Impact resistant wrappable corrugated multi-layer woven sleeve and method of construction thereof

Abstract

A wrappable, wavy fabric sleeve and method of construction are provided. The sleeve includes a wall having opposing edges wrapped around a central axis in an overlapping relationship. The wall has multiple layers on top of each other. Each layer includes warp yarns extending generally parallel to the central axis woven with weft yarns extending generally transverse to the warp yarns. Each layer includes a plurality of annular first bands and a plurality of annular second bands alternating with each other along the length of the layer. The first bands of each layer include monofilament weft yarns and multifilament weft yarns, and the second bands of each layer include only one of monofilament weft yarns or multifilament weft yarns. The first bands lie on top of each other to form peaks, and the second bands lie on top of each other to form valleys, thereby giving the wall a wavy profile.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 975,124, filed February 11, 2020, and U.S. Utility Patent Application No. 17 / 173,134, filed February 10, 2021, the entire disclosures of which are incorporated herein by reference in their entireties.

[0002] FIELD OF THEINVENTION FIELD OF THEINVENTION This invention relates generally to textile sleeves for protecting elongated members, and more particularly to impact resistant, corrugated, wrappable, multi-layer woven tubular sleeves. [Background technology]

[0003] It is known to include elongated members, such as various types of wires, wire harnesses, cables, and conduits, in woven sleeves to provide protection to the elongated members against impact and abrasion, fluid and thermal effects. In applications where high impact resistance is required to prevent damage to the sleeve and contents therein, wrappable woven sleeves having multiple layers are known. Each of the layers of the multi-layer wall are typically formed to have the same, non-varying, uniform weave pattern throughout them, such that wrapping the walls of the sleeve brings the opposing edges into overlapping relationship with one another, thereby encircling the elongated object protected therein, and the multiple layers typically make the sleeve stiff and less flexible, thereby making it difficult to route the sleeve along a tortuous path without the sleeve buckling and / or opening, particularly along the overlapping edges.

[0004] What is needed, therefore, is a wrappable multi-layer woven sleeve that provides enhanced protection, particularly against impact, abrasion, and contamination, to an elongated member contained therein, while allowing it to be freely routed around a tortuous path, while maintaining a rolled configuration without buckling and / or opening along overlapping ends, while maintaining an aesthetically pleasing appearance, is economical to manufacture and assemble, and exhibits a long useful life. Summary of the Invention

[0005] One aspect of the disclosure provides a wrappable, corrugated, multi-layered woven sleeve for routing and protecting an elongated member. The sleeve includes an elongated, multi-layered wall having opposed edges extending lengthwise between opposed ends. The opposed edges are wrappable in overlapping relationship about a central axis to bound a central cavity. The wall has a plurality of layers extending in overlying relationship between opposed ends. Each of the layers includes warp yarns extending generally parallel to the central axis woven with weft yarns extending generally transversely to the warp yarns. Each of the layers includes a plurality of first annular bands, hereinafter referred to as annular bands A, and a plurality of second annular bands, hereinafter referred to as annular bands B, with annular bands A, B alternating with each other along each layer and along the length of the wall. The annular bands A of each layer include monofilament and multifilament weft yarns, and the annular bands B of each layer include only one of monofilament or multifilament weft yarns. The annular bands A of each layer are radially aligned in overlapping relationship with one another and the annular bands B of each layer are radially aligned in overlapping relationship with one another. The annular bands A of each layer form peaks while the annular bands B of each layer form valleys, causing the wall to have a corrugated profile, thereby enhancing the flexibility of the wall and allowing it to be pulled over a serpentine path without kinking.

[0006] In accordance with another aspect of the invention, a multi-layer wall includes a radially outermost layer, a radially innermost layer, and at least one intermediate layer sandwiched between the radially outermost layer and the radially innermost layer.

[0007] According to another aspect of the invention, at least one of the radially outermost layer, the radially innermost layer, and the intermediate layer may have a different weave pattern than at least one of the other layers.

[0008] In accordance with another aspect of the invention, the radially outermost layer, the radially innermost layer, and the intermediate layer may be woven from any one of a plain weave pattern, a twill weave pattern, a basket weave pattern, and a satin weave pattern, and at least some or all of the layers may be woven from the same weave pattern, or at least some or all of the layers may be woven from different weave patterns.

[0009] According to another aspect of the invention, there is provided a method of constructing a wrappable corrugated multi-layered textile sleeve. The method includes weaving an elongated wall having opposed edges extending lengthwise between opposed ends, the elongated wall being configured to be wrapped about a central axis with the opposed edges in overlapping relationship to bound a central cavity. Further, weaving the wall to include a plurality of layers extending in overlying relationship between the opposed edges and the opposed ends, each of the layers including warp yarns extending generally parallel to the central axis woven with weft yarns extending generally transversely to the warp yarns. Further, weaving each of the layers including a plurality of annular bands A and a plurality of annular bands B, the annular bands A and B alternating with each other along the length of the wall. Further, weaving the annular bands A of each layer including monofilament and multifilament weft yarns, and weaving the annular bands B of each layer including only one of monofilament or multifilament weft yarns. Further, the annular bands A of each layer are radially aligned in overlapping relationship with one another, and the annular bands B of each layer are radially aligned in overlapping relationship with one another, with the annular bands A of each layer forming peaks and the annular bands B of each layer forming valleys, such that the wall has a corrugated profile, thereby enhancing the flexibility of the wall and enabling it to be pulled over a serpentine path without kinking.

[0010] In accordance with another aspect of the invention, the method may further include weaving a multi-layer wall including a radially outermost layer, a radially innermost layer, and at least one intermediate layer sandwiched between the radially outermost layer and the radially innermost layer.

[0011] In accordance with another aspect of the invention, the method may further include weaving at least one of the radially outermost layer, the radially innermost layer, and the intermediate layer with a weave pattern that is different from at least one of the other layers.

[0012] In accordance with another aspect of the invention, the method may further include weaving the radially outermost layer, the radially innermost layer, and the intermediate layer with any one of a plain weave pattern, a twill weave pattern, a basket weave pattern, and a satin weave pattern, where at least some or all of the layers may be woven with the same weave pattern or at least some or all of the layers may be woven with different weave patterns.

[0013] According to another aspect of the invention, the method may further include weaving the wall comprising at least one of a thermosetting yarn and a heat shrinkable yarn, the heat shrinkable yarn being provided as a high length shrinkage yarn having a length shrinkage of 4-20% or more when exposed to a heat treatment process, thereby causing an increased density in the wall, thus increasing the cut resistance, impact resistance, and overall protective attributes of the wall. [Brief description of the drawings]

[0014] 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. [Figure 1] 1 is a schematic perspective view of a wrappable multi-layer woven sleeve constructed in accordance with one aspect of the present invention shown wrapped around an elongated member to be protected; FIG. [Diagram 2] 2 is a cross-sectional view taken generally along line 2-2 of FIG. 1 with the elongated member removed. [Diagram 3]2 is a schematic plan view of the wall layers of the sleeve of FIG. 1 shown in a flattened state prior to wrapping. [Figure 3A] FIG. 4 is an enlarged partial view of the wall of FIG. 3 illustrating its weft bands with the warp threads omitted for clarity purposes only. [Figure 3B] 3B is a view similar to FIG. 3A illustrating a wall constructed according to another embodiment of the present disclosure. [Figure 4] 4 is a schematic plan view of the layers of the wall of FIG. 3 illustrating different weave patterns and weave densities between the layers. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] Referring more particularly to the drawings, Figure 1 illustrates generally a flexible, wrappable, multi-layered, woven sleeve, hereinafter referred to as sleeve 10, constructed in accordance with one aspect of the present invention having a corrugated wall 12 wrapped around an elongated member 11 to be protected, such as a wire harness, conduit, or the like. Wall 12 includes and has opposed edges 14, 16 extending longitudinally between opposed ends 18, 20. Opposing edges 14, 16 are wrapped in overlapping relation to one another about a central axis 22 to bound a central cavity 24 through which elongated member 11 extends and within which elongated member 11 is protected against impact forces, such as may be experienced in, by way of example and not limitation, vehicle impacts, abrasion, and contamination ingress. The wall 12 has a plurality of layers, including at least one pair of layers, which are shown in Fig. 2 by way of example and not limitation as four layers 26a, 26b, 26c, 26d extending over and against one another between the opposing ends 18, 20. It should be understood that each of the layers 26a, 26b, 26c, 26d (which may be constructed such that each layer has the same or substantially the same construction (substantially is intended to mean that there may be slight differences between the layers, such as, for example, weaving patterns, but it should be further understood that the underlying premise of the present disclosure is maintained within each layer to form a corrugated wall, as discussed further below)) includes warp yarns 28 extending generally parallel to the central axis 22, woven with weft yarns, also referred to as fill yarns 30, which extend generally transversely to the warp yarns 28. When the opposing edges 14, 16 are wrapped in overlapping relationship, one of the layers forms a radially outermost layer 26a and one of the layers forms a radially innermost layer 26d. Each of the layers 26a, 26b, 26c, 26d includes a plurality of annular first bands A and a plurality of annular second bands B that alternate with one another along the length of the wall 12, as shown in Figures 3 and 3A.The annular first bands A of each layer 26a, 26b, 26c, 26d include monofilament weft yarns 30' and multifilament weft yarns 30', and the annular second bands B of each layer 26a, 26b, 26c, 26d include only one of monofilament weft yarns 30', shown in FIG. 3A as monofilament weft yarns 30', or multifilament weft yarns 30", shown in FIG. 3B as multifilament weft yarns 30". The annular first bands A of each layer 26a, 26b, 26c, 26d are radially aligned in overlapping relationship with one another, and the annular second bands B of each layer 26a, 26b, 26c, 26d are radially aligned in overlapping relationship with one another. The annular first bands A of each layer 26 a, 26 b, 26 c, 26 d form peaks P having a generally convex outer surface profile, while the annular second bands B of each layer 26 a, 26 b, 26 c, 26 d form valleys V having a generally concave outer surface profile, such that wall 12 has a wavy profile including alternating peaks P and valleys V along its length, thereby enhancing the bending flexibility of wall 12 and enabling it to be pulled over a tortuous, serpentine path in a zigzag manner, including around sharp bends and corners, without twisting.

[0016] To facilitate maintaining the wall 12 in its wrapped state around the elongated member 11, at least a portion of the weft yarns 30 in layers 26a, 26b, 26c, 26d may be provided as heat set weft yarns, and may be provided as monofilament weft yarns 30' and / or multifilament weft yarns 30". Thus, any suitable heat treatment process causes the wall 12 to assume a heat set tubular shape such that in the absence of an externally applied force on the opposing edges 14, 16, the wall 12 remains biased to its wrapped tubular state, and allows an external force to be applied to move the opposing edges 14, 16 away from one another to insert the elongated member 11 into the cavity 24 during assembly and to remove the elongated member 11 from the cavity during use, and allows the opposing edges 14, 16 to automatically move back into overlapping relationship with one another upon removal of the external force.

[0017] To enhance the protective attributes of wall 12, including impact resistance, cut resistance, and resistance to contamination ingress, at least a portion of warp yarns 28 and / or weft yarns 30 in layers 26a, 26b, 26c, 26d can be provided as high shrinkage yarns, where high shrinkage means shrinkage in length of 4-20% or more. Any suitable heat treatment process can then increase the density of wall 12 via shrinkage of the high shrinkage yarns.

[0018] According to one aspect of the disclosure, as shown in FIG. 4, the radially outermost layer 26a can be woven to have a first weave pattern WPa having a first weave tightness (density) WDa, and the radially innermost layer 26d can be woven to have a second weave pattern WPd having a second weave tightness (density) WDd, the first weave tightness (density) WDa being greater than the second weave tightness (density) WDd. Thus, when the layers 26a, 26d are heat set, the innermost layer 26d is caused to incorporate the heat set such that wrinkles are not formed therein. It should be appreciated that the intermediate layers 26b, 26c sandwiched between the radially outermost layer 26a and the radially innermost layer 26d can be woven to have respective weave patterns WPb, WPc of decreasing weave tightness relative to one another, such that the weave tightnesses (densities) WDa, WDb, WDc, WDd decrease relatively from the radially outermost layer 26a to the radially innermost layer 26d. Thus, WDa>WDb>WDc>WDd. As a result, when wall 12 is heat set, each of layers 26a, 26b, 26c, 26d remains smooth and wrinkle-free.

[0019] Additionally, within the above-mentioned embodiments, the warp yarns 28 and / or weft yarns 30 may be provided as high tenacity yarns from high tenacity polyethylene terephthalate (PET), para-aramid, liquid crystal polymer, and the like. High tenacity, defined herein in grams / denier, is between 4 and 10 grams / denier, which provides increased cut resistance and absorbs an increased amount of impact energy without breaking, thereby providing optimal crash resistance and protection to the elongated member 11. Furthermore, to increase the density and impact resistance of the wall 12, at least a portion of the warp yarns 28 and / or weft yarns 30 may be provided with high shrinkage, defined herein as shrinking between 4-20% or more of the pre-treated, pre-shrunk length, where shrinking the yarns draws the yarns 28, 30 together, increasing the density of the wall 12.

[0020] According to one aspect of the disclosure, a method of constructing a wrappable multi-layer (two or more layers) woven sleeve 10 is provided. The method includes weaving an elongated wall 12 having opposed edges 14, 16 extending longitudinally between opposed ends 18, 20, the elongated wall 12 configured to be wrapped about a central axis 22 and bring the opposed edges 14, 16 into overlapping relationship with one another to bound a central cavity 24. Additionally, the method includes weaving the wall 12 to include a plurality of layers 26a, 26b, 26c, 26d extending in overlying relationship with one another between the opposed ends 18, 20 and between the opposed edges 14, 16. The method further includes weaving each of the layers 26a, 26b, 26c, 26d including warp yarns 28 extending generally parallel to the central axis 22 with weft yarns 30 extending generally transverse to the warp yarns 28, where one of the layers 26a is woven to form a radially outermost layer and one of the layers 26d is woven to form a radially innermost layer. Furthermore, weaving each of the layers 26a, 26b, 26c, 26d including a plurality of first annular bands A and a plurality of second annular bands B, where the annular bands A and B alternate with each other along each of the layers 26a, 26b, 26c, 26d and along the length of the wall 12. Furthermore, annular band A of each layer 26a, 26b, 26c, 26d is woven containing both monofilament weft yarns 30' and multifilament weft yarns 30", and annular band B of each layer 26a, 26b, 26c, 26d is woven containing only one of monofilament weft yarns 30' or multifilament weft yarns 30". Further, by radially aligning the annular bands A of each layer 26a, 26b, 26c, 26d in overlapping relationship with one another and by radially aligning the annular bands B of each layer 26a, 26b, 26c, 26d in overlapping relationship with one another, the annular bands A of each layer 26a, 26b, 26c, 26d forming peaks P and the annular bands B of each layer 26a, 26b, 26c, 26d forming valleys V, the wall 12 forms a corrugated profile along its length, thereby enhancing the flexibility of the wall 12 and enabling it to be routed over a serpentine path without kinking.

[0021] 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 other than as specifically described.

Claims

1. A wrappable multi-layer woven sleeve for routing and protecting an elongated member, comprising: A wall having opposed edges extending lengthwise between opposed ends, the opposed ends being wrappable in overlapping relationship about a central axis to bound a central cavity, the wall having a plurality of layers extending in overlying relationship to one another, each of the layers including warp yarns extending generally parallel to the central axis woven with weft yarns extending generally transverse to the warp yarns, each of the layers including a plurality of annular first bands and a plurality of annular second bands, the first bands and the second bands of each of the layers alternating with one another along the length of the wall. wherein the first bands of each layer include monofilament and multifilament weft yarns and the second bands of each layer include only one of monofilament or multifilament weft yarns, the first bands of each layer are radially aligned in overlapping relationship with one another and the second bands of each layer are radially aligned in overlapping relationship with one another, the first bands of each layer form peaks and the second bands of each layer form valleys, the peaks and valleys alternating with one another along the central axis.

2. 2. The wrappable, multi-layer, woven sleeve of claim 1, wherein the plurality of layers includes a radially outermost layer, a radially innermost layer, and at least one intermediate layer sandwiched between the radially outermost layer and the radially innermost layer.

3. 3. The wrappable, multi-layer, woven sleeve of claim 2, wherein at least one of the radially outermost layer, the radially innermost layer, and the at least one intermediate layer has a different weave pattern than at least one of the other layers.

4. 4. The wrappable multi-layer woven sleeve of claim 3, wherein the radially outermost layer, the radially innermost layer, and the at least one intermediate layer are woven from any one of a plain weave pattern, a twill weave pattern, a basket weave pattern, and a satin weave pattern.

5. The wrappable, multi-layer woven sleeve of claim 4 , wherein at least some of the layers are woven with the same weave pattern.

6. The wrappable, multi-layer woven sleeve of claim 2 , wherein at least some of the layers are woven with the same weave pattern.

7. 7. The wrappable, multi-layer woven sleeve of claim 6, wherein all of said layers are woven with the same weave pattern.

8. 10. The wrappable, multi-layer woven sleeve of claim 1, wherein the second band of each layer includes only monofilament weft yarns.

9. 10. The wrappable, multi-layer woven sleeve of claim 1, wherein the second band of each layer includes only multifilament weft yarns.

10. 3. The wrappable, multi-layer, woven sleeve of claim 2, wherein the radially outermost layer has a first weave density and the radially innermost layer has a second weave density, the first weave density being greater than the second weave density.

11. The wrappable, multi-layer, woven sleeve of claim 1 , wherein the opposing edges are biased in overlapping relationship with one another by at least one heat set yarn.

12. 1. A method of constructing a wrappable multi-layer woven sleeve, comprising: weaving an elongated wall including a plurality of overlying layers having opposed edges extending longitudinally along a central axis between opposed ends; weaving each of the layers including warp yarns extending generally parallel to the central axis with weft yarns extending generally transverse to the warp yarns; weaving each of the layers to include a plurality of annular first bands and a plurality of annular second bands alternating with one another along a length of the layer; weaving the annular first band of each layer, the first band including monofilament weft yarns and multifilament weft yarns; weaving said annular second band of each layer including only one of monofilament weft yarns or multifilament weft yarns; radially aligning the annular first bands of each layer in overlapping relationship with one another; radially aligning the annular second bands of each layer in overlapping relationship with one another; forming a peak in the annular first band of each layer and a valley in the annular second band of each layer to provide the wall with a corrugated profile.

13. 13. The method of claim 12, further comprising weaving the plurality of layers to include a radially outermost layer, a radially innermost layer, and at least one intermediate layer sandwiched between the radially outermost layer and the radially innermost layer.

14. 14. The method of claim 13, further comprising weaving at least one of the radially outermost layer, the radially innermost layer, and the at least one intermediate layer with a different weave pattern than at least one of the other layers.

15. 14. The method of claim 13, further comprising weaving the radially outermost layer, the radially innermost layer, and the at least one intermediate layer with any one of a plain weave pattern, a twill weave pattern, a basket weave pattern, and a satin weave pattern.

16. 16. The method of claim 15, further comprising weaving the radially outermost layer, the radially innermost layer, and the at least one intermediate layer with the same weave pattern.

17. 16. The method of claim 15, further comprising weaving the radially outermost layer, the radially innermost layer, and the at least one intermediate layer, each having a different weave pattern.

18. 14. The method of claim 13, further comprising weaving the radially outermost layer with a first weave density and weaving the radially innermost layer with a second weave density, the first weave density being greater than the second weave density.

19. The method of claim 12 further comprising weaving the wall comprising at least one of a heat set yarn and a heat shrink yarn.

20. 20. The method of claim 19, further comprising providing the heat shrinkable yarn such that upon exposure to a heat treatment process it shrinks in length by at least 4%.

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