Self-wrapping multilayer wear-resistant and EMI-resistant sleeve, and method for constructing the same.

Abstract

A wrapable abrasion-resistant and EMI-resistant sleeve for routing elongated components and protecting them from EMI exposure, while also providing additional mechanical protection against other environmental conditions such as abrasion, impact, and contamination. The sleeve comprises a woven outer layer having opposing outer edges extending longitudinally between opposing ends of the woven outer layer. The woven outer layer includes warp filaments extending substantially parallel to the opposing edges and weft filaments extending substantially transversely to the warp filaments. The sleeve comprises a textile inner layer having opposing inner edges extending longitudinally between opposing ends. The textile inner layer includes conductive filaments entangled with each other to be electrically conductive. The weft filaments of the woven outer layer are thermoformed and biased so that they overlap each other at the opposing outer and inner edges.

Description

Technical Field

[0001] Cross - Reference to Related Applications This PCT international patent application claims the benefit and priority of U.S. Patent Application No. 18 / 220,546, filed on July 11, 2023, the entire disclosure of which is incorporated herein by reference in its entirety.

Background Art

[0002] Background of the Invention 1. Technical Field The present invention generally relates to a textile sleeve for protecting an elongated member, and more particularly to a self - winding multi - layer sleeve having abrasion - resistant and electromagnetic interference - resistant properties. 2. Related Art For example, it is known to enclose and protect an elongated member such as a wire and a wire harness within a wrap - around woven sleeve to provide protection to the wire from electromagnetic interference (EMI). However, the sleeve is generally susceptible to wear due to abrasion. Also, in addition to having abrasion resistance, a wrap - around sleeve should be lightweight, flexible such that the sleeve can be routed around corners and along tortuous paths to provide optimal protection in physically harsh environments such as those encountered in automobiles, and further have high durability and impact resistance.

Summary of the Invention

Means for Solving the Problems

[0003] Summary of the Invention One aspect of the present invention provides a wrapable abrasion-resistant and EMI-resistant sleeve for routing and protecting an elongated member from EMI exposure, while also providing mechanical protection against other environmental conditions such as abrasion, impact, and contamination. The sleeve comprises a woven outer layer having opposing outer edges extending longitudinally between opposing ends of the woven outer layer. The woven outer layer includes warp filaments extending substantially parallel to the opposing edges and weft filaments extending substantially transversely to the warp filaments. The sleeve comprises a textile inner layer having opposing inner edges extending longitudinally between opposing ends. The textile inner layer includes conductive filaments entangled with each other so as to be electrically conductive. The weft filaments of the woven outer layer are thermoformed and biased so as to overlap each other at the opposing outer and inner edges.

[0004] According to another aspect of the present invention, the woven outer layer is woven using only non-conductive filaments. According to another aspect of the present invention, the inner conductive filament is a non-conductive filament coated with a conductive coating.

[0005] According to another aspect of the present invention, the inner layer of conductive filaments is braided with non-conductive filaments.

[0006] According to another aspect of the present invention, the non-conductive filament of the inner layer is a monofilament.

[0007] According to another aspect of the present invention, the non-conductive filament of the inner layer is a multifilament.

[0008] According to another aspect of the present invention, the inner layer of the textile is entangled only with conductive filaments.

[0009] According to another aspect of the present invention, the conductive filament is a wire. According to another aspect of the present invention, the woven outer layer and the textile inner layer are sewn together near their opposing outer and inner edges.

[0010] According to another aspect of the present invention, the non-conductive filaments of the woven outer layer include monofilaments.

[0011] According to another aspect of the present invention, the non-conductive filaments of the woven outer layer include multifilaments.

[0012] According to another aspect of the present invention, the weft filament is provided as a completely monofilament, and the warp filament is provided comprising a multifilament.

[0013] According to another aspect of the present invention, the non-conductive filaments of the woven outer layer are entirely monofilament.

[0014] According to another aspect of the present invention, the sleeve further comprises a drain wire fixed to the inner layer of the textile and electrically communicating with the inner layer.

[0015] According to another aspect of the present invention, the drain wire extends outward from at least one of the opposing ends of the sleeve to ground the sleeve to a suitable earth source.

[0016] According to another aspect of the present invention, the drain wire is a braided or twisted metal wire.

[0017] Another aspect of the present invention provides a method for constructing a self-wrapping abrasion-resistant and EMI-resistant sleeve for routing and protecting an elongated member. The method involves weaving warp filaments together with weft filaments to form an outer layer having opposing outer edges extending longitudinally between opposing ends, the warp filaments extending generally parallel to the opposing edges, and the weft filaments extending generally transversely to the warp filaments. Furthermore, the filaments are entangled to form a textile inner layer having opposing inner edges extending longitudinally between opposing ends, and at least a portion of the filaments in the textile inner layer include conductive filaments entangled to be electrically conductive to each other. Furthermore, the outer layer is fixed to the inner layer to form a wall, and the wall is wrapped around a central longitudinal axis so that the opposing outer edges overlap with the opposing inner edges. Subsequently, the weft filaments of the woven outer layer are thermoformed to maintain the opposing outer and inner edges in a biased overlapping relationship.

[0018] According to another aspect of the present invention, the method may further include weaving the outer layer with only non-conductive filaments.

[0019] According to another aspect of the present invention, the method may further include forming a textile inner layer by entangling conductive filaments with non-conductive filaments.

[0020] According to another aspect of the present invention, the method may further include entangling the inner layer of conductive filaments with non-conductive filaments in the braiding process.

[0021] According to another aspect of the present invention, the method may further include entangling conductive filaments in the inner layer with non-conductive filaments in the weaving process.

[0022] According to another aspect of the present invention, the method may further include forming the inner layer of the textile using only conductive filaments.

[0023] According to another aspect of the present invention, the method may further include entangling an inner layer formed only of conductive filaments in a weaving process.

[0024] According to another aspect of the present invention, the method may further include entangling an inner layer formed only of conductive filaments in a braiding process.

[0025] According to another aspect of the present invention, the method may further include providing conductive filaments as non-conductive filaments coated with a conductive material.

[0026] According to another aspect of the present invention, the method may further include providing non-conductive filaments of the conductive filaments as monofilaments and / or multifilaments.

[0027] Brief Description of the Drawings These and other aspects, features, and advantages will become readily apparent to those skilled in the art in light of the detailed description of the presently preferred embodiments and best modes, the appended claims, and the accompanying drawings.

Brief Description of the Drawings

[0028] [Figure 1] FIG. 1 is a schematic perspective view of a self-wrapping abrasion and EMI sleeve that holds and protects an elongated member therein, constructed in accordance with one aspect of the present invention. [Figure 2] FIG. 2 is a cross-sectional view taken substantially along line 2-2 of FIG. 1 before the sleeve is disposed around the elongated member. [Figure 3A] FIG. 3A is an exploded perspective view of an inner layer and an outer layer of the sleeve of FIG. 1 according to one aspect of the present disclosure, fixed to each other and before being thermoformed into a self-wrapping configuration. [Figure 3B] FIG. 3B is an exploded perspective view of an inner layer and an outer layer of a sleeve according to another aspect of the present disclosure, fixed to each other and before being thermoformed into a self-wrapping configuration. [Figure 4A]Figure 4A is a perspective view of the braided inner layer according to one embodiment of this disclosure, before it is fixed to the outer layer. [Figure 4B] Figure 4B is a perspective view of the braided inner layer according to another aspect of this disclosure, before it is fixed to the outer layer. [Figure 5A] Figure 5A is a perspective view of a woven inner layer according to one embodiment of the present disclosure, before it is fixed to the outer layer. [Figure 5B] Figure 5B is a perspective view of a woven inner layer according to another aspect of this disclosure, before it is fixed to the outer layer. [Figure 6A] Figure 6A is a perspective view of a woven outer layer according to one embodiment of the present disclosure, before it is fixed to the inner layer. [Figure 6B] Figure 6B is a perspective view of a woven outer layer according to another aspect of this disclosure, before it is fixed to the inner layer. [Modes for carrying out the invention]

[0029] Detailed description of preferred embodiments Referring more closely to the drawings, Figure 1 shows a schematic diagram of a self-winding abrasion-resistant and EMI-resistant sleeve, hereafter referred to as sleeve 10, constructed according to one aspect of the present invention. Sleeve 10 has a self-winding elongated wall 12 for routing an elongated member, such as a wire or wire harness 14, and protecting it from exposure to EMI, abrasion, impact, and other environmental conditions such as contamination by fluids and debris. The elongated wall 12 has opposing edges 16, 17 that extend parallel or approximately parallel (not exactly parallel, but in the sense that someone casually looking at the edges 16, 17 would see and describe as parallel) to a central longitudinal axis 18 between opposing ends 19, 21, where the edges 16, 17 self-wind in an overlapping relationship in a "cigarette winding" manner to completely enclose the elongated member 14 within the central cavity 20 of sleeve 10. The cavity 20 is easily accessible along the entire length of the wall 12 by separating the opposing edges 16 and 17 from each other, and as a result, for example during maintenance, a radially elongated member 14 relative to the shaft 18 can be easily placed into the cavity 20 and, conversely, removed from the cavity 20. As shown in Figures 2, 3A, and 3B, the sleeve 10 comprises a woven outer layer 12a having opposing outer edges 16a and 17a extending longitudinally between the opposing ends 19a and 21a of the woven outer layer 12a. The woven outer layer 12a includes warp filaments 22 extending generally parallel to the opposing edges 16a and 17a and weft filaments 24 extending generally transversely to the warp filaments 22. The sleeve 10 further comprises a textile inner layer 12b having opposing inner edges 16b, 17b that extend longitudinally between opposing ends 19b, 21b of the textile inner layer 12b. The textile inner layer 12b includes conductive filaments 26 that are entangled with each other so as to be electrically conductive. The weft filaments 24 of the woven outer layer 12a are thermoformed through a thermoforming process while the wall 12 is wound around a appropriately sized (diameter) mandrel, and biased so that the opposing outer edges 16a, 17a and opposing inner edges 16b, 17b overlap each other.Conductive filaments, and conductive wires 26 having, for example, a diameter of about 0.05 to 0.2 mm, and in one non-limiting embodiment, a diameter of 0.8 to 1.2 mm (not limited by example), provide resistance to low-frequency EMI, such as below 100 MHz, and high-frequency EMI, such as above 1 GHz. To maximize protection against low-frequency EMI, the conductive filament 26 may be provided as a wire including individual continuous wire filaments or bundled wire filaments, such as a mini-braid of continuous wire filaments. The wire 26 may be provided having a copper core encapsulated by a tin outer layer, or copper-coated nickel, not limited by example. The conductive filament 26, according to another aspect of the disclosure, in one non-limiting embodiment, includes non-conductive filaments such as monofilaments or multifilaments coated with a conductive material, such as any conductive metal.

[0030] The wall 12 can be constructed to have any appropriate size, including length and diameter, depending on the application.

[0031] The woven outer layer 12a is woven solely of non-conductive filaments 28. The wall 12 is formed to self-wind by heat-setting (thermoforming) at least some or all of the non-conductive weft filaments 24 of the outer layer 12a into a curled shape, as described above, and biased so that the opposing edges 16, 17 overlap each other. The heat-set filaments 24 are provided as heat-settable monofilaments to maximize the self-curl bias when heat-set, and may also be provided as a polyphenylene sulfide material to provide an excellent balance of properties including high temperature resistance, chemical resistance, fluidity, dimensional stability, and electrical properties. Once the wall 12 is formed by fixing the outer layer 12a and the inner layer 12b together, it is wrapped around a mandrel having a predetermined diameter, and the opposing edges 16, 17 are arranged in a desired overlapping relationship. Then, appropriate heat is applied to the wall 12 so that the heat-settable weft yarn 24 of the outer layer 12a can be heat-set, in which case the heat-set weft yarn 24 takes on a curled shape with the radius of curvature of the mandrel, thereby providing the wall 12 with a source of internal bias to bias the opposing edges 16, 17 and maintain them in an overlapping relationship. Naturally, the opposing edges 16, 17 can be pulled apart from each other under appropriately applied external forces sufficient to overcome the bias imparted by the heat-set weft yarn 24, for example, as may be desired for mounting, maintenance, or replacement of elongated members 14. The non-conductive warp filaments 22 of the outer layer 12a may be provided as multifilaments (Figure 6A) and / or multifilaments (Figure 6B), depending on whether enhanced abrasion resistance is desired (monofilament in Figure 6A) or enhanced coverage is desired (multifilament in Figure 6B). It should be recognized that the weft filaments 24 may be provided entirely as monofilaments and the warp filaments may be provided entirely as multifilaments, or that the weft filaments 24 may be provided entirely as monofilaments and the warp filaments may be provided entirely as monofilaments.

[0032] The inner layer 12b may include conductive filaments 26 entangled with non-conductive filaments 30. According to one aspect of the present disclosure, the entanglement used to construct the inner layer 12b may include weaving the conductive filaments 26 together with the non-conductive filaments 30, as shown in Figures 3A and 5A. The non-conductive filaments 30 may be supplied as monofilaments and / or multifilaments. Alternatively, the inner layer 12b may be woven with conductive filaments 26 alone, as shown in Figure 5B. According to another aspect of the present disclosure, the entanglement used to construct the inner layer 12b may include braiding the conductive filaments 26 with non-conductive filaments 30, as shown in Figures 3B and 4A. The non-conductive filaments 30 may be supplied as monofilaments and / or multifilaments. Alternatively, the inner layer 12b may be braided with conductive filaments 26 alone, as shown in Figure 4B.

[0033] The woven outer layer 12a and the textile inner layer 12b are fixed to each other so as not to separate. According to one aspect of the present disclosure, the woven outer layer 12a and the textile inner layer 12b are sewn to each other near their respective opposing outer edges 16a, 17a and opposing inner edges 16b, 17b. This seam may be formed along the entire length of the opposing edges 16, 17.

[0034] The sleeve 10 may further include a drain wire 32 fixed to the inner layer 12b of the textile so as to be electrically connected to the conductive filament 26. According to another aspect of the present disclosure, the drain wire 32 extends outward from at least one of the opposing ends 19, 21 of the sleeve 10 to ground the sleeve 10 to a suitable grounding source (not shown). The drain wire 32 may be entangled with the inner layer 12b during the construction of the inner layer 12b in a weaving or braiding process.

[0035] According to another aspect of the present invention, a method is provided for constructing a self-wrapping abrasion-resistant and EMI-resistant sleeve 10 for routing and protecting an elongated member 14. The method includes weaving warp filaments 22 together with weft filaments 24 to form an outer layer 12a having opposing outer edges 16a, 17a extending longitudinally between opposing ends 19a, 21a, the warp filaments 22 extending generally parallel to the opposing edges, and the weft filaments 24 extending generally transversely to the warp filaments 22. Furthermore, the filaments are entangled to form a textile inner layer 12b having opposing inner edges 16b, 17b extending longitudinally between opposing ends 19b, 21b, and at least a portion of the filaments of the textile inner layer 12b includes conductive filaments 26 that are entangled to be electrically conductive with each other. Furthermore, the outer layer 12a is fixed to the inner layer 12b to form a wall 12, and the wall 12 is wrapped around the central vertical axis 18 so that the opposing outer edges 17a and 17b overlap with the opposing inner edges 16a and 16b. After that, the weft filaments 24 of the woven outer layer 12a are thermoformed to maintain the opposing outer edges 17a and 17b and the opposing inner edges 16a and 16b in a biased overlapping relationship.

[0036] According to another aspect of the present invention, the method may further include weaving the outer layer 12a with only non-conductive filaments 28.

[0037] According to another aspect of the present invention, the method may further include forming the textile inner layer 12b by entangling the conductive filaments 26 of the inner layer 12b with non-conductive filaments 30.

[0038] According to another aspect of the present invention, the method may further include entangling the conductive filaments 26 of the inner layer 12b with the non-conductive filaments 30 in the braiding process.

[0039] According to another aspect of the present invention, the method may further include entangling the conductive filaments 26 of the inner layer 12b with the non-conductive filaments 30 in the weaving process.

[0040] According to another aspect of the present invention, the method may further include forming the inner layer 12b of the textile with only the conductive filaments 26.

[0041] According to another aspect of the present invention, the method may further include entangling an inner layer 12b formed solely of conductive filaments 26 during the weaving process.

[0042] According to another aspect of the present invention, the method may further include entangling the inner layer 12b, which is formed solely of conductive filaments 26, during the braiding process.

[0043] According to another aspect of the present invention, the method may further include providing a conductive filament 26 as a non-conductive monofilament and / or multifilament coated with a conductive material such as a conductive metal coating.

[0044] Clearly, many modifications and variations of the present invention are possible in light of the above teachings. All features of all claims and all embodiments are intended to be combined with one another, insofar as such combinations do not contradict each other. It should be understood that, within the scope of the appended claims, the present invention may be carried out in ways other than those specifically described.

Claims

1. A self-wrapping, wear-resistant, and EMI-resistant sleeve for routing and protecting an elongated member, wherein the self-wrapping, wear-resistant, and EMI-resistant sleeve is The woven outer layer comprises a woven outer layer having opposing outer edges extending longitudinally between opposing ends of the woven outer layer, the woven outer layer having warp filaments extending substantially parallel to the opposing edges and weft filaments extending substantially transversely to the warp filaments, and the self-wrapping abrasion-resistant and EMI-resistant sleeve further, It comprises a textile inner layer having opposing inner edges that extend longitudinally between opposing ends, and the textile inner layer has conductive filaments that are intertwined with each other so as to be electrically conductive. The weft filaments of the woven outer layer are thermoformed and biased so that the opposing outer and inner edges overlap each other, in a self-wrapping, abrasion-resistant, and EMI-resistant sleeve.

2. The self-wrapping, abrasion-resistant, and EMI-resistant sleeve according to claim 1, wherein the woven outer layer is woven solely of non-conductive filaments.

3. The self-winding, wear-resistant, and EMI-resistant sleeve according to claim 2, wherein the conductive filament of the inner layer is braided with a non-conductive filament.

4. The self-wrapping, wear-resistant, and EMI-resistant sleeve according to claim 3, wherein the non-conductive filament of the inner layer is a monofilament.

5. The self-wrapping, wear-resistant, and EMI-resistant sleeve according to claim 3, wherein the non-conductive filament of the inner layer is a multifilament.

6. The self-wrapping, abrasion-resistant, and EMI-resistant sleeve according to claim 2, wherein the inner layer of the textile is entangled only with conductive filaments.

7. The self-winding, wear-resistant, and EMI-resistant sleeve according to claim 1, wherein the conductive filament is a non-conductive filament coated with a conductive coating.

8. The self-wrapping abrasion-resistant and EMI-resistant sleeve according to claim 1, wherein the woven outer layer and the textile inner layer are sewn together near the opposing outer and inner edges.

9. The self-wrapping, wear-resistant, and EMI-resistant sleeve according to claim 2, wherein the non-conductive filaments of the woven outer layer include monofilaments.

10. The self-wrapping, wear-resistant, and EMI-resistant sleeve according to claim 9, wherein the non-conductive filaments of the woven outer layer include multifilaments.

11. The self-wrapping, wear-resistant, and EMI-resistant sleeve according to claim 10, wherein the weft filament is provided entirely as a monofilament, and the warp filament is provided comprising a multifilament.

12. The self-wrapping, wear-resistant, and EMI-resistant sleeve according to claim 9, wherein the non-conductive filaments of the woven outer layer are entirely monofilaments.

13. The self-winding, wear-resistant, and EMI-resistant sleeve according to claim 1, further comprising a drain wire fixed to the inner layer of the textile so as to be electrically connected to the conductive filament.

14. The drain wire extends outward from at least one of the opposing ends, according to claim 13, in the self-wrapping, wear-resistant, and EMI-resistant sleeve.

15. A method for constructing a self-wrapping, wear-resistant, and EMI-resistant sleeve for routing and protecting an elongated member, wherein the method is: The method includes weaving warp filaments together with weft filaments to form an outer layer having opposing outer edges extending longitudinally between opposing ends, wherein the warp filaments extend generally parallel to the opposing edges, and the weft filaments extend generally transversely to the warp filaments, and the method further includes The method includes intertwining filaments to form a textile inner layer having opposing inner edges extending longitudinally between opposing ends, wherein at least a portion of the filaments includes conductive filaments intertwined to be electrically conductive with each other, and the method further includes The outer layer is fixed to the inner layer to form a wall, Wrapping the wall around the central vertical axis so that the opposing outer edges overlap with the opposing inner edges, A method comprising thermoforming the weft filaments of the woven outer layer to maintain the opposing outer edges and opposing inner edges in a biased overlapping relationship.

16. The method according to claim 15, further comprising weaving the outer layer using only non-conductive filaments.

17. The method according to claim 16, further comprising forming the textile inner layer by intertwining the conductive filaments of the inner layer with non-conductive filaments.

18. The method according to claim 17, further comprising entangling the conductive filaments of the inner layer with non-conductive filaments in the braiding process.

19. The method according to claim 17, further comprising entangling the conductive filaments of the inner layer with non-conductive filaments in the weaving process.

20. The method according to claim 16, further comprising forming the inner layer of the textile with only the conductive filaments.

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