can extend over a single fill yarn and under a single fill yarn in repetition. 
     In accordance with another aspect of the invention, the discrete bundles can extend over a plurality of the fill yarns and under a plurality of the fill yarns in repetition. 
     In accordance with another aspect of the invention, each discrete bundle can extend over a pair of the fill yarns and under a pair of the fill yarns in repetition. 
     In accordance with another aspect of the invention, the opposite edges of the wall can be biased into overlapping relation with one another by the fill yarns. 
     In accordance with another aspect of the invention, at least some of the warp yarns are provided as multifilament yarns. 
     In accordance with another aspect of the invention, each of the warp yarns can be provided as a multifilament yarn. 
     In accordance with another aspect of the invention, each of the fill yarns can be provided as a monofilament yarn. 
     In accordance with another aspect of the invention, at least some of the warp yarns can be provided as monofilament yarns. 
     In accordance with another aspect of the invention, each of the warp yarns can be provided as a monofilament yarn. 
     In accordance with another aspect of the invention, a method of constructing a textile sleeve is provided. The method includes weaving an elongate wall having opposite edges extending parallel to a central longitudinal axis of the sleeve with the wall being having warp yarns extending parallel to the central longitudinal axis and fill yarns extending transverse to the warp yarns. Further, the method includes weaving the warp yarns in discrete bundles of yarns, with each of the bundles having warp yarns arranged in side-by-side abutting relation with one another, wherein the warp yarns in each discrete bundle extends over and under the same fill yarns with one another. 
     In accordance with another aspect of the invention, the method can further include weaving the bundles over and under a single fill yarn. 
     In accordance with another aspect of the invention, the method can further include weaving the bundles over a plurality of fill yarns to form outwardly facing floats. 
     In accordance with another aspect of the invention, the method can further include heat-setting at least some of the fill yarns to bias the opposite edges into overlapping relation with one another. 
     In accordance with another aspect of the invention, the method can further include providing at least some of the warp yarns as multifilament yarns. 
     In accordance with another aspect of the invention, the method can further include providing the fill yarns as multifilament yarns. 
     In accordance with another aspect of the invention, the method can further include providing the fill yarns as monofilament yarns. 
     In accordance with another aspect of the invention, the method can further include providing at least some of the warp yarns as monofilament yarns. 
     In accordance with another aspect of the invention, the method can further include forming each of the discrete bundles including multifilament and monofilament yarns. 
     In accordance with another aspect of the invention, the method can further include weaving the warp yarns and the fill yarns in a basket weave pattern. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       These and other aspects, features and advantages will become readily apparent to those skilled in the art in view of the following detailed description of presently preferred embodiments and best mode, appended claims, and accompanying drawings, in which: 
         FIG. 1  is schematic perspective view of a woven, self-wrapping sleeve constructed in accordance with one aspect of the invention, with the sleeve shown carrying and protecting elongate members therein; 
         FIG. 2  is an enlarged partial view of a wall of the sleeve of  FIG. 1  constructed in accordance with one embodiment of the invention; 
         FIG. 2A  is a view similar to  FIG. 2  of a wall of the sleeve of  FIG. 1  constructed in accordance with another embodiment of the invention; 
         FIG. 2B  is a view similar to  FIG. 2  of a wall of the sleeve of  FIG. 1  constructed in accordance with yet another embodiment of the invention; 
         FIG. 2C  is a view similar to  FIG. 2  of a wall of the sleeve of  FIG. 1  constructed in accordance with yet another embodiment of the invention; 
         FIG. 3  is a view similar to  FIG. 2  of a wall of the sleeve of  FIG. 1  constructed in accordance with yet another embodiment of the invention; 
         FIG. 3A  is a view similar to  FIG. 3  of a wall of the sleeve of  FIG. 1  constructed in accordance with yet another embodiment of the invention; 
         FIG. 3B  is a view similar to  FIG. 3  of a wall of the sleeve of  FIG. 1  constructed in accordance with yet another embodiment of the invention; and 
         FIG. 3C  is a view similar to  FIG. 3  of a wall of the sleeve of  FIG. 1  constructed in accordance with yet another embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring in more detail to the drawings,  FIG. 1  shows schematic representation of a woven, self-wrapping textile sleeve, referred to hereafter as sleeve  10 , constructed in accordance with one aspect of the invention. The sleeve  10  has a wrappable elongate wall  12  for routing and protecting elongate members, such as wires or a wire harness  14 , for example, from exposure to abrasion and the ingress of contamination, debris and the like. The elongate wall  12  has opposite edges  16 ,  17  extending generally parallel to a central, longitudinal axis  18 , wherein the edges  16 ,  17  are preferably biased into overlapping relation with one another in “cigarette wrapped” fashion to fully enclose the elongate members  14  within a central cavity  20  of the sleeve  10 . The cavity  20  is readily accessible along the full length of the wall  12  so that the elongate members  14  can be readily disposed radially into the cavity  20 , and conversely, removed from the cavity  20 , such as during service. To provide the desired protection to the elongate members  14  against abrasion, the wall  12  is woven with individual, discrete warp yarn bundles  22  extending generally parallel to the central longitudinal axis  18 , wherein each bundle  22  is made up of a plurality of warp yarns  23  arranged in side-by-side, abutting relation with one another. The wall  12  is further woven with weft yarns, also commonly referred to as fill yarns  24 , extending generally circumferentially about the wrapped wall  12  in generally transverse relation to the warp yarns  23 . The fill yarns  24  can be provided, at least in part, as heat-settable yarns, if desired, such that upon heat-setting the fill yarns  24  while a curled or wrapped configuration, the wall  12  is biased to self-curl the opposite edges  16 ,  17  into overlapping relation with one another. The bias is imparted by heat-setting the fill yarns  24 , such as heat-settable monofilament or multifilament yarns, into their curled configuration about the central longitudinal axis  18 . 
     Depending on the application needs, the wall  12  can be constructed having any suitable size, including length and diameter. When the wall  12  is in its self-wrapped tubular configuration, generally free from any externally applied forces, the edges  16 ,  17  preferably overlap one another at least slightly to fully enclose the cavity  20 , and thus, provide enhanced protection to the wires  14  contained in the cavity  20 . The edges  16 ,  17  are readily extendable away from one another under an externally applied force sufficient to overcome the bias imparted by the fill yarns  24  to at least partially open and expose the cavity  20 . Accordingly, the wires  14  can be readily disposed into the cavity  20  during assembly or removed from the cavity  20  during service. Upon releasing the externally applied force, the edges  16 ,  17  return automatically to their natural, overlapping self-wrapped position under the bias imparted by the heat-set fill monofilament yarns  24 . 
     The discrete warp yarn bundles  22  can be formed of any suitable monofilament and/or multifilament yarns, with an exemplary embodiment of the bundles  22  being shown in  FIG. 2  as being formed entirely with a plurality of multifilament warp yarns  23 . The multifilament warp yarns  23 , in addition to providing enhanced abrasion resistance as a result of being bundled in side-by-side, abutting or substantially abutting relation with one another, provide enhanced, optimal surface area coverage to the wall  12 , thereby inhibiting the ingress of contamination, debris, or the like into the cavity  20 , thereby providing enhanced protection to the elongate members  14  contained within the cavity  20 . In addition, the multifilament yarns  23  facilitate maintaining the fill yarns  24  in their intended, as woven positions by imparting enhanced friction on the fill yarns  24 , while also providing the sleeve  10  with sufficient flexibility for routing around corners, for example. In one exemplary sleeve embodiment, the bundles  22  were formed with pairs of the warp yarns  23 , wherein the warp yarns  23  were provided as multifilaments having a denier between about 300-500, with an ends-per-inch between about 75-90. The discrete bundles  22  are shown in  FIG. 2 , by way of example and without limitation, as being woven in a modified basket-type weave pattern, with each bundle  22  extending over a single fill yarn  24  and then under a single fill yarn  24 , in repeating fashion. 
     The fill yarns  24  can be provided as any suitable monofilament and/or multifilament material, including heat-settable monofilament and/or multifilament polymeric material, such as polyphenylene sulfide (PPS) or polyethyleneterephthalate (PET), for example. In the exemplary sleeve embodiment shown in  FIG. 2 , the fill yarns  24  are heat-settable monofilaments. The monofilaments  24  preferably have a reduced cross-section area (reduced diameter) relative to the warp yarns  23 , which facilitates providing the sleeve  10  with an increased degree of flexibility in comparison to that if the monofilaments were larger. 
     In  FIG. 2A , another exemplary embodiment of a sleeve  10 ′ constructed in accordance with the invention is shown, wherein the same reference numerals as used in  FIG. 2 , coupled with a single prime (&#39;), are used to identify similar features. The sleeve  10 ′ is similar to the sleeve  10  of  FIG. 2 ; however, rather than the warp yarns being provided as multifilaments, the warp yarns  23 ′ are provided as monofilaments, thereby rendering the entire sleeve  10 ′ as being constructed of monofilaments. The monofilaments used for the warp yarns  23 ′ are at least slightly greater in diameter than the monofilaments used for the fill yarns  24 ′. Otherwise, the pattern of weave of the sleeve  10 ′ is the same as that for the sleeve  10 , and thus, no further description is necessary. 
     In  FIG. 2B , another exemplary embodiment of a sleeve  10 ″ constructed in accordance with the invention is shown, wherein the same reference numerals, coupled with a double prime (″), are used to identify similar features. The sleeve  10 ″ is similar to the sleeve  10  of  FIG. 2 ; however, rather than the warp yarns being provided as multifilaments, each discrete bundle  22 ″ is formed with a monofilament warp yarn  23 ″ and a multifilament warp yarn  23 ″. The monofilaments used for the warp yarns  23 ″ can be the same as those used for the warp yarns of the sleeve  10 ′ of the  FIG. 2A , while the multifilament warp yarns  23 ″ can be the same as those used for the warp yarns of the sleeve  10 , with the effective diameters of the monofilament and multifilament warp yarns  23 ″ being the same or generally the same. Otherwise, the pattern of weave of the sleeve  10 ″ is the same as that for the sleeve  10 , and thus, no further description is necessary. 
     In  FIG. 2C , another exemplary embodiment of a sleeve  10 ′″ constructed in accordance with the invention is shown, wherein the same reference numerals, coupled with a triple prime (′″), are used to identify similar features. The sleeve  10 ′″ is similar to the sleeve  10  of  FIG. 2 ; however, rather than the fill yarns being provided as monofilaments, the fill yarns  24 ′″ are provided as multifilaments, thereby rendering the entire sleeve  10 ′″ as being constructed of multifilaments. As with all the prior embodiments, the fill yarns  24 ′″ are woven as individual yarn filaments, and thus, do not extend over and under the same warp yarns as an immediately adjacent fill yarn. The fill yarns  24 ′″, as with the previous embodiments, have an effective diameter that is less than the effective diameter of the individual warp yarns  23 ′″, with an exemplary embodiment being constructed with fill yarns  24 ′″ having a denier between about 200-400 with a pick-per-inch between about 30-50. Otherwise, the pattern of weave of the sleeve  10 ′″ is the same as that for the sleeve  10 , and thus, no further description is necessary. 
     In  FIG. 3 , another exemplary embodiment of a sleeve  110  constructed in accordance with the invention is shown, wherein the same reference numerals as used in  FIG. 2 , offset by a factor of  100 , are used to identify like features. The sleeve  110  is similar to the sleeve  10  of  FIG. 2 ; however, rather than the warp yarns  123  and bundles  122  thereof extending over and under a single monofilament fill yarn  123 , the discrete bundles of warp yarns  123  extend over a pair of fill yarns  124  and then under a pair of fill yarns  124  in a repetitious pattern, thereby forming a true basket weave pattern. As such, the warp yarns  123  form outwardly facing warp floats  26  extending over a plurality of the fill yarns  124 , wherein the floats  26  function to provide further enhanced protection against abrasive forces sliding along the length of the sleeve  10  in the direction indicated by arrow A. Otherwise, the sleeve  110  remains the same as discussed for the sleeve  10  of  FIG. 2 , such that the yarn materials and relative sizes for the warp yarns  123  and the fill yarns  124  are the same, and thus, no further discussion is needed. 
     In  FIG. 3A , another exemplary embodiment of a sleeve  110 ′ constructed in accordance with the invention is shown, wherein the same reference numerals as used in  FIG. 3 , coupled with a single prime (′), are used to identify similar features. The sleeve  110 ′ is similar to the sleeve  110  of  FIG. 3 ; however, rather than the warp yarns being provided as multifilaments, the warp yarns  123 ′ are provided as monofilaments, thereby rendering the entire sleeve  110 ′ as being constructed of monofilaments. The monofilaments used for the warp yarns  123 ′ are at least slightly greater in diameter than the monofilaments used for the fill yarns  124 ′. Otherwise, the pattern of weave of the sleeve  110 ′ is the same as that for the sleeve  110 , and thus, no further description is necessary. 
     In  FIG. 3B , another exemplary embodiment of a sleeve  110 ″ constructed in accordance with the invention is shown, wherein the same reference numerals as used in  FIG. 3 , coupled with a double prime (″), are used to identify similar features. The sleeve  110 ″ is similar to the sleeve  110  of  FIG. 3 ; however, rather than the warp yarns being provided as multifilaments, each discrete bundle  122 ″ is formed with a monofilament warp yarn  123 ″ and a multifilament warp yarn  123 ″, thereby resulting in a monofilament and a multifilament being in side-by-side, abutting relation with one another. The monofilaments used for the warp yarns  123 ″ can be the same as those used for the warp yarns of the sleeve  110 ′ of the  FIG. 3A , while the multifilament warp yarns  123 ″ can be the same as those used for the warp yarns of the sleeve  110  of  FIG. 3 , with the effective diameters of the monofilament and multifilament warp yarns  123 ″ being the same or generally the same. Otherwise, the pattern of weave of the sleeve  110 ″ is the same as that for the sleeve  110 , and thus, no further description is necessary. 
     In  FIG. 3C , another exemplary embodiment of a sleeve  110 ′″ constructed in accordance with the invention is shown, wherein the same reference numerals as used in  FIG. 3 , coupled with a triple prime (′″), are used to identify similar features. The sleeve  110 ′″ is similar to the sleeve  110  of  FIG. 3 ; however, rather than the fill yarns being provided as monofilaments, the fill yarns  124 ′″ are provided as multifilaments, thereby rendering the entire sleeve  110 ′″ as being constructed of multifilaments. The fill yarns  124 ′″, as with the previous embodiments, have an effective diameter that is less than the effective diameter of the individual warp yarns  123 ′″, with an exemplary embodiment being constructed with fill yarns  124 ′″ having a denier between about 200-400 with a pick-per-inch between about 30-50. Otherwise, the pattern of weave of the sleeve  110 ′″ is the same as that for the sleeve  110 , and thus, no further description is necessary. 
     Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.