Patent Description:
This invention relates generally to textile sleeves, and more particularly to braided textile sleeves and to their method of construction.

It is known to protect temperature sensitive elongate members, such as wires and temperature sensitive sensors connected thereto with heat resistant tubular members, such as solid polymeric or metal tubing. Although known tubing can provide protection to wires extending therethrough against high heat, such tubing is generally stiff and inflexible, and thus, the ability to route the wires along meandering paths is limited. Some attempts to provide more flexible tubular members, such as via braiding, have been made; however, the heat resistance of such braided tubular members, also referred to a sleeves or sheaths, is generally limited to temperatures below about <NUM> degrees Fahrenheit (<NUM> degrees Celsius). In addition, the resistance to abrasion provided by braided sleeves is generally low, and thus, the sleeves can be worn over time, thereby subjecting the wire(s) therein to damage.

Prior patent document <CIT> describes a textile sleeve for routing and protecting elongate members. The sleeve includes an elongate, braided wall having a circumferentially continuous, tubular outer periphery extending along a central axis between opposite open ends. The wall includes bundles of shrinkable yarns braided with bundles of non-shrinkable yarns. The shrinkable yarn provides the wall with an ability to be radially contracted from a first, diametrically enlarged assembly state to a second, diametrically shrunken state.

Accordingly, what is needed is a protective sleeve that provides protection to an elongate member extending therethrough against high heat, such as temperatures above <NUM> degrees Fahrenheit (<NUM> degrees Celsius), that is flexible, is abrasion resistant and is resistant to fraying.

In accordance with one aspect of the invention, a protective textile sleeve is provided. The protective braided sleeve comprises; a seamless, circumferentially continuous, flexible tubular wall extending lengthwise along a central longitudinal axis between opposite ends; said wall including a plurality of yarns braided with one another in a first non-heat-treated state, a first plurality of said plurality of yarns being substantially non-heat-shrinkable yarns and a second plurality of said plurality of yarns being heat-shrinkable yarns; and said heat-shrinkable yarns being configured to shrink lengthwise at a temperature that does not cause said non-heat-shrinkable yarns to shrink substantially and to cause said substantially non-heat-shrinkable yarns to be axially bunched into a second heat-treated state. The non-heat-shrinkable yarn and the heat-shrinkable yarn are braided in a respective <NUM>: <NUM> braid pattern, with the non-heat-shrinkable yarn and the heat-shrinkable yarn alternating with one another in opposite S and Z helical directions in a ratio of ends of the non-heat-shrinkable yarn to the heat-shrinkable yarn of <NUM>:<NUM>.

Accordingly, by way of example and without limitation, the heat-shrinkable yarns may shrink lengthwise greater than <NUM> percent of their original length, such as between about <NUM>-<NUM> percent of their original length or more, while the non-heat-shrinkable yarn may shrink about <NUM> percent of their original length or less when the sleeve is exposed to a heat-shrink, heat treatment process.

In accordance with another aspect of the invention, the heat-shrinkable and non-heat-shrinkable yarns are braided with one another such that the heat-shrinkable yarns, upon being shrank, cause the non-heat-shrinkable yarns to be axially compressed (gathered, bunched, warped) such that the thickness of the braided wall of the sleeve may be increased by between about <NUM>-<NUM> percent relative to the thickness prior to heat-shrinking the heat-shrinkable yarns, with the increased wall thickness providing an increased resistance to abrasion, an increased resistance to fraying, an increased resistance to the ingress of contamination, an increased level of thermal insulation and an increased level of protection against high temperature thermal conditions.

In accordance with another aspect of the invention, upon heat-shrinking the heat-shrinkable yarns, the non-heat-shrinkable yarns are axially compressed and bunched between the heat-shrink yarns, thereby increasing the density of the wall, which in turn increases the resistance to abrasion, increases the thermal insulation and increases the level of protection against high temperature thermal conditions, increases the resistance to the ingress of contamination, and increases the resistance to fraying of the yarns upon cutting the sleeve wall to length and fraying of the ends of the sleeve while in use.

In accordance with another aspect of the invention, the non-heat-shrinkable yarn and the heat-shrinkable yarn can be provided in an equal number of ends braided with one another, thereby providing a uniform appearance and a uniform level of protection about the entirety of the sleeve.

In accordance with another aspect of the invention, the non-heat-shrinkable yarn can be provided as a monofilament and/or multifilament, as desired, to provide the sleeve with the desired type of abrasion resistance protection, coverage and flexibility.

In accordance with another aspect of the invention, the non-heat-shrinkable yarn can be provided as aramid multifilament, thereby enhancing the resistance of the sleeve to degradation when exposed to high temperatures, such as in excess of <NUM> degrees Fahrenheit (<NUM> degrees Celsius).

In accordance with another aspect of the invention, the heat-shrinkable yarn can be provided as polyether ether ketone (PEEK) monofilament.

In accordance with another aspect of the invention, the wall may have a first thickness prior to exposing the wall to a predetermined temperature and a second thickness after exposing the wall to the predetermined temperature, with the second thickness being between about <NUM>-<NUM> percent greater than the first thickness, thereby increasing the abrasion resistance, increasing the resistance to the ingress of contamination, and increasing the heat-resistance of the wall.

In accordance with another aspect of the invention, the wall has a first length prior to exposing the wall to the predetermined temperature and a second length after exposing the wall to the predetermined temperature, the second length being less than the first length, thereby contributing to the increased abrasion resistance, the increased resistance to the ingress of contamination, and the increased heat-resistance of the wall.

In accordance with another aspect of the invention, the second length is at least <NUM> percent less than the first length.

In accordance with another aspect of the invention, the second plurality of yarns shrink lengthwise at least <NUM> percent of an as braided length upon exposing the wall to the predetermined temperature and the first plurality of yarns shrink lengthwise less than <NUM> percent of an as braided length upon exposing the wall to said predetermined temperature, thereby contributing to the increased thickness of the wall upon exposing the wall to the predetermined temperature, thus, increasing the abrasion resistance, the increased resistance to the ingress of contamination, and the increased heat-resistance of the wall.

In accordance with another aspect of the invention, the second plurality of yarns can be provided as monofilaments and the first plurality of yarns can be provided as multifilaments.

In accordance with another aspect of the invention, the wall can be braided including only the first plurality of yarns and the second plurality of yarns.

In accordance with another aspect of the invention, a method of constructing a protective textile sleeve is provided. The method of constructing a protective textile sleeve, comprises: braiding a first plurality of yarns with a second plurality of yarns to form a seamless tubular wall extending lengthwise along a central longitudinal axis, with the resulting seamless tubular wall having a first thickness, the first plurality of yarns being substantially non-heat-shrinkable yarns and the second plurality of yarns being heat-shrinkable yarns; and exposing the braided wall to a predetermined temperature and causing the second plurality of yarns to shrink lengthwise and causing the first plurality of yarns to become axially bunched under a force imparted by the second plurality of yarns causing the seamless tubular wall to expand to a second thickness that is greater than the first thickness.

The non-heat-shrinkable yarn and the heat-shrinkable yarn are braided in a respective <NUM>:<NUM> braid pattern, with the non-heat-shrinkable yarn and the heat-shrinkable yarn alternating with one another in opposite and helical directions in a ratio of ends of the non-heat-shrinkable yarn to the heat-shrinkable yarn of <NUM>:<NUM> to provide the sleeve with a substantially balanced content and uniform distribution of the non-heat-shrinkable yarns and heat-shrinkable yarns.

In accordance with another aspect of the invention, the method can further include increasing the first thickness of the braided wall from when the wall is in a first, non-heat-treated state to the second thickness when the wall is in a second, heat-treated state, such as being greater than <NUM> percent, and preferably being greater than <NUM> percent, and more preferably being greater than <NUM> percent of the first thickness, thereby increasing the resistance of the wall to abrasion and increasing the thermal insulation properties of the wall to provide the elongate member bounded by the wall with enhanced protection against the ingress of contamination and against high temperature external environmental thermal conditions, such as above <NUM> degrees Fahrenheit (<NUM> degrees Celsius).

In accordance with another aspect of the invention, the method can further include increasing a first density of the braided wall from when the wall is in the first, non-heat-treated state to a second density when the wall is in the second, heat-treated state, such that the second density is significantly greater than the first density, such as being greater than <NUM> percent, and preferably being greater than <NUM> percent, and more preferably being greater than <NUM> percent of the first density, thereby significantly increasing the resistance of the wall to abrasion, increasing the thermal insulation properties of the wall to provide the elongate member bounded by the wall with enhanced protection against high temperature external environmental thermal conditions, increasing the resistance to the ingress of contamination, and further increasing the resistance of the yarns to fraying while being cut and while in use.

In accordance with another aspect of the invention, the method can further include increasing the first thickness between about <NUM>-<NUM> percent to the second thickness upon exposing the braided wall to the predetermined temperature.

In accordance with another aspect of the invention, the method can further include causing the second plurality of yarns to shrink lengthwise at least <NUM> percent upon exposing the braided wall to the predetermined temperature and causing the first plurality of yarns to shrink lengthwise less than <NUM> percent upon exposing the braided wall to the predetermined temperature, thereby causing the second plurality of yarns to impart an axially directed force on the first plurality of yarns and causing the first plurality of yarns to be bunched to increase the thickness of the braided wall.

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:.

Referring in more detail to the drawings, <FIG> illustrate a tubular braided protective textile sleeve, referred to hereafter as sleeve <NUM>, constructed in accordance with one aspect of the invention. The sleeve <NUM>, as braided in a single, continuous braiding process, has a braided, circumferentially continuous, seamless tubular wall <NUM> bounding a through passage, also referred to as cavity <NUM>, extending lengthwise along a central longitudinal axis <NUM> between open opposite ends <NUM>, <NUM>, wherein the cavity <NUM> receives an elongate member <NUM> to be protected, such as a wire harness, conduit, pipe, or the like. The wall <NUM> is braided including a plurality of ends (end, as understood in the art is a single yarn filament, whether a monofilament or a multifilament) of yarn braided with one another, with a plurality of the yarns being non-heat-shrinkable, high temperature yarns <NUM> (<FIG>; high temperature meaning able to withstand temperatures in excess of <NUM> degrees Fahrenheit (<NUM> degrees Celsius) without being altered in material property or length) and a plurality of the yarns being heat-shrinkable yarns <NUM> (a cross-linked heat-shrinkable yarn meaning that the yarns <NUM> can be activated to shrink <NUM>% or more, up to <NUM>%, of their original, non-activated length; <FIG>). The heat-shrinkable yarns <NUM> are shrinkable at a temperature in a heat-treatment process that does not cause the high temperature yarns <NUM> to shrink, or at least does not cause the high temperature yarns to shrink substantially. Accordingly, by way of example and without limitation, the heat-shrinkable yarns <NUM> may shrink lengthwise (axially) greater than <NUM> percent of their original length, such as between about <NUM>-<NUM> percent, while the non-heat-shrinkable, high temperature yarn <NUM> may shrink about <NUM> percent, or less, of their original length when the sleeve <NUM> is exposed to the heat treatment process. Accordingly, upon the sleeve <NUM> being heat-treated, the heat-shrinkable yarns <NUM> are shrunken lengthwise between about <NUM>-<NUM> percent, while the non-heat-shrinkable, high temperature yarn <NUM> remain substantially non-shrunk. As such, as shown in <FIG>, the non-heat-shrinkable, high temperature yarn <NUM> are caused to taken on a meandering, serpentine configuration along their length as a result of being axially compressed, also referred to as axially gathered, axially warped or axially bunched, such that the effective thickness of the braided wall <NUM> of the sleeve <NUM> is increased, such as by at least <NUM> percent, and more preferably between about <NUM>-<NUM> percent from a first thickness t1 (<FIG>; illustrating a portion of the wall <NUM>, with it to be recognized that the remaining unseen portion of the wall <NUM> is the same as the portion shown) before heat-shrinking the heat-shrinkable yarns <NUM>, to a second thickness t2 (<FIG>; illustrating a portion of the wall <NUM>, with it to be recognized that the remaining unseen portion of the wall <NUM> is the same as the portion shown) after heat-shrinking the heat-shrinkable yarns <NUM>, and the density of the wall <NUM> is increased from a first density d1 before heat-shrinking the heat-shrinkable yarns <NUM> (<FIG>) to a second density d2 after heat-shrinking the heat-shrinkable yarns <NUM> (<FIG>), wherein d2 is greater than <NUM> percent of d1, and preferably being greater than <NUM> percent, and more preferably being greater than <NUM> percent of d1. The increased wall thickness t2 and the increased density d2 provide synergies including an increased resistance to abrasion; an increased level of thermal insulation, an increased thermal protection against high temperature thermal conditions, and an increased resistance to fraying of the yarns <NUM>, <NUM> upon cutting the sleeve wall <NUM> to length and fraying of the ends <NUM>, <NUM> of the sleeve <NUM> while in use (<FIG>).

The braided yarns <NUM>, <NUM> forming the entirety of the wall <NUM>, or substantially entirety if other yarns are included, can be provided in a desired number of relative ends (an end is known as a single yarn) alternated with one another about the circumference of the sleeve <NUM> in the opposite S and Z helical directions (S and Z directions illustrated in the Figures, as would be understood by a skilled artisan in the textile arts upon viewing the disclosure herein) in a ratio of ends of high temperature yarn <NUM> to heat-shrinkable yarn <NUM> of <NUM>:<NUM> (<FIG> and <FIG>), to provide the sleeve <NUM> with a substantially circumferentially balanced content of the yarns <NUM>, <NUM> and a uniform thickness and density about the circumference and along the length of the sleeve <NUM>. In accordance with the invention, the non-heat-shrinkable yarn <NUM> and the heat-shrinkable yarn <NUM> are braided in a respective <NUM>: <NUM> braid pattern, with the non-heat-shrinkable yarn <NUM> and the heat-shrinkable yarn <NUM> alternating with one another in opposite S and Z helical directions.

In accordance with another aspect of the disclosure, the heat-shrinkable yarn <NUM> can be provided as any suitable heat-shrinkable monofilament and/or multifilament. In one example, wherein a ¼ inch diameter sleeve was produced, by way of example and without limitation, the heat-shrinkable yarn <NUM> was provided as a monofilament of PEEK having a diameter of about <NUM> and a heat-shrink ratio of about <NUM> percent at a heat-treat temperature of about <NUM> degrees Fahrenheit (<NUM> degrees Celsius), by way of example and without limitation. Further, in the example embodiment, the non-heat-shrinkable yarn <NUM> was provided as a multifilament of aramid having a diameter of about <NUM> and a heat-shrink ratio of about <NUM> percent at a heat-treat temperature of about <NUM> degrees Fahrenheit (<NUM> degrees Celsius), by way of example and without limitation. Upon heat-treating the exemplary wall <NUM>, such as at a temperature between about <NUM>-<NUM> degrees Fahrenheit (<NUM>-<NUM> degrees Celsius) for between about <NUM>-<NUM> minutes, by way of example and without limitation, the length shrink ratio was about <NUM> percent, such that the length L1 of the sleeve <NUM> (<FIG>) prior to being heat-treated was reduced to a length L2 (<FIG>; L1 x <NUM>%), while the thickness t1 of the wall <NUM> (<FIG>) increased about <NUM> percent to t2 (<FIG>; caused by the axial bunching and meandering of the non-heat-shrinkable yarn <NUM>, as shown in <FIG>, prior to the wall <NUM> being heat-treated and in <FIG> after the wall <NUM> being heat-treated). The resulting sleeve <NUM> was provided with an increased resistance to an ingress of contamination, an increased resistance to abrasion and increased thermal properties allowing it to withstand and protect an electrical member contained therein against an external environmental temperature up to about <NUM> degrees Fahrenheit (<NUM> degrees Celsius) for up to about <NUM> hours, with the sleeve <NUM> retaining high flexibility and diametrically expansive properties. It is contemplated herein that any desired diameter sleeve can be produced using a suitably sized diameter non-heat-shrinkable yarn <NUM> and heat-shrinkable yarn <NUM> and number of ends thereof, as will be understood by a person possessing ordinary skill in the art.

In accordance with another aspect of the disclosure, a method of constructing a braided textile sleeve <NUM> is provided. The method includes braiding a plurality of yarns <NUM>, <NUM> with one another to form a seamless tubular wall <NUM> extending lengthwise along a central longitudinal axis <NUM> in a first non-heat-treated state, with at least some of the yarns being provided as non-activatable, non-heat-shrinkable yarns <NUM> and at least some of the yarns being provided as activatable, heat-shrinkable yarns <NUM>. Then, heat-treating the braided wall at a first temperature to cause the activatable, heat-shrinkable yarns <NUM> to shrink lengthwise, while not causing the non-activatable, non-heat-shrinkable yarns <NUM> to shrink or shrink substantially at the first temperature.

The method further includes braiding the non-heat-shrinkable yarns <NUM> and the heat-shrinkable yarns <NUM> in alternating relation with one another in a <NUM>:<NUM> braid pattern, with the non-heat-shrinkable yarn <NUM> and the heat-shrinkable yarn <NUM> alternating with one another in opposite S and Z helical directions to provide the sleeve <NUM> with a substantially balanced content of the non-heat-shrinkable yarns <NUM> and heat-shrinkable yarns <NUM>.

In accordance with another aspect of the disclosure, the method can further include heat-treating the braided wall <NUM> to cause the heat-shrinkable yarns <NUM> to shrink lengthwise between about <NUM>-<NUM> percent, while maintaining the non-heat-shrinkable yarns <NUM> in a non-heat-shrunk or substantially non-heat-shrunk state, such that the length of the non-heat-shrinkable yarns <NUM> remains within about <NUM> percent of their original, as braided, length.

In accordance with another aspect of the disclosure, the method can further include increasing a first thickness t1 of the braided wall <NUM> from when the wall <NUM> is in a first, non-heat-treated state to a second thickness t2 upon completing the heat-treating process, wherein the first thickness t1 is increased generally between about <NUM>-<NUM> percent to the second thickness t2, and preferably between about <NUM>-<NUM>, and more preferably between about <NUM>-<NUM> percent, and in one embodiment, by about <NUM> percent, thereby increasing the abrasion resistance, density, thermal resistance and end-fray resistance of the wall <NUM>.

Claim 1:
A protective braided sleeve (<NUM>), comprising:
a seamless, circumferentially continuous, flexible tubular wall (<NUM>) extending lengthwise along a central longitudinal axis (<NUM>) between opposite ends (<NUM>, <NUM>);
said wall including a plurality of yarns braided with one another in a first non-heat-treated state, a first plurality (<NUM>) of said plurality of yarns being substantially non-heat-shrinkable yarns and a second plurality (<NUM>) of said plurality of yarns being heat-shrinkable yarns; and
said heat-shrinkable yarns being configured to shrink lengthwise at a temperature that does not cause said non-heat-shrinkable yarns to shrink substantially and to cause said substantially non-heat-shrinkable yarns to be axially bunched into a second heat-treated state;
wherein the non-heat-shrinkable yarn (<NUM>) and the heat-shrinkable yarn (<NUM>) are braided in a respective <NUM>:<NUM> braid pattern,
characterised in that the non-heat-shrinkable yarn and the heat-shrinkable yarn are alternating with one another in opposite S and Z helical directions in a ratio of ends of the non-heat-shrinkable yarn (<NUM>) to the heat-shrinkable yarn (<NUM>) of <NUM>:<NUM>.