Self-wrapping textile sleeve having wear indicator yarn and method of construction thereof

Abstract

A fabric sleeve for routing and protecting an elongated member includes a wall having opposed edges extending longitudinally in a generally parallel relationship with a central longitudinal axis between opposed ends. The wall includes warp yarns extending longitudinally between opposed ends and weft yarns extending circumferentially about the central longitudinal axis. At least some of the weft yarns are provided as bicomponent yarns having a central core of heat set material that urges the opposed edges into overlapping relationship with one another, and an outer sheath surrounding the central core. The central core and outer sheath are different colors from one another such that if a portion of the outer sheath is torn or worn, the central core becomes identifiable and visible.

Description

[Technical field]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 303,450, filed January 26, 2022, and priority to U.S. Provisional Patent Application No. 18 / 101,368, filed January 25, 2023, each of which is incorporated by reference in its entirety.

[0002] FIELD OF THEINVENTION The present invention relates generally to a woven sleeve for protecting an elongated member, and more particularly to a self-wrapping woven sleeve. [Background technology]

[0003] It is known to encase and protect elongated members, such as wires and wire harnesses, in protective woven sleeves, for example in automobiles, aircraft, or aerospace vehicles, to provide protection for the wires against the effects of abrasion, fluids, and heat. In order to provide the desired protection for the elongated members, the physical integrity of the woven fabric forming the walls of the sleeve must not be compromised. Although woven sleeves generally provide adequate protection for elongated members, such as wire harnesses, conduits, etc., protected within the central cavity of the woven sleeve, the desired protection may be reduced if the woven fabric becomes worn or otherwise damaged. If one or more threads of the woven fabric become worn, the overall structure of the woven fabric may eventually be compromised, particularly if the worn thread breaks. If the structure of the woven fabric is compromised, the level of protection for the elongated members may be reduced and therefore the intended function of the elongated members may be compromised. It is therefore desirable to know when the structural integrity of the woven sleeve becomes compromised to allow appropriate maintenance to be performed on the sleeve before the intended function of the elongated members is compromised. Summary of the Invention [Means for solving the problem]

[0004] One aspect of the present invention provides a woven sleeve having one or more indicator yarns that indicate the presence of wear before the structural integrity of the woven sleeve is compromised to a degree that would otherwise degrade the intended performance of the elongated member.

[0005] Another aspect of the invention provides one or more indicator yarns that are heat set to circumferentially bound a central cavity of a woven sleeve, biasing opposing edges of the woven wall of the sleeve into overlapping relationship to prevent ingress of contamination into the central cavity of the sleeve.

[0006] Another aspect of the present invention provides one or more indicator threads to change color in areas that become compromised to provide a proactive indication that it is time to replace the woven sleeve to avoid the level of protection desired by the woven sleeve being compromised to a degree that would otherwise degrade the intended performance of the elongated member.

[0007] In accordance with these and other aspects of the invention, a woven sleeve is provided having an elongated wall configured to bound a cavity extending through a central longitudinal axis of the sleeve for routing and protecting an elongated member within the cavity. The wall has opposed edges extending longitudinally in a generally parallel relationship to one another between opposed ends. The wall includes warp yarns extending generally parallel to the opposed edges and weft yarns extending generally transversely to the warp yarns. At least some of the weft yarns are formed from a heat-settable material such that, when heat-set, the opposed edges are urged into overlapping relationship to circumferentially bound the cavity. At least some of the warp yarns and / or weft yarns include bicomponent yarns having a central core and an outer sheath surrounding and encapsulating the central core. The central core and the outer sheath are different colors from one another such that, if the outer sheath is torn or worn, the central core becomes identifiable and visible.

[0008] According to another aspect of the invention, at least some of the weft yarns can be provided as bicomponent yarns, the bicomponent weft yarns having at least one of a central core and an outer sheath as a heat settable material.

[0009] In accordance with another aspect of the invention, at least some of the weft yarns may be provided as bicomponent yarns, the weft bicomponent yarns having a central core of a heat settable material.

[0010] According to another aspect of the invention, the entire weft yarn may be provided as a bicomponent yarn. According to another aspect of the invention, the entire warp yarn may be provided as a bicomponent yarn.

[0011] In accordance with another aspect of the invention, all of the weft and warp yarns can be provided as bicomponent yarns, with at least some of the weft bicomponent yarns having a central core as a heat settable material.

[0012] According to another aspect of the invention, the thickness of the outer sheath of the bicomponent yarn can be provided having a predetermined thickness such that when the central core is exposed, it provides sufficient protection to the elongated member to allow smooth performance by the elongated member and therefore time to replace the woven sleeve without compromising the performance of the elongated member.

[0013] According to another aspect of the invention, an outer sheath is provided having a maximum first outer diameter and a central core is provided having a maximum second outer diameter, the maximum second outer diameter being between 5-95% of the maximum first outer diameter.

[0014] According to another aspect of the invention, an outer sheath is provided having a maximum first outer diameter and a central core is provided having a maximum second outer diameter, the maximum second outer diameter being between 50-80% of the maximum first outer diameter.

[0015] In accordance with another aspect of the invention, a woven sleeve for routing and protecting an elongated member includes a wall having opposed edges extending longitudinally in a generally parallel relationship about a central longitudinal axis between opposed ends, the wall including warp yarns extending longitudinally between the opposed ends and weft yarns extending circumferentially about the central longitudinal axis, at least some of the weft yarns being formed from bicomponent yarns having a central core of heat set material urging the opposed edges into overlapping relationship with one another and an outer sheath surrounding the central core, the central core and the outer sheath being different colors such that if a portion of the outer sheath tears or wears, the central core becomes identifiable and visible, thereby indicating that it is time to repair or replace the woven sleeve.

[0016] In accordance with another aspect of the invention, a fabric sleeve for routing and protecting an elongated member includes a wall having opposed edges extending longitudinally in a generally parallel relationship with a central longitudinal axis between opposed ends, the wall including warp yarns extending longitudinally between opposed ends and weft yarns extending circumferentially about the central longitudinal axis, at least some of the weft yarns being formed from bicomponent yarns having a central core of heat set material urging the opposed edges into overlapping relationship with one another and an outer sheath surrounding the central core, the central core and the outer sheath being different colors from one another such that if a portion of the outer sheath is torn or worn away, the central core becomes identifiable and visible.

[0017] According to another aspect of the invention, a method of constructing a protective sleeve is provided. The method includes weaving an elongated wall having opposed edges extending longitudinally in a generally parallel relationship to one another between opposed ends, and heat setting the wall to urge the opposed edges into overlapping relationship to bound a cavity extending a central longitudinal axis of the sleeve for routing and protecting the elongated member within the cavity. The method further includes weaving the wall including warp yarns extending generally parallel to the opposed edges and weft yarns extending generally transverse to the warp yarns, and providing at least some of the weft yarns formed from a heat-settable material such that, when heat set, the opposed edges are urged into overlapping relationship to circumferentially bound the cavity. The method further includes providing at least some of the warp and / or weft yarns as bicomponent yarns having a central core and an outer sheath surrounding and encapsulating the central core, the central core and the outer sheath being different colors from one another such that, if the outer sheath is torn or worn, the central core becomes identifiable and visible.

[0018] According to another aspect of the invention, the method can further include providing an entire weft yarn comprising bicomponent yarn.

[0019] According to another aspect of the invention, the method may further include providing at least some of the warp yarns comprising bicomponent yarns.

[0020] According to another aspect of the invention, the method can further include providing an outer sheath having a maximum first outer diameter and providing a central core having a maximum second outer diameter, the maximum second outer diameter being between 5-95% of the maximum first outer diameter.

[0021] According to another aspect of the invention, the method can further include providing a maximum second outer diameter that is between 20-40% of the maximum first outer diameter.

[0022] According to another aspect of the invention, a method is provided for visually indicating when a protective self-rolling sleeve, woven with warp and weft yarns, wrapped around an elongated member to be protected needs to be changed before the elongated member is compromised. The method includes providing at least some of the warp and / or weft yarns as bicomponent yarns having a central core and an outer sheath that surrounds and encapsulates the central core, the central core and the outer sheath being different colors from one another, such that when the outer sheath tears or wears, the central core becomes identifiable and visible, thereby indicating that it is time to replace the protective self-rolling sleeve.

[0023] These and other aspects, features, and advantages will become readily apparent to those of ordinary skill in the art in view of the following detailed description of the presently preferred embodiments and best mode, the appended claims, and the accompanying drawings. [Brief description of the drawings]

[0024] [Figure 1] FIG. 1 is a schematic perspective view of a woven, self-wrapping sleeve constructed in accordance with one aspect of the present invention, the sleeve shown being wrapped around and protecting an elongated member therein. [Diagram 2] 2 is an enlarged schematic partial view of the woven wall of the woven self-wrapping sleeve of FIG. 1; [Figure 3A] FIG. 2 is an end view of an indicator bicomponent yarn constructed in accordance with a non-limiting embodiment of the present invention shown in an unworn condition. [Figure 3B] FIG. 3B is a view similar to FIG. 3A showing the indicator bicomponent yarn in a worn condition, with the central core of the bicomponent yarn becoming identifiable and visible, indicating it is time to replace the worn self-wrapping sleeve. [Figure 4] 1 is a woven diagram of a woven sleeve constructed in accordance with one aspect of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0025] Referring more particularly to the drawings, FIG. 1 illustrates a schematic diagram of a self-wrapping woven sleeve, hereinafter referred to as sleeve 10, constructed in accordance with one embodiment of the present invention. Sleeve 10 has a self-wrapping elongated wall, hereinafter referred to as wall 12, for routing an elongated member, such as a fluid conduit, gas conduit, wire, or wiring harness 14, and protecting it from, for example, exposure to abrasion and ingress of contamination, debris, and the like. Wall 12 has opposed longitudinally extending edges 16, 17 extending generally parallel to a central longitudinal axis 18 between opposed ends 19, 21. Edges 16, 17 are biased into overlapping relationship with one another in a "cigarette wrap" manner to completely surround elongated member 14 within a central cavity 20 of sleeve 10. The bias imparted by wall 12 is what causes wall 12 to be "self-wrapping." Thus, while in a relaxed state, opposed edges 16, 17 are biased into overlapping relationship with one another. Cavity 20 extends along a central longitudinal axis 18 and is readily accessible along the entire length of wall 12 by manually separating opposing edges 16, 17 from one another under an applied force sufficient to cause the opposing edges 16, 17 to separate against a bias provided by wall 12. As such, elongated member 14 can be readily positioned within cavity 20 radially relative to axis 18 and, conversely, removed from cavity 20, such as during use.

[0026] The wall 12 is woven with warp yarns 22 extending generally parallel to the central longitudinal axis 18, and fill yarns, also commonly referred to as weft yarns 24, extending generally circumferentially around the wrapped wall 12 in a generally transverse relationship to the warp yarns 22. At least some or all of the weft yarns 24 are provided as heat-settable yarns, such that when the fill yarns 24 are heat-set into a heat-set state while in a curled wrapped configuration, the wall 12 is biased to self-curl under a bias imparted by the heat-set fill yarns 24, also referred to as self-wrap, such that the opposing edges 16, 17 are biased into an overlapping relationship with one another. The bias is imparted by the heat-set weft yarns 24 into a curled configuration about the central longitudinal axis 18, thereby causing the wall 12 to self-curl, also referred to as self-wrap. According to a non-limiting embodiment, the wall 12 can be woven in the weave pattern shown in FIG. 4, although it should be appreciated that any suitable weave pattern can be used depending on the requirements of the application.

[0027] Depending on the needs of the application, the wall 12 can be constructed having any suitable size, including length and diameter. When the wall 12 is in its self-wound tubular configuration, generally in the absence of externally applied forces, the edges 16, 17 preferably overlap one another in an at least slightly self-biased manner to completely enclose the central cavity 20, thus providing enhanced protection to the elongated member 14 contained in the cavity 20. The edges 16, 17 are easily extensible toward one another under a manually applied external force sufficient to overcome the shape memory bias heat-set in the weft yarns 24 to at least partially open and expose the cavity 20. Thus, the elongated member 14 can be easily placed within the cavity 20 during assembly or removed from the cavity 20 during use. Upon release of the manually applied external force, the opposing edges 16, 17 automatically return to their curled shape via the heat-set bias, whereby the opposing edges 16, 17 are in overlapping relationship with one another under the bias imparted by the heat-set weft yarns 24.

[0028] The warp yarns 22 can be provided comprising any suitable monofilament and / or multifilament material. As such, the warp yarns 22 can be provided entirely as monofilament, entirely as multifilament, or both monofilament and multifilament as desired. Multifilaments are used to extend "cover" protection and increase flexibility as desired. Multifilaments provide enhanced cover protection because the individual filaments of the multifilament can spread out and match adjacent yarns, thereby occupying an increased surface area compared to monofilament yarns. The warp yarns 22 can be provided with any desired thermoplastic material, such as, by way of example and not limitation, one or more of polyester, PPS, Nomex, and further include, by way of example and not limitation, inorganic materials, such as, by way of example and not limitation, one or more of fiberglass and basalt.

[0029] The weft yarns 24 can be provided comprising any suitable monofilament and / or multifilament material, including heat-settable monofilament and / or multifilament polymeric materials. As such, the weft yarns 24 can be provided as both heat-settable monofilaments (although non-heat-settable monofilaments can be used) and high coverage multifilaments. The monofilaments and multifilaments of the weft yarns 24 can be woven alternately with each other along the length of the sleeve 10 to enhance the self-wrapping ability of the wall 12 and to enhance the optical coverage to prevent viewing through the wall 12 to the cavity 20, thereby enhancing protection against the ingress of contamination. The weft yarns 24 can be provided with any desired thermoplastic material, such as, by way of example and not limitation, one or more of polyester, PPS, Nomex, and further include inorganic materials, such as, by way of example and not limitation, one or more of fiberglass and basalt.

[0030] At least some of the warp yarns 22 and / or weft yarns 24 include bicomponent yarns 26 (FIG. 3A) having a central core 28 and an outer sheath 30 that surrounds and encapsulates the central core 28. Although the bicomponent yarns 26 have a central core / outer sheath structure, they are considered monofilaments (single filaments) herein. The central core 28 and the outer sheath 30 are different colors from one another, so that when a portion of the outer sheath 30 tears or wears through its thickness (t; FIG. 3A) (FIG. 3B), the color of the central core 28 becomes discernibly visible against the different color of the outer sheath 30 to an observer or imaging device viewing the exterior surface of the sleeve 10. When the central core 28 becomes exposed and visible, an indication is provided that it is time to replace the sleeve 10 before the functionality of the elongated member 14 is compromised. Although the outer sheath 30 has worn and / or cracked sufficiently to expose the central core 28, the wall 12, as a result of the unworn core 28, is still able to provide the desired protection to the elongated member 14 to prevent damage to the elongated member 14 for a period of time sufficient to allow repair and / or replacement of the sleeve 10. If the sleeve 10 is not repaired or replaced after the visual indication (the exposed central core 28) occurs, the likelihood of damage to the elongated member 14 increases over time.

[0031] According to an exemplary embodiment, at least some of the weft yarns 24 can be provided as bicomponent yarns 26. Additionally, the weft bicomponent yarns 26 can be provided with a central core 28 formed from one color of heat-settable material, preferably a bright, easily visualized color, while the outer sheath 30 is formed from a material of a different color. The central core 28 and the outer sheath 30 can be formed from the same material or different materials. According to a non-limiting embodiment, the central core 28 is formed from a heat-settable material, such as polyethylene, and the outer sheath is formed from an abrasion-resistant material, such as polyamide, although it is contemplated that the central core 28 and the outer sheath 30 can be formed from the same heat-settable material. However, it is contemplated that the central core 28 can be formed from a non-heat-settable material, and the outer sheath 30 is formed from a heat-settable material. According to another exemplary embodiment, the entire weft yarns 24 can be provided as bicomponent yarns 26, with at least some or all of the bicomponent yarns 26 including a heat-settable central core 28. According to yet another exemplary embodiment, all of the warp yarns 22 may be provided as bicomponent yarns 26, with the central core 28 formed having a material of a first color, and the outer sheath 30 formed from a material of a different second color. Thus, in view of the above, all of the weft yarns 24 and all of the warp yarns 22 may be provided as bicomponent yarns 26, with at least some of the weft bicomponent yarns 26 having the central core 28 as a heat settable material to facilitate formation of the sleeve 10 having its self-wrapped configuration.

[0032] According to another embodiment, the thickness (t) of the outer sheath 30 of the bicomponent yarn 26 is provided having a predetermined thickness such that, once the central core 28 is exposed, sufficient protection is provided by the woven sleeve 10 without immediate concern of damage to the elongated member 14. Thus, while the central core 28 is exposed, the uncompromised performance of the elongated member 14 is maintained by the sleeve 10 for a period of time (the period of time generally depends on the harness of the surrounding atmosphere, but in any case, a typical application may allow weeks or months for repairing and / or replacing the sleeve 10 without compromising the useful performance of the elongated member). The outer sheath 30 is provided having a maximum first outer diameter (D) and the central core 28 is provided having a maximum second outer diameter (d), the maximum second outer diameter (d) being between 5-95% of the maximum first outer diameter (D). Thus, the thickness (t) of the outer sheath is provided having a thickness (t) of the maximum outer diameter (D).

[0033]

number

[0034] %. In one exemplary embodiment, the maximum second outer diameter (d) is between 20-40% of the maximum first outer diameter (D), such that the thickness (t) of the outer sheath is in the range of between 30-40% of the maximum first outer diameter (D), and in one non-limiting embodiment, the maximum second outer diameter (d) is about 30% of the maximum first outer diameter (D), such that the thickness (t) of the outer sheath is about 35% of the maximum first outer diameter (D).

[0035] According to another aspect, a method of constructing the protective sleeve 10 is provided. The method includes weaving an elongated wall 12 having opposing edges 16, 17 extending longitudinally in generally parallel relationship to one another between opposing ends 19, 21, with warp yarns 22 extending generally parallel to the opposing edges 16, 17 and weft yarns 24 extending generally transversely to the warp yarns 22, providing at least some of the weft yarns 24 to be formed from a heat-settable material, and heat-setting the wall 12 to urge the opposing edges 16, 17 into overlapping relationship with one another to bound a cavity 20 extending along a central longitudinal axis 18 of the sleeve 10, wherein at least some of the warp yarns 22 and / or weft yarns 24 are bicomponent yarns having a central core 28 and an outer sheath 30 surrounding and encapsulating the central core 28, wherein the central core 28 and the outer sheath 30 are different colors from one another such that when the outer sheath 30 is torn or worn (FIG. 3B), the central core 28 becomes identifiable and visible.

[0036] 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 each other unless such combinations are mutually inconsistent. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.

Claims

1. A fabric sleeve for routing and protecting an elongated member, comprising: a wall having opposed edges extending longitudinally in generally parallel relationship to one another between opposed ends, said wall having warp yarns extending generally parallel to said opposed edges and weft yarns extending generally transversely to said warp yarns, at least some of said weft yarns being formed from a heat-settable material such that when said heat-settable material is heat-set, said opposed edges are biased into overlapping relationship with one another, at least some of said warp yarns and / or said weft yarns comprising bicomponent yarns having a central core and an outer sheath surrounding said central core, said central core and said outer sheath being of different colors such that when a portion of said outer sheath is torn or worn away, said central core becomes identifiable and visible; Woven sleeve.

2. The woven sleeve of claim 1 , wherein at least some of said weft yarns are provided as said bicomponent yarns, said weft bicomponent yarns having said central core as said heat settable material.

3. The woven sleeve of claim 2 , wherein the entirety of said weft yarns is provided as said bicomponent yarn.

4. The woven sleeve of claim 2 , wherein at least some of said warp yarns are provided as said bicomponent yarns.

5. The woven sleeve of claim 4 , wherein the entirety of said warp yarns are provided as said bicomponent yarns.

6. The woven sleeve of claim 1 , wherein at least some of said warp yarns are provided as said bicomponent yarns.

7. The woven sleeve of claim 6 , wherein the entirety of said warp yarns are provided as said bicomponent yarns.

8. The woven sleeve of claim 1 , wherein the entirety of the weft yarns and the warp yarns are provided as the bicomponent yarns, and at least some of the weft bicomponent yarns have the central core as the heat-settable material.

9. 2. The woven sleeve of claim 1, wherein the outer sheath is provided with a maximum first outer diameter and the central core is provided with a maximum second outer diameter, the maximum second outer diameter being between 5-95% of the maximum first outer diameter.

10. The woven sleeve of claim 9, wherein the maximum second outer diameter is between 20-40% of the maximum first outer diameter.

11. A fabric sleeve for routing and protecting an elongated member, comprising: a wall having opposed edges extending longitudinally between opposed ends in a generally parallel relationship to a central longitudinal axis, said wall having warp yarns extending longitudinally between said opposed ends and weft yarns extending circumferentially about said central longitudinal axis, at least some of said weft yarns being formed from bicomponent yarns having a central core and an outer sheath, at least one of said central core and outer sheath being formed from a heat set material which urges said opposed edges into overlapping relationship with one another, said central core and said outer sheath being different colors from one another such that when a portion of said outer sheath is torn or worn away, said central core becomes identifiable and visible; Woven sleeve.

12. The woven sleeve of claim 11 , wherein the entirety of said weft yarns is provided as said bicomponent yarn.

13. The woven sleeve of claim 11 , wherein at least some of said warp yarns are provided as said bicomponent yarns.

14. 12. The woven sleeve of claim 11, wherein the outer sheath is provided with a maximum first outer diameter and the central core is provided with a maximum second outer diameter, the maximum second outer diameter being between 5-95% of the maximum first outer diameter.

15. The woven sleeve of claim 14, wherein the maximum second outer diameter is between 20-40% of the maximum first outer diameter.

16. 1. A method of constructing a protective sleeve, comprising: weaving an elongated wall having opposed edges extending longitudinally in generally parallel relationship to one another between opposed ends, the elongated wall having warp yarns extending generally parallel to the opposed edges and weft yarns extending generally transverse to the warp yarns, providing at least some of the weft yarns to be formed from a heat settable material; heat setting the heat-settable material to urge the opposed edges into overlapping relationship to bound a cavity extending along a central longitudinal axis of the sleeve between the opposed ends; Including, at least some of the warp and / or weft yarns are bicomponent yarns having a central core and an outer sheath surrounding and encapsulating the central core, the central core and the outer sheath being of different colors such that if the outer sheath is torn or worn, the central core becomes identifiable and visible; method.

17. The method of claim 16, further comprising providing the entirety of the weft yarns comprising the bicomponent yarn.

18. The method of claim 16, further comprising providing at least some of the warp yarns comprising the bicomponent yarn.

19. 17. The method of claim 16, further comprising providing the outer sheath with a maximum first outer diameter and providing the central core with a maximum second outer diameter, the maximum second outer diameter being between 5-95% of the maximum first outer diameter.

20. The method of claim 19, further comprising providing the maximum second outer diameter that is between 20-40% of the maximum first outer diameter.

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