Flexible, arc resistant, fluid repellent, high temperature resistant, wear resistant, circumferentially continuous seamless textile sleeve and method of making same

Abstract

A textile sleeve having a seamless, circumferentially continuous wall comprising a textile layer formed by interlacing yarns with one another. The textile layer has an outer surface and an opposing inner surface defining a closed cavity extending longitudinally along a central longitudinal axis between opposing open ends. At least some of the yarns include heat resistant multifilaments and heat resistant monofilaments, and a silicon-based coating adhered to the outer surface.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. application serial number 18 / 118,506, filed on March 7, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates generally to textile sleeves for protecting elongated members and, more particularly, to flexible, circumferentially continuous, seamless textile sleeves having arc resistance, abrasion resistance, heat resistance, and fluid repellency properties. Background Art

[0004] It is well known to provide protection for cables, wires, and hoses by containing and protecting elongated components such as wires and harnesses within a circumferentially continuous tubular textile sleeve. However, these sleeves typically have multiple layers, each specialized for a different type of protection. While these multilayer sleeves can provide adequate protection for a variety of environmental conditions, they are unfortunately bulky, have thick, multilayered walls, each containing a different type of yarn, thus requiring increased volume, and are often relatively heavy and inflexible. Furthermore, the necessity of including multiple layers can be problematic in certain applications, particularly those requiring routing cables, wires, or hoses through confined winding areas, and in applications with weight restrictions, such as aircraft and aerospace applications. Summary of the Invention

[0005] One aspect of the present invention provides a textile sleeve for routing and protecting an elongated member. The textile sleeve includes a circumferentially continuous seamless wall. The circumferentially continuous seamless wall comprises a textile layer having an outer surface and an opposing inner surface, the inner surface defining an enclosed cavity extending longitudinally along a central longitudinal axis between opposing open ends. The textile layer is formed from interwoven yarns, at least some of which comprise heat-resistant multifilament yarns and heat-resistant monofilament yarns, and a silicone-based coating adhered to the outer surface of the textile layer.

[0006] According to another aspect of the present invention, the yarns may include warp yarns extending generally parallel to the central longitudinal axis and weft yarns extending generally transverse to the central longitudinal axis, the warp yarns and the weft yarns being interwoven together.

[0007] According to another aspect of the present invention, the warp yarns may be made entirely of heat-resistant multifilament yarns, while the weft yarns may include heat-resistant monofilament yarns.

[0008] According to another aspect of the present invention, the weft yarn may include heat-resistant monofilaments and heat-resistant multifilaments.

[0009] According to another aspect of the present invention, the heat-resistant multifilament yarn may be meta-aramid.

[0010] According to another aspect of the present invention, the denier of the heat-resistant warp multifilament yarn may be between about 100-3000, and the denier of the heat-resistant weft multifilament yarn may be between about 50-1000.

[0011] According to another aspect of the present invention, the diameter of the heat-resistant monofilament may be between 0.1 and 0.5 mm.

[0012] According to another aspect of the present invention, the heat-resistant monofilament may be polyetheretherketone (PEEK).

[0013] According to another aspect of the present invention, the silicon-based coating may include at least one or both of a flame retardant and a thermal stabilizer.

[0014] According to another aspect of the present invention, the thickness of the silicon-based coating is between 0.1-3.0 mm.

[0015] According to another aspect of the invention, the textile layer is circumferentially continuous and seamless.

[0016] According to another aspect of the invention, the textile layer has opposing edges extending longitudinally between opposing open ends, the opposing edges overlapping each other and forming a seam between the overlapping edges, wherein the silicone-based coating is circumferentially continuous and seamless to close the seam between the overlapping opposing edges.

[0017] According to another aspect of the present invention, a method for manufacturing a wrappable sleeve for routing and protecting an elongated member from arcing, abrasion, thermal conditions (including high heat and flame), fluid (water / fuel) intrusion, and other environmental conditions (such as contamination), and preventing fluid absorption into the wrappable sleeve wall, is provided. The method includes interweaving heat-resistant yarns to form a textile layer having an outer surface and an inner surface, the inner surface defining a cavity extending longitudinally along a central longitudinal axis between opposing open ends. Furthermore, a silicone-based coating is bonded to the outer surface of the textile layer, such that the silicone-based coating is circumferentially continuous and seamless along the length of the textile layer.

[0018] According to another aspect of the present invention, the method may further include interweaving the yarns during a weaving process, a knitting process, or a braiding process. If weaving, the method may further include weaving the yarns, wherein the yarns include warp yarns extending generally parallel to a central longitudinal axis, the warp yarns being entirely heat-resistant multifilament yarns, and weft yarns extending generally transverse to the warp yarns, the weft yarns comprising heat-resistant monofilament yarns.

[0019] According to another aspect of the present invention, the method may further include providing a weft yarn including the heat-resistant monofilament and the heat-resistant multifilament.

[0020] According to another aspect of the present invention, the method may further include providing warp multifilaments having a denier between about 100-3000 and weft multifilaments having a denier between about 50-1000.

[0021] According to another aspect of the present invention, the method may further include providing the weft yarn monofilaments having a diameter between about 0.1-0.5 mm.

[0022] According to another aspect of the present invention, the method may further include weaving the warp yarns and the weft yarns into one of a plain, twill, basket weave, or satin pattern.

[0023] According to another aspect of the present invention, the method may further include alternating weaving weft monofilaments and multifilaments along the entire length of the wall.

[0024] According to another aspect of the present invention, the method may further include providing the silicon-based coating to a thickness between about 0.1-3.0 mm.

[0025] According to another aspect of the present invention, the method may further include providing a silicon-based coating including at least one of a flame retardant and a thermal stabilizer.

[0026] According to another aspect of the present invention, the method may further include forming the textile layer into a circumferentially continuous seamless layer.

[0027] According to another aspect of the present invention, the method may further include forming the textile layer having opposed edges extending longitudinally between opposed open ends, and wrapping the opposed edges around one another in overlapping relation. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The foregoing and other aspects, features, and advantages will become apparent to those skilled in the art in view of the following detailed description of the presently preferred embodiment and best mode, the appended claims, and the accompanying drawings, in which: FIG1A is a schematic perspective view of a textile sleeve made in accordance with one aspect of the present invention, the textile sleeve being shown arranged around an elongated member to be protected therein; FIG1B is a schematic perspective view of a textile sleeve made in accordance with another aspect of the present invention, the textile sleeve being shown arranged around an elongated member to be protected therein; FIG2A is an end view of the sleeve of FIG1A taken along the central longitudinal axis; FIG2B is an end view taken along the central longitudinal axis of the sleeve of FIG1B; and Figure 3A- Figure 3C Different embodiments of a textile layer that can wrap around a sleeve are shown in Figures 1A and 1B. DETAILED DESCRIPTION

[0029] Referring to the accompanying drawings in more detail, Figure 1A-1B and Figure 2A-2BSchematic diagrams of circumferentially continuous seamless textile sleeves (hereinafter referred to as sleeves 10a, 10b, respectively) constructed according to various aspects of the present invention are shown. The sleeves 10a and 10b, respectively, have flexible, circumferentially continuous, seamless elongated walls 12a and 12b for routing and protecting elongated members 14, such as cables, wires, and pipes, from arcing (the passage of current from a cable or wire to another conductor through an air gap, thereby confining the energy of the cable or wire within the walls 12a, 12b and preventing the energy from being released from the sleeves 10a, 10b), abrasion, thermal conditions (including high heat and flame), fluid absorption and intrusion (such as water, oil, fuel, etc.), and other environmental conditions (such as contamination). The walls 12a, 12b can be constructed to have any suitable dimensions, including length and diameter. The walls 12a, 12b have an inner surface 15 and an opposing outer surface 17. The walls 12a, 12b, respectively, have a woven (FIG. 3A), knitted (FIG. 3B), or fabricated from yarn 24. Figure 3B ) or braiding ( FIG. 3C ) to form inner interwoven textile layers 23a, 23b, wherein at least some of the yarns 24 comprise heat-resistant multifilament yarns 24a and heat-resistant monofilament yarns 24b. This enables the sleeves 10a, 10b to withstand exposure to high temperatures and flames for a predetermined period of time, including up to approximately two hours or longer, while protecting the elongated member 14 from thermal damage. A silicone-based coating 26 is adhered to the outer surfaces 17 of the interwoven textile layers 23a, 23b, and as shown, adheres to the entire outer surface 17, thereby forming a circumferentially continuous, seamless silicone-based coating 17 around the interwoven textile layers 23a, 23b. Thus, the silicone-based coating 26 enhances the aforementioned level of protection provided to the elongated member 14, particularly against arcing and liquid absorption / intrusion. The interwoven textile layer 23a is formed as a circumferentially continuous, seamless layer, while the interwoven textile layer 23b has opposing edges 16, 18 extending longitudinally between opposing open ends 19, 21. The opposing edges 16, 18 overlap and wrap around each other, forming a seam between the overlapping edges 16, 18. The silicon-based coating 26 is circumferentially continuous and seamless, and can seal the seam between the overlapping opposing edges 16, 18, thereby making the wall 12b circumferentially continuous and seamless.

[0030] The silicone-based coating 26 is a fluid-impermeable coating, and is therefore impermeable to water, fuels (e.g., kerosene), oils, etc., thereby rendering the walls 12a and 12b fluid-impermeable and fluid-repellent. This prevents liquids from being absorbed by the interwoven layers 23a and 23b, thereby preventing water, fuels, etc. from impairing the ability of the sleeves 10a and 10b to provide the desired level of protection. The silicone-based coating 26 may include at least one or both of a flame retardant and a thermal stabilizer, and its thickness may range from 0.1 to 3.0 mm. This allows the walls 12a and 12b to have a narrower profile, thereby enhancing flexibility and the ability to be deployed in relatively confined spaces.

[0031] In a preferred embodiment of FIG3A , the interwoven yarns 24 are woven and include warp yarns 36 extending generally parallel to the central longitudinal axis 20 and weft yarns 38 extending generally transverse to the central longitudinal axis 20. The warp yarns 36 can be woven with the weft yarns 38 in any desired weave pattern, including, for example, plain weave, twill, satin, or basket weave (or basketweave), with a plain weave pattern being preferred to provide a smooth, stable, and uniform protective pattern. The smoothness thereof facilitates adhesion of the silicone-based coating 26 to the outer surface 17. The warp yarns 36 can be made entirely of multifilament yarns 24a, which are heat-resistant (high temperature resistant), while the weft yarns can include monofilament yarns 24b, which are also heat-resistant (high temperature resistant) and highly abrasion-resistant. Furthermore, if it is desired to provide the wall 12b with a self-wrapping structure, the monofilaments 24b can also provide a heat-setting function, thereby applying a thermally formed bias in the wall 12 through heat setting to maintain the opposing edges 16, 18 in overlap in the absence of an external force sufficient to overcome the internal bias. Of course, the silicone-based coating 26 functions to seal and close the seam formed between the opposing edges 16, 18, thereby rendering the sleeve 10a circumferentially continuous and seamless along its length. The weft yarn 38 can further include heat-resistant multifilaments 24a. The weft monofilaments 24b and the weft multifilaments 24a can be provided in any desired ratio. In a presently preferred embodiment, the weft monofilaments 24b and the weft multifilaments 24a are woven alternately in a 1:1 ratio.

[0032] The warp multifilaments 36, 24a can be meta-aramid with a denier between approximately 100 and 3000 tex, while the weft multifilaments 38, 24a can be provided with a denier between approximately 50 and 1000 tex. The weft monofilaments 38, 24b can be polyetheretherketone (PEEK) with a diameter between 0.1 and 0.5 mm. Because the effective diameter of the weft multifilaments 38, 24a is smaller than that of the warp multifilaments 36, 24a, the weave can be more compact and dense, thereby enhancing protection for the elongated member 14.

[0033] 3B and 3C, textile layers 23a, 23b may be knitted or woven using the multifilament yarns 24a and monofilament yarns 24b described above. It should be appreciated that any desired combination of multifilament yarns 24a and / or monofilament yarns 24b may be used to form the knitted or woven interwoven yarns 24.

[0034] According to another aspect of the present invention, a method of manufacturing a textile sleeve 10a, 10b is provided. The method includes interweaving heat-resistant yarns 24 to form textile layers 12a, 12b having an outer surface 17 and an inner surface 15, wherein the inner surface defines a cavity 22 extending longitudinally along a central longitudinal axis 20 between opposing open ends 19, 21. Furthermore, a silicone-based coating 26 is bonded to the outer surface 17 of the textile layers 12a, 12b, such that the silicone-based coating 26 is circumferentially continuous and seamless along the length of the textile layers 12a, 12b.

[0035] The method may further include interweaving the yarns 24 during a weaving process, a knitting process, or a braiding process. If woven, the method may further include weaving the yarns, wherein the yarns include warp yarns 36 extending generally parallel to the central longitudinal axis 20 and weft yarns 38 extending generally transverse to the warp yarns 36, wherein the warp yarns 36 are provided entirely as heat-resistant multifilament yarns 24a, and the weft yarns 38 include heat-resistant monofilament yarns 24b.

[0036] According to another aspect, the weft yarn 38 may further include heat-resistant monofilaments 24b and multifilaments 24a.

[0037] The method may further include providing the warp multifilaments 36, 24a having a denier between about 100-3000 tex and providing the weft multifilaments 38, 24a having a denier between about 50-1000 tex.

[0038] The method further includes providing a weft monofilament 24b having a diameter between 0.1 and 0.5 mm.

[0039] Additionally, the method includes weaving the warp yarns 36 and the weft yarns 38 into one of a plain, twill, basket weave, or satin pattern.

[0040] The method further includes alternately weaving the weft monofilaments 24b and the weft multifilaments 24a along the entire length of the wall 12 so that the ratio of the monofilaments 24b to the weft multifilaments 24a is 1:1.

[0041] The method may further include providing the silicon-based coating 26 to a thickness between about 0.1-3.0 mm, and in one exemplary embodiment, between about 0.1-1.00 mm.

[0042] The method may further include providing a silicone-based coating 26 including at least one of a flame retardant and a thermal stabilizer to enable the sleeve to withstand high heat and flame exposure for a predetermined time period, including up to about 2 hours, while protecting the elongated member therein from damage.

[0043] The method may further include forming the textile layer 12a into a circumferentially continuous and seamless layer.

[0044] The method may further include forming a textile layer 12b having opposing edges 16, 18 extending longitudinally between opposing open ends 19, 21 and wrapping the opposing edges 16, 18 in overlapping relationship with each other.

[0045] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is contemplated that all features of all claims and all embodiments may be combined with one another, provided such combinations do not conflict with one another. Therefore, it should be understood that, within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described.

Claims

1. A textile sleeve for laying and protecting an elongated member, comprising: A seamless, circumferentially continuous wall comprising a textile layer having an outer surface and an opposed inner surface, the inner surface defining an enclosed cavity extending longitudinally along a central longitudinal axis between opposed open ends, the textile layer being formed from yarns interwoven with one another, wherein at least some of the yarns comprise heat-resistant multifilaments and heat-resistant monofilaments, and a silicone-based coating adhered to the outer surface of the textile layer.

2. The textile sleeve according to claim 1, wherein The yarns include warp yarns extending generally parallel to the central longitudinal axis and weft yarns extending generally transverse to the central longitudinal axis, the warp yarns being interwoven with the weft yarns.

3. The textile sleeve according to claim 2, wherein: The warp yarns are entirely composed of the heat-resistant multifilament yarns, and the weft yarns include the heat-resistant monofilament yarns.

4. The textile sleeve according to claim 3, wherein The weft yarn includes the heat-resistant multifilament.

5. The textile sleeve according to claim 4, wherein The heat-resistant multifilament is meta-aramid.

6. The textile sleeve according to claim 4, wherein The heat-resistant warp multifilament yarn has a denier of about 100-3000 dtex, and the heat-resistant weft multifilament yarn has a denier of about 50-1000 dtex.

7. The textile sleeve according to claim 6, wherein The diameter of the heat-resistant monofilament is between about 0.1 and 0.5 mm.

8. The textile sleeve of claim 5, wherein: The heat-resistant monofilament is PEEK.

9. The textile sleeve of claim 1, wherein: The silicon-based coating includes at least one of a flame retardant and a thermal stabilizer.

10. The textile sleeve of claim 1, wherein: The thickness of the silicon-based coating is between about 0.1 and 3.0 mm.

11. The textile sleeve of claim 1 , wherein: The textile layer is circumferentially continuous and seamless.

12. The textile sleeve of claim 1, wherein: The textile layer has opposing edges extending longitudinally between the opposing open ends, the opposing edges overlapping each other and forming a seam between the overlapping edges, wherein the silicone-based coating is circumferentially continuous and seamless to close the seam between the overlapping opposing edges.

13. A method of constructing a textile sleeve for routing and protecting an elongated member from arcing, heat, flame, abrasion, and fluid intrusion, comprising: interweaving heat-resistant yarns together to form a textile layer having an outer surface and an inner surface, the inner surface defining a cavity extending longitudinally along a central longitudinal axis between opposed open ends; as well as A silicon-based coating is bonded to the outer surface of the textile layer so that the silicon-based coating is circumferentially continuous and seamless along the length direction of the textile layer.

14. The method of claim 13, further comprising interweaving the yarns during the weaving process.

15. The method of claim 17, further comprising weaving yarns comprising warp yarns made entirely of heat-resistant multifilament yarns extending generally parallel to the central longitudinal axis and weft yarns comprising monofilament yarns extending generally transverse to the warp yarns.

16. The method of claim 15, further comprising weaving a weft yarn comprising a heat-resistant multifilament yarn.

17. The method of claim 16, further comprising providing the warp multifilaments with a denier between about 100-3000 dtex and providing the weft multifilaments with a denier between about 50-1000 dtex.

18. The method of claim 17, further comprising providing the weft monofilaments to have a diameter between about 0.1 and 0.5 mm.

19. The method of claim 13, further comprising forming the textile layer into a circumferentially continuous seamless layer.

20. The method of claim 13, further comprising forming the textile layer having opposing edges extending longitudinally between opposing open ends, and wrapping the opposing edges about one another in overlapping relation.

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