Patent Description:
It is known to contain elongate members, such as wires, wire harnesses, cables and conduits of various types in woven sleeves to provide protection to the elongate members against impact and abrasion, fluid and thermal affects. In applications where high impact resistance is needed to prevent damage to the sleeve and the contents therein, wrappable woven sleeves having multiple layers are known. Each of the layers of the multilayered wall are typically formed having the same, non-varying, uniform weave pattern over their entirety, and thus, upon wrapping the wall of the sleeve to bring opposite edges into overlapping relation with one another, thereby encircling the elongate member being protected therein, the multiple layers typically result in the sleeve being stiff and inflexible, thereby making it difficult to route the sleeve along a meandering path, particularly without causing the sleeve to buckle and/or open along overlapping edges.

Accordingly, what is needed is a wrappable, multilayered woven sleeve that provides enhanced protection to an elongate member contained therein, particularly against impact, abrasion and contamination, while being able to be freely routed about meandering paths while maintaining its wrapped configuration without buckling and/or opening along the overlapping edges, while maintaining an aesthetically pleasing appearance, being economical in manufacture and assembly, and exhibiting a long and useful life.

Patent document <CIT> describes a wrappable textile sleeve and method of construction thereof, wherein the wrappable textile sleeve comprises one woven layer comprising a plurality of first and second annular bands arranged in alternation to each other along a longitudinal axis of the textile sleeve and wherein the first and second annular bands differ in their weft densities. Patent document <CIT> describes a multilayer textile sleeve and method of construction thereof. Patent document <CIT> describes a vibration absorbing hose.

One aspect of the disclosure provides a wrappable, corrugated, multilayered woven sleeve for routing and protecting elongate members. The sleeve includes an elongate multilayered wall having opposite edges extending lengthwise between opposite ends. The opposite edges are wrappable about a central axis into overlapping relation with one another to bound a central cavity. The wall has a plurality of layers extending in overlying relation with one another between the opposite ends. Each of the layers include warp yarns extending generally parallel to the central axis woven with fill yarns extending generally transversely to the warp yarns. Each of the layers include a plurality of first annular bands, referred to hereafter as annular bands A, and a plurality of second annular bands, referred to hereafter as annular bands B, wherein the annular bands A, B alternate with one another along each layer and along the length of the wall. The annular bands A of each layer include monofilament weft yarn and multifilament weft yarn and the annular bands B of each layer include only one of monofilament weft yarn or multifilament weft yarn. The annular bands A of each layer are radially aligned in overlapping relation with one another and the annular bands B of each layer are radially aligned in overlapping relation with one another. The annular bands A of each layer form peaks, while the annular bands B of each layer form valleys, such that the wall has a corrugated contour, thereby enhancing the flexibility of the wall to allow it to be routed over meandering paths without kinking.

In accordance with another aspect of the invention, the multilayered wall includes a radially outermost layer, a radially innermost layer, and at least one intermediate layer sandwiched between the radially outermost layer and the radially innermost layer.

In accordance with another aspect of the invention, at least one of the radially outermost layer, the radially innermost layer, and the intermediate layer (s) can have a different weave pattern from at least one of the other layers.

In accordance with another aspect of the invention, the radially outermost layer, the radially innermost layer, and the intermediate layer (s) can be woven from any one of a plain weave pattern, a twill weave pattern, a basket weave pattern, and a satin weave pattern, wherein at least some or all of the layers may be woven with the same weave pattern, or at least some or all of the layers may be woven with a different weave pattern.

In accordance with another aspect of the invention, a method of constructing a wrappable, corrugated, multilayered woven sleeve is provided. The method includes weaving an elongate wall having opposite edges extending lengthwise between opposite ends, with the elongate wall being configured to be wrapped about a central axis to bring the opposite edges into overlapping relation with one another to bound a central cavity. Further, weaving the wall to include a plurality of layers extending in overlying relation with one another between the opposite edges and the opposite ends, with each of the layers including warp yarns extending generally parallel to the central axis woven with fill yarns extending generally transversely to the warp yarns. Further yet, weaving each of the layers including a plurality of annular bands A and a plurality of annular bands B, with the annular bands A and the annular bands B alternating with one another along the length of the wall. Further yet, weaving the annular bands A of each layer including monofilament weft yarn and multifilament weft yarn and weaving the annular bands B of each layer including only one of monofilament weft yarn or multifilament weft yarn. Further, radially aligning the annular bands A of each layer in overlapping relation with one another and radially aligning the annular bands B of each layer in overlapping relation with one another, wherein the annular bands A of each layer form peaks and the annular bands B of each layer form valleys, such that the wall has a corrugated contour, thereby enhancing the flexibility of the wall to allow it to be routed over meandering paths without kinking.

In accordance with another aspect of the invention, the method can further include weaving the multilayered wall including a radially outermost layer, a radially innermost layer, and at least one intermediate layer sandwiched between the radially outermost layer and the radially innermost layer.

In accordance with another aspect of the invention, the method can further include weaving at least one of the radially outermost layer, the radially innermost layer, and the intermediate layer(s) having a different weave pattern from at least one of the other layers.

In accordance with another aspect of the invention, the method can further include weaving the radially outermost layer, the radially innermost layer, and the intermediate layer(s) having any one of a plain weave pattern, a twill weave pattern, a basket weave pattern, and a satin weave pattern, wherein at least some or all of the layers may be woven with the same weave pattern, or at least some or all of the layers may be woven with a different weave pattern.

In accordance with another aspect of the invention, the method can further include weaving the wall including at least one of heat-settable yarns and heat-shrinkable yarns, wherein the heat-shrinkable yarns are provided as high length shrinkage yarns having a shrinkage in length between <NUM>-<NUM>% or greater upon being exposed to a heat-treatment process, thereby causing the wall to take on an increased density, thus, increasing the cut resistance, impact resistance, and overall protective attributes of the wall.

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:.

Referring in more detail to the drawings, <FIG> schematically illustrates a flexible, wrappable, multilayered, woven sleeve, referred to hereafter as sleeve <NUM>, constructed in accordance with one aspect of the invention having a corrugated wall <NUM> wrapped about an elongate member <NUM> to be protected, such as a wire harness, conduit, or the like. The wall <NUM> includes has opposite edges <NUM>, <NUM> extending lengthwise between opposite ends <NUM>, <NUM>. The opposite edges <NUM>, <NUM> are wrappable about a central axis <NUM> into overlapping relation with one another to bound a central cavity <NUM>, through which the elongate member <NUM> extends and in which the elongate member <NUM> is protected against impact forces, such as may be experienced in a vehicle crash, abrasion, and ingress of contamination, by way of example and without limitation. The wall <NUM> has a plurality of layers, including at least a pair of layers and shown in <FIG> as four layers 26a, 26b, 26c, 26d, by way of example and without limitation, extending in overlying, abutting relation with one another between the opposite ends <NUM>, <NUM>. Each of the layers 26a, 26b, 26c, 26d, as best shown for one of the layers in <FIG>, with it to be understood that each layer can be constructed having the same or substantially the same construction (substantially is intended to mean slight differences could exist between the layers, such as weave pattern, for example, though it is to be further understood that the underlying premise of the disclosure is maintained within each layer to form a corrugated wall, as discussed further below) include warp yarns <NUM> extending generally parallel to the central axis <NUM> woven with weft yarns, also referred to as fill yarns <NUM>, extending generally transversely to the warp yarns <NUM>. Upon wrapping the opposite edges <NUM>, <NUM> into overlapping relation with one another, one of the plurality of layers forms a radially outermost layer 26a and one of the plurality of layers forms a radially innermost layer 26d. Each of the layers 26a, 26b, 26c, 26d include a plurality of annular first bands A and a plurality of annular second bands B alternating with one another along the length of the wall <NUM>, as shown in <FIG>. The annular first bands A of each layer 26a, 26b, 26c, 26d include monofilament weft yarn <NUM>' and multifilament weft yarn <NUM>" and the annular second bands B of each layer 26a, 26b, 26c, 26d include only one of monofilament weft yarn <NUM>' or multifilament weft yarn <NUM>", shown in <FIG> as monofilament weft yarn <NUM>' and shown in <FIG> as multifilament weft yarn <NUM>". The annular first bands A of each layer 26a, 26b, 26c, 26d are radially aligned in overlapping relation with one another and the annular second bands B of each layer 26a, 26b, 26c, 26d are radially aligned in overlapping relation with one another. The annular first bands A of each layer 26a, 26b, 26c, 26d form peaks P having a generally convex outer surface contour, while the annular second bands B of each layer 26a, 26b, 26c, 26d form valleys V having a generally concave outer surface contour, such that the wall <NUM> has a corrugated contour, including peaks P and valleys V alternating with one another along its length, thereby enhancing the bending flexibility of the wall <NUM> to allow it to be routed over winding, meandering paths in zig-zag fashion, including around sharp bends and corners, without kinking.

To facilitate maintaining the wall <NUM> in its wrapped state about the elongate member <NUM>, at least some of the fill yarns <NUM> within the layers 26a, 26b, 26c, 26d can be provided as heat-settable fill yarns, and can be provided as monofilament weft yarn <NUM>' and/or as multifilament weft yarn <NUM>". As such, any suitable heat treat process causes the wall <NUM> to take on a heat-set tubular shape to remain biased in its wrapped tubular state absent an externally applied force to the opposite edges <NUM>, <NUM>, wherein an externally applied force can be applied to separate the opposite edges <NUM>, <NUM> away from one another to insert the elongate member <NUM> into the cavity <NUM> during assembly and to remove the elongate member <NUM> from the cavity during service, whereupon removal of the externally applied force allows the opposite edges <NUM>, <NUM> to automatically move back into overlapping relation with one another.

To enhance the protective attributes of the wall <NUM>, including its impact resistance, cut-through resistance, and resistance to ingress of contamination, at least some of the warp <NUM> and/or fill yarns <NUM> within the layers 26a, 26b, 26c, 26d can be provided as high shrinkage yarn, with high shrinkage meaning shrinking in length between <NUM>-<NUM>% or more. As such, any suitable heat treat process causes the wall <NUM> to become increased in density via the shrinking of the high shrinkage yarn(s).

In accordance with an aspect of the disclosure, as shown in <FIG>, the radially outermost layer 26a can be woven having a first weave pattern WPa having a first weave tightness (density) WDa and the radially innermost layer 26d can be woven having a second weave pattern WPd having a second weave tightness (density) WDd, with the first weave tightness (density) WDa being greater than the second weave tightness (density) WDd. As such, upon heat-setting the layers 26a, 26d, the innermost layer 26d is caused to take on a heat-set with without having wrinkles formed therein. It is to be recognized that the intermediate layers 26b, 26c sandwiched between the radially outermost layer 26a and the radially inner most layer 26d can be woven having respective weave patterns WPb, WPc decreasing in weave tightness (density) relative to one another such that the weave tightnesses (densities) WDa, WDb, WDc, WDd decrease relative to one another progressively from the radially outermost layer 26a to the radially innermost layer 26d. Accordingly, WDa>WDb>WDc>WDd. As a result, upon heat-setting the wall <NUM>, each of the layers 26a, 26b, 26c, 26d remains smooth and free from wrinkles.

In addition, within the aspects discussed above, the warp yarns <NUM> and/or fill yarns <NUM> can be provided as high tenacity yarns, such as from high tenacity polyethylene terephthalate (PET), para-aramid, liquid-crystal polymer, and the like. The high tenacity, defined herein by grams/denier, is provided being between <NUM>-<NUM> grams/denier, which provides increased resistance to cut-through and absorbs an increased amount of impact energy without breaking, thereby provided optimal crash resistance and protection to the elongate member <NUM>. To further yet increase the density and impact resistance of the wall <NUM>, at least some of the warp yarns <NUM> and/or fill yarns <NUM> can be provided having a high shrinkage, wherein high shrinkage is defined herein as shrinking lengthwise between <NUM>-<NUM>% or more of a pre-treated, pre-shrunken length, whereupon shrinking the yarns, the yarns <NUM>, <NUM> are drawn together to increase the density of the wall <NUM>.

Claim 1:
A wrappable, multilayered woven sleeve (<NUM>) for routing and protecting elongate members (<NUM>), comprising:
a wall (<NUM>) having opposite edges (<NUM>, <NUM>) extending lengthwise between opposite ends (<NUM>, <NUM>), said opposite edges being wrappable about a central axis (<NUM>) into overlapping relation with one another to bound a central cavity (<NUM>), said wall having a plurality of layers (26a, 26b, 26c, 26d) extending in overlying relation with one another, each of said layers including warp yarns (<NUM>) extending generally parallel to the central axis woven with fill yarns (<NUM>) extending generally transversely to said warp yarns, each of said layers including a plurality of annular first bands (A) and a plurality of annular second bands (B), said first bands and said second bands of each of said layers alternating with one another along the length of the wall, said first bands of each layer including monofilament weft yarn (<NUM>') and multifilament weft yarn (<NUM>") and said second bands of each layer including only one of monofilament weft yarn or multifilament weft yarn, said first bands of each layer being radially aligned in overlapping relation with one another and said second bands of each layer being radially aligned in overlapping relation with one another, said first bands of each layer forming peaks (P) and said second bands of each layer forming valleys (V), said peaks and said valleys alternating with one another along said central axis.