Multi-layer braided tubular sleeve and method of making same

Abstract

The present application discloses a multi-layer tubular cannula (10) comprising: a braided tubular inner wall (14b) extending about a central axis (18) between opposing first and second inner ends (26a, 26b); and a braided tubular outer wall (14a) extending about the central axis between the opposing first and second outer ends (24a, 24b). The first inner end portion (26a) is joined with the first outer end portion (24a) by a first joining joint (22a), the second inner end portion (26b) is joined with the second outer end portion (24b) by a second joining joint (22b), and the inner wall (14b) is separated from the outer wall (14a) over a length extending between the first and second joining joints (22a, 22b).

Description

Cross-references to related applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 546,430, filed October 30, 2023, and U.S. Provisional Patent Application No. 63 / 526,468, filed July 13, 2023, and to U.S. Patent Application No. 18 / 770,420, filed July 11, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] The present invention generally relates to textile sleeves for protecting slender components, and more specifically to multilayer braided tubular sleeves. Background Technology

[0003] In existing technologies, it is known to place slender components such as cables, wire harnesses, electrical cables, and various conduits within braided sleeves to resist impact, abrasion, fluid, and thermal effects. In applications requiring high impact resistance to prevent damage to the sleeve and internal components, wrap-around and circumferentially continuous tubular sleeves are known. Wrap-around sleeves require auxiliary fixing devices (such as clamps, straps, and tape) to secure them to the protected slender components, resulting in additional manpower and time consumption during assembly, thus increasing assembly costs. Furthermore, inventory management of these auxiliary fixing devices also creates cost pressures. More seriously, there is a risk of these devices coming loose during use, potentially exposing the slender components directly to environmental influences. Additionally, wrap-around sleeves often suffer from uneven thickness—their relative edges need to overlap, resulting in thickened areas on the outer contour of the sleeve, limiting its application in confined spaces and increasing installation difficulty. Another drawback is the need to stock multiple sizes for different diameter applications, further increasing inventory pressure and cost burden.

[0004] For circumferentially continuous tubular casings, thick walls are typically required to achieve the necessary impact resistance, which limits their application in confined spaces. When high impact resistance is required, the challenge lies in achieving sufficient wall thickness to provide the necessary impact resistance while maintaining high flexibility so that the casing can be laid around sharp corners and along winding paths.

[0005] Therefore, there is an urgent need for a sleeve that can provide enhanced protection for slender internal components (especially against impact, abrasion and contamination), while also being flexible, easy to assemble, inexpensive to manufacture and assemble, and having a long service life. Summary of the Invention

[0006] One aspect of the invention provides a multilayer tubular sleeve including a braided tubular inner wall extending about a central axis between opposing first and second inner ends. The sleeve has a braided tubular outer wall extending about the central axis between opposing first and second outer ends. The first inner end is coupled to the first outer end via a first coupling joint, and the second inner end is coupled to the second outer end via a second coupling joint, and the inner wall is substantially separated from the outer wall along its length extending between the first and second coupling joints.

[0007] According to another aspect of the invention, at least one of the braided tubular inner wall and the braided tubular outer wall is braided from a heat-setting yarn, which is heat-setting treated to offset at least one braided tubular inner wall and the braided tubular outer wall into a cylindrical tube.

[0008] According to another aspect of the invention, each of the braided tubular inner wall and the braided tubular outer wall is woven from heat-set yarn, which is heat-set to offset the braided tubular inner wall and the braided tubular outer wall into a cylindrical tube.

[0009] According to another aspect of the invention, the braided tubular inner wall and the braided tubular outer wall are woven with yarns of different colors, one of which represents a specific function, such as electrical (high voltage) wiring.

[0010] According to another aspect of the invention, the first inner end is thermally fused with the first outer end, and the second inner end is thermally fused with the second outer end.

[0011] According to another aspect of the invention, the inner wall is completely separated from the outer wall over the entire length between the opposing first inner end and the second inner end and the opposing first outer end and the second outer end, thereby allowing the inner wall and the outer wall to expand and contract independently of each other and to move relative to each other, thereby improving the impact resistance of the wall.

[0012] According to another aspect of the invention, one of the braided tubular inner wall and the braided tubular outer wall may be woven with 100% recycled yarn, while the other may be woven with 100% virgin yarn.

[0013] According to another aspect of the invention, the multilayer tubular structure may include a braided tubular intermediate wall that extends about a central axis between a first intermediate end of an opening and a second intermediate end of an opening opposite to the first intermediate end, and the tubular intermediate wall is substantially separated from the tubular inner wall and outer wall along the length extending between the first and second joints.

[0014] According to another aspect of the invention, the multilayer tubular sleeve comprises a braided tubular inner wall and a braided tubular outer wall, wherein the inner wall extends about a central axis between opposing first inner ends and second inner ends, and the outer wall extends about a central axis between opposing first outer ends and second outer ends. The first inner end is joined to the first outer end via a first coupling joint, and the second inner end is joined to the second outer end via a second coupling joint, and the inner wall and outer wall are substantially separate along the length extending between the first coupling joint and the second coupling joint.

[0015] According to another aspect of the present invention, a method for manufacturing a multilayer tubular sleeve includes: weaving a tubular inner wall extending around a central axis between opposing first inner ends and second inner ends; in the weaving operation, weaving a tubular outer wall outside the tubular inner wall, the outer wall extending around a central axis between opposing first outer ends and second outer ends; joining the first inner end to the first outer end and joining the second inner end to the second outer end; and separating the inner wall from the outer wall over a length L extending between opposing first inner ends and second inner ends and opposing first outer ends and second outer ends.

[0016] The method may further include: joining the first inner end to the first outer end in a thermal cutting operation, and joining the second inner end to the second outer end in a thermal cutting operation.

[0017] The method may also include thermoforming at least one of the tubular outer wall and tubular inner wall during the hot rounding process to maintain the shape of the wall as a cylindrical tube.

[0018] The method may further include: joining the first inner end to the first outer end in a thermal cutting operation, and joining the second inner end to the second outer end in a thermal cutting operation.

[0019] The method may further include: weaving a tubular intermediate wall around the tubular inner wall by a weaving operation before the outer wall of the tube, the tubular intermediate wall extending between a first intermediate end of the opening and a second intermediate end of the opening opposite to the first intermediate end; joining the first intermediate end to the inner end and the first outer end by a first connecting joint, joining the second intermediate end to the second inner end and the outer end by a second connecting joint, and separating the tubular intermediate wall from the tubular inner wall and the tubular outer wall along the length extending between the first connecting joint and the second connecting joint. Attached Figure Description

[0020] These aspects, features, and advantages of the present invention will be readily understood by those skilled in the art through the following detailed description of the present preferred embodiments and best modes, the appended claims, and the accompanying drawings, wherein: Figure 1 This is a schematic perspective view of a tubular multilayer braided sleeve according to one aspect of the present invention, the sleeve being disposed around an elongated member to be protected; Figure 2 It is along Figure 1 A side sectional view of the tubular multi-layer braided sleeve, roughly taken from line 2-2 in the middle; Figure 3 To and Figure 2 A similar view shows a tubular multilayer braided sleeve constructed according to another embodiment of the invention. Detailed Implementation

[0021] Please refer to the detailed description in the attached diagram. Figure 1 and Figure 2 A multi-layered braided sheathing tube, hereinafter referred to as sheath 10, is shown, the construction of which conforms to one aspect of this disclosure. Figure 1 In this configuration, a sleeve 10 is arranged around an elongated member 12 to be protected. The sleeve 10 has an elongated, multi-layered braided wall 14 comprising a circumferentially continuous tubular outer wall 14a and a circumferentially continuous tubular inner wall 14b, the inner wall 14b enclosing an inner cavity 16 extending along a central longitudinal axis 18 between opposing open ends 19 and 20. It should be understood that, due to the circumferentially continuous tubular structure, the inner and outer walls 14a and 14b do not have longitudinally extending free sides, but are seamless, preventing the wall 14 from unfolding or opening along its length. The outer wall 14a extends about the central axis 18 between opposing first outer ends 24a and second outer ends 24b, and the inner wall 14b extends about the central axis 18 between opposing first inner ends 26a and second inner ends 26b. The first inner end 26a or the first inner end portion (hereinafter, "part" is intended to encompass the distance immediately adjacent to the first end 26a and the second end 26b, and the distance spanned by a length of approximately 0.1-25 mm extending from the first end 26a and the second end 26b along the central longitudinal axis 18 of the sleeve 10) is coupled to the first outer end 24a or the first outer end portion via the first coupling joint 22a, and the second inner end 26b or the second inner end portion is coupled to the second outer end 24b or the second outer end portion via the second coupling joint 22b. According to a non-limiting embodiment, the first coupling joint 22a and the second coupling joint 22b can extend circumferentially around the wall 14, and even extend around the entire circumference of the wall 14. The inner wall 14b is completely detached from the outer wall 14a over a length L extending between the first coupling joint 22a and the second coupling joint 22b opposite to the first coupling joint, thereby allowing the inner wall 14b and the outer wall 14a to move, expand, and contract independently of each other. The ability of the inner wall 14b and the outer wall 14a to expand and contract independently enhances the flexibility of the sleeve 10. Simultaneously, by allowing relative movement between the outer wall 14a and the inner wall 14b to more effectively absorb impact forces, the impact resistance of the wall 14 is improved. The outer wall 14a can be overbraided around the inner wall 14b, in which case the two walls 14a and 14b can have the same or substantially the same diameter, thereby minimizing the profile dimensions of the sleeve 10 in applications requiring confined spaces; alternatively, different diameter designs can be used as needed.

[0022] At least one of the braided tubular inner wall 14b and the braided tubular outer wall 14a is braided using heat-setting yarn (also known as thermoforming yarn). The heat-setting yarn is then heat-set to bias and maintain at least one of the braided tubular inner wall 14b and the braided tubular outer wall 14a as a cylindrical tube, thereby simplifying the assembly process of the sleeve 10 on the elongated member 12. According to one non-limiting aspect, the braided tubular inner wall 14b is braided using heat-setting yarn that is subsequently heat-set, while the braided tubular outer wall 14a is braided using non-heat-setting yarn, wherein the heat-setting yarn of the inner wall 14b is biased and maintains the braided tubular outer wall 14a as a cylindrical tube (also known as a tubular shape). According to another non-limiting aspect, each of the braided tubular inner wall 14b and the braided tubular outer wall 14a is entirely braided from heat-set yarns that are heat-set to offset and maintain the braided tubular inner wall 14b and the braided tubular outer wall 14a as cylindrical tubes, thereby maximizing the tubular compressive strength of the sleeve 10. The heat-set and non-heat-set yarns can be in multifilament and / or monofilament form, wherein the heat-set yarn is made from at least one or more of PET, nylon, PP, PE, PPS, and PEEK yarns. The denier value of the multifilament yarn can range from 50 to 10,000. Practice has shown that relatively coarser multifilament yarns provide better bulk, enhancing both the cushioning and energy absorption performance of the sleeve 10 and its flexibility. The number of yarn plies can be flexibly adjusted according to specific application requirements. The present invention envisions that the denier value (multifilament) and / or diameter (monofilament) of the yarn used for weaving the outer wall 14a and the denier value and / or diameter of the yarn used for weaving the inner wall 14b can be different as required.

[0023] According to one aspect, the first inner end 26a or end portion is thermally fused with the first outer end 24a or end portion to form a first joint 22a, and the second inner end 26b or end portion is thermally fused with the second outer end 24b or end portion to form a second joint 22b. The thermal fusion can be performed during the cutting of the wall 14 of the sleeve 10 to the desired length. A hot wire cutter can be used to perform the thermal cutting operation. To maximize the strength of the circumferentially extending joints 22a and 22b, both the outer wall 14a and the inner wall 14b can be made of heat-stable / heat-fusible yarn, or even both can be entirely composed of heat-stable / heat-fusible yarn, thereby maximizing the amount of molten material forming the first joint 22a and the second joint 22b.

[0024] The braided tubular inner wall 14b and the braided tubular outer wall 14a can be woven from yarns of different colors. Therefore, different colored yarns can be used to identify different functions. For example, one wall (such as the outer wall 14a) can be colored with orange yarn to indicate high-voltage characteristics, thereby alerting the personnel observing the sleeve 10; while the other wall (such as the inner wall 14b) can be formed using standard, lower-cost black yarn or other materials, thereby maximizing the cost-effectiveness of manufacturing the sleeve 10.

[0025] According to another aspect, one of the braided tubular inner wall 14b and the braided tubular outer wall 14a may be at least partially braided using 100% recycled yarn, while the other of the braided tubular inner wall 14b and the braided tubular outer wall 14a may be at least partially braided using 100% virgin yarn. Furthermore, one of the braided tubular inner wall 14b and the braided tubular outer wall 14a may be entirely braided using 100% recycled yarn, while the other of the braided tubular inner wall 14b and the braided tubular outer wall 14a may be entirely braided using 100% virgin yarn.

[0026] According to another aspect of the invention, a method of constructing a multilayer tubular sleeve 10 includes: weaving a tubular inner wall 14b extending around a central axis 18 between opposing first inner ends 26a and second inner ends 26b; in the weaving operation, weaving a tubular outer wall 14a outside the tubular inner wall 14b such that the tubular outer wall 14a extends around the central axis 18 between opposing first outer ends 24a and second outer ends 24b; joining the first inner end 26a to the first outer end 24a via a first coupling joint 22a; and joining the second inner end 26b to the second outer end 24b via a second coupling joint 22b such that the inner wall 14b remains separated from the outer wall 14a along a length L extending between the first coupling joint 22a and the second coupling joint 22b.

[0027] The method may further include: joining a first inner end portion 26a to a first outer end portion 24a during a thermal cutting operation, and joining a second inner end portion 26b to a second outer end portion 24b during a thermal cutting operation.

[0028] The method may also include thermoforming at least one or both of the tubular outer wall 14a and the tubular inner wall 14b during a thermoforming (also known as thermoforming or thermoshaping) process to maintain the wall 14 in a cylindrical tube shape.

[0029] The method may further include: joining a first inner end portion 26a to a first outer end portion 24a during a thermal cutting operation, and joining a second inner end portion 26b to a second outer end portion 24b during a thermal cutting operation.

[0030] The method may also include weaving a tubular inner wall 14b and a tubular outer wall 14a, such that the two contain yarns of different colors, the different colors of the yarns representing different types of protection.

[0031] Figure 3 Another embodiment of a multilayer braided sheath tube constructed according to the present invention is shown, hereinafter referred to as sheath 110, wherein the same features are identified by reference numerals differing by 100.

[0032] The sleeve 110 has an elongated, multi-layered braided wall 114, which includes: a circumferentially continuous tubular outer wall 114a, a circumferentially continuous tubular inner wall 114b defining an inner cavity 116, and at least one circumferentially continuous tubular intermediate wall 114c extending along a central longitudinal axis 118 between opposing open ends 119, 120. It should be understood that the circumferentially continuous tubular structure ensures that the outer wall 114a, inner wall 114b, and intermediate wall 114c are seamless, without any longitudinally extending free sides, thus preventing the wall 114 from unfolding or opening along its length. An outer wall 114a extends about a central axis 118 between opposing first outer ends 124a and second outer ends 124b; an inner wall 114b extends about a central axis 118 between opposing first inner ends 126a and second inner ends 126b; at least one intermediate wall 114c (illustrated as a single wall, but not limited thereto) extends about a central axis 118 between opposing first intermediate ends 128a and second intermediate ends 128b. The first inner end 126a is joined to the first outer end 124a and the first intermediate end 128a via a circumferentially extending joint 122a, and the second inner end 126b is joined to the second outer end 124b and the second intermediate end 128b via a circumferentially extending joint 122b. The inner wall 114b, outer wall 114a, and intermediate wall 114c are completely separated from each other along a length L extending between the joints 122a and 122b, thereby allowing the inner wall 114b, outer wall 114a, and intermediate wall 114c to slide axially and expand and contract independently of each other. This ability to slide and expand independently along the axial direction enhances the impact resistance of wall 114 by allowing walls 114a, 114b, and 114c to move and displace relative to each other and to better absorb impact forces. The intermediate wall 114c can be woven around the inner wall 114b, and the outer wall 114a can be woven around the intermediate wall 114c, wherein each wall 114a, 114b, and 114c can be woven with the same or substantially the same diameter. However, to enhance impact resistance and flexibility, the intermediate wall 114c may be woven with a diameter slightly larger than that of the inner wall 114b, and the outer wall 114a may be woven with a diameter slightly larger than that of the intermediate wall 114c, thereby providing a small gap between the respective walls 114a, 114b, 114c to allow relative movement between the walls 114a, 114b, 114c during impact and bending.

[0033] According to another aspect, the construction method of the multilayer tubular sleeves 10, 110 includes: weaving tubular inner walls 14b, 114b extending around the central axis 18, 118 between opposing first inner ends 26a, 126a and second inner ends 26b, 126b; and during the weaving process, weaving tubular outer walls 14a, 114a outside the tubular inner walls 14b, 114b, such that the tubular outer walls 14a, 114a around the central axis 18, 118 at opposing first outer wall ends 24a, 124a and second inner ends 26b, 126b. The inner walls 14b and 114b extend between the two outer wall ends 24b and 124b; and the first inner ends 26a and 126a are joined to the first outer ends 24a and 124a at the first joints 22a and 122a, and the second inner ends 26b and 126b are joined to the second outer ends 24b and 124b at the second joints 22b and 122b, and the inner walls 14b and 114b are completely separated from the outer walls 14a and 114a within the length L of the extension between the joints 22a and 122a and 22b and 122b.

[0034] The method may further include: joining the first inner ends 26a, 126a to the first outer ends 24a, 124a during a thermal cutting operation, and joining the second inner ends 26b, 126b to the second outer ends 24b, 124b during a thermal cutting operation.

[0035] The method may further include: thermoforming at least one or all of the tubular outer walls 14a, 114a and / or the tubular inner walls 14b, 114b during the hot rounding process, so that the walls 14, 114 maintain the shape of a cylindrical tube.

[0036] The method may further include: combining the first inner ends 26a, 126a with the first outer ends 24a, 124a in a thermal cutting operation, and combining the second inner ends 26b, 126b with the second outer ends 24b, 124b in a thermal cutting operation.

[0037] The method may further include: in the weaving operation, weaving at least one (shown as a single) tubular intermediate wall 114c outside the tubular inner wall 114b, the tubular intermediate wall 114c extending about a central axis 118 between opposing first intermediate ends 128a and second intermediate ends 128b; and joining the first inner end 126a, the first outer end 124a and the first intermediate end 128a together at a first joint 122a, joining the second inner end 126b, the second outer end 124b and the second intermediate end 128b together at a second joint 122b, and completely separating the inner wall 114b, the outer wall 114a and the intermediate wall 114c from each other along a length L extending between the first joint 122a and the second joint 122b.

[0038] Obviously, based on the above description, the present invention can be modified and varied in many ways. All features of the claims and embodiments can be combined with each other, as long as such combinations do not contradict each other. Therefore, it should be understood that within the scope of the appended claims, the present invention can be implemented in ways different from those specifically described.

Claims

1. A multi-layer tubular sleeve, comprising: A braided tubular inner wall extends around a central axis between a first inner end of an opening and a second inner end of an opening opposite the first inner end; as well as The inner wall is a braided tubular outer wall that extends around a central axis between a first outer end of an opening and a second outer end of an opening opposite to the first outer end. The first inner end is connected to the first outer end via a first connecting joint, and the second inner end is connected to the second outer end via a second connecting joint. The inner wall is substantially separate from the outer wall along the length extending between the first and second connecting joints.

2. The multilayer tubular sleeve as claimed in claim 1, wherein at least one of the braided tubular inner wall and the braided tubular outer wall is woven from heat-setting yarn, and the heat-setting yarn is heat-setting treated to offset the at least one braided tubular inner wall and the braided tubular outer wall into a cylindrical tube.

3. The multilayer tubular sleeve as claimed in claim 2, wherein each of the braided tubular inner wall and the braided tubular outer wall is woven from heat-setting yarn, and the heat-setting yarn is heat-setting treated to offset the braided tubular inner wall and the braided tubular outer wall into a cylindrical tube.

4. The multilayer tubular sleeve as claimed in claim 3, wherein each of the braided tubular inner wall and the braided tubular outer wall is entirely woven from heat-setting yarn, and the heat-setting yarn is heat-setting to offset the braided tubular inner wall and the braided tubular outer wall into a cylindrical tube.

5. The multilayer tubular sleeve as claimed in claim 2, wherein the braided tubular inner wall and the braided tubular outer wall are woven with yarns containing different colors from each other.

6. The multilayer tubular sleeve as claimed in claim 1, wherein the first joint is a first thermomelted welded joint, and the second joint is a second thermomelted welded joint.

7. The multilayer tubular sleeve of claim 6, wherein the braided tubular inner wall is completely separated from the braided tubular outer wall over its entire length extending between the first thermofusion weld joint and the second thermofusion weld joint.

8. The multilayer tubular sleeve as claimed in claim 7, wherein the first thermofusion weld joint and the second thermofusion weld joint are continuous in the circumferential direction.

9. The multilayer tubular sleeve as claimed in claim 1, wherein at least one of the braided tubular inner wall and the braided tubular outer wall is woven from 100% recycled yarn.

10. The multilayer tubular sleeve as described in claim 1, further comprising: A braided tubular intermediate wall extends around a central axis between a first intermediate end of an opening and a second intermediate end of an opening opposite to the first intermediate end, the tubular intermediate wall being substantially separate from the tubular inner wall and the tubular outer wall along the length extending between the first and second joints.

11. A multi-layered tubular sleeve, comprising the following parts: A braided tubular inner wall extends around a central axis between a first inner end of an opening and a second inner end of an opening opposite the first inner end; and The inner wall is a braided tubular outer wall that extends around a central axis between a first outer end of an opening and a second outer end of an opening opposite to the first outer end. The first inner end is connected to the first outer end via a first connecting joint, and the second inner end is connected to the second outer end via a second connecting joint. The inner wall is substantially separate from the outer wall along the length extending between the first and second connecting joints.

12. The multilayer tubular sleeve of claim 11, wherein at least one of the braided tubular inner wall and the braided tubular outer wall is woven from heat-setting yarn, and the heat-setting yarn is heat-setting treated to offset the at least one braided tubular inner wall and the braided tubular outer wall into a cylindrical tube.

13. A method for manufacturing a multilayer tubular sleeve, comprising: A tubular inner wall is woven around a central axis between a first inner end and a second inner end opposite to the first inner end; A tubular outer wall is woven onto the tubular inner wall by a weaving operation, the tubular outer wall extending about a central axis between a first outer end and a second outer end opposite the first outer end; and The first inner end is joined to the first outer end by a first connecting joint, and the second inner end is joined to the second outer end by a second connecting joint, thereby separating the inner wall from the outer wall along the length extending between the first connecting joint and the second connecting joint.

14. The method of claim 13, further comprising forming the first and second joints by a thermal cutting operation.

15. The method of claim 14, further comprising performing a thermal cutting operation using a hot wire cutter.

16. The method of claim 14, further comprising thermoforming the heat-stable yarns of the tubular outer wall and the tubular inner wall during the thermal rounding process, so that the tubular outer wall and the tubular inner wall maintain the shape of a cylindrical tube.

17. The method of claim 13, further comprising thermoforming at least one of the heat-stable yarns of the tubular outer wall and the tubular inner wall during the thermal rounding process, so that the tubular outer wall and the tubular inner wall maintain the shape of a cylindrical tube.

18. The method of claim 17, further comprising thermoforming the heat-stable yarns of the tubular outer wall and the tubular inner wall during the thermal rounding process.

19. The method of claim 13, further comprising: Before weaving the tubular outer wall, a tubular intermediate wall is woven around the tubular inner wall by a weaving operation. The tubular intermediate wall extends between a first intermediate end of an opening and a second intermediate end of an opening opposite to the first intermediate end. The first intermediate end is joined to the inner end and the first outer end by a first joint, and the second intermediate end is joined to the second inner end and the outer end by a second joint. The tubular intermediate wall is then separated from the tubular inner wall and the tubular outer wall along the length extending between the first joint and the second joint.

20. The method of claim 13, further comprising: The inner and outer walls of the tube are woven together to contain yarns of different colors.

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