Flexible, wear-resistant woven sleeve and method of construction thereof

Abstract

A woven sleeve and method of construction are provided. The sleeve (10, 10') has a flexible, abrasion-resistant, elongated wall (12, 12') constructed from woven monofilament and / or multifilament yarns. The wall is configured to define a cavity extending along the sleeve's central axis (18). The wall is woven with warp yarns (23) extending generally parallel to the sleeve's central axis and weft yarns (24) extending circumferentially around the sleeve and generally transverse to the central axis. The warp yarns are bundled into individual, separate groups (22), each group (22) including a plurality of yarns (23) in adjacent relationship with one another, with each of the yarns (23) within the same separate group (22) interwoven on the same side of a common weft yarn (24).

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 62 / 824,217, filed March 26, 2019, the entire contents of which are incorporated herein by reference.

[0002] Background of the Invention 1.Technical Field FIELD OF THE INVENTION This invention relates generally to textile sleeves for protecting elongated members, and more particularly to woven sleeves. [Background technology]

[0003] 2. Related technologies It is known to house and protect elongated members, such as wires and wire harnesses, in automobiles, aircraft, or aerospace vehicles, for example, in woven protective sleeves to provide the wires with protection against abrasion, fluids, and thermal influences. To achieve multiple types of desired protection and to provide optimal protection for the elongated members against the influence of abrasion, the protective sleeve may have multiple layers, some of which are specifically provided for different types of protection. For example, one layer may be provided for optical coverage to inhibit viewing through the sleeve, e.g., a sheet of plastic material, while another layer may be provided for abrasion resistance and yet another layer may be provided for protection against thermal conditions. While the above-mentioned multi-layer sleeves may provide suitable protection against various environmental conditions, unfortunately, they are typically bulky, requiring increased space volume, and they tend to be relatively heavy and exhibit low flexibility. Furthermore, providing suitable protection against abrasion may still be challenging. Having to include multiple layers can be problematic in some applications, particularly those requiring cables or hoses to be routed through tight, tortuous areas and those with weight restrictions, such as, for example, aircraft and aerospace applications. Summary of the Invention [Means for solving the problem]

[0004] Summary of the Invention One aspect of the present invention provides a woven textile sleeve for routing and protecting an elongated member, the textile sleeve including an elongated wall configured to define a cavity extending along a central longitudinal axis of the sleeve. The wall is woven with warp yarns extending parallel to the central longitudinal axis and weft yarns extending transversely relative to the warp yarns. The warp yarns are woven as separate bundles of yarn filaments. Each separate bundle of yarn filaments includes multiple yarn filaments arranged in abutting side-by-side relationship. The yarn filaments in each separate bundle extend above and below the same weft yarn.

[0005] According to another aspect, the present invention provides a method of constructing a textile sleeve, the method including weaving an elongated wall configured to define a central cavity extending parallel to a central longitudinal axis of the sleeve, the wall having warp yarns extending parallel to the central longitudinal axis and weft yarns extending transversely relative to the warp yarns, weaving the warp yarns in separate bundles of yarns, each bundle having a plurality of yarn filaments disposed in adjacent abutting relationship with one another, the yarn filaments in each separate bundle extending above and below the same weft yarn, and weaving a weft yarn including monofilaments and multifilaments.

[0006] Another aspect of the present invention provides a woven sleeve for routing elongated members and protecting them from exposure to abrasion and other environmental conditions, such as contamination. The sleeve has a flexible, wear-resistant wall constructed from woven monofilament and multifilament yarns. The wall is configured to define a cavity extending along the central axis of the sleeve between its open ends. The wall is woven with warp yarns extending generally parallel to the central axis of the sleeve and fill (also called weft) yarns extending circumferentially around the central axis of the sleeve and generally transversely to the central axis. The warp yarns are bundled into individual, separate groups, each group including a plurality of monofilaments in close, adjacent, abutting relationship, with each monofilament within the same separate group interlaced to extend above and below the same side of the same (common) weft yarn. The bundled warp yarn groups provide enhanced abrasion resistance to abrasive forces along the length of the sleeve while providing a sleeve having a relatively reduced weight compared to a similar plain weave sleeve of the same size (plain weave does not include separate groups of adjacent yarns), and the synergistic effect provided by the warp and weft yarns further provides a sleeve with enhanced optical coverage, the ability to bend smoothly around tortuous paths and corners without kinking, while also being economical to manufacture and use.

[0007] In accordance with another aspect of the present invention, the wall of the sleeve may be constructed as a circumferentially continuous seamless tubular wall.

[0008] In accordance with another aspect of the invention, the wall of the sleeve may be formed as a wrappable wall having opposed edges extending generally parallel to the central axis, the opposed edges configured to overlap one another to define a cavity configured to receive the elongated member to be protected.

[0009] In accordance with another aspect of the present invention, separate bundles of warp monofilaments may extend over and under a single weft yarn in a repeating manner.

[0010] In accordance with another aspect of the present invention, separate bundles of warp monofilaments may extend over a plurality of weft yarns and under a plurality of weft yarns in a repeating manner.

[0011] In accordance with another aspect of the present invention, each separate bundle of warp monofilaments may be provided having three (3) or more monofilaments to provide enhanced abrasion resistance.

[0012] In accordance with another aspect of the invention, the weft yarns may be provided as multifilaments and monofilaments, the multifilaments providing enhanced optical coverage and the monofilaments being heat set to urge opposing edges of the walls into overlapping relationship with one another.

[0013] In accordance with another aspect of the invention, the weft yarns may be provided to include multifilaments and monofilaments in alternating relationship with one another along the length of the sleeve, with closely adjacent weft yarns each extending above and below the same warp yarn to provide the sleeve with an optimal self-wrapping configuration and optimal optical coverage.

[0014] In accordance with another aspect of the invention, a weft yarn may be provided that includes multifilaments and monofilaments in a bundled, side-by-side relationship, with each pick of the weft yarn including multifilaments and monofilaments that are either pulled in a parallel relationship, twisted, or served together, with the bundled multifilament and monofilament weft yarns extending above and below the same warp yarn in a side-by-side relationship to provide an optimal self-wrapping configuration and optimal optical coverage for the sleeve.

[0015] In accordance with another aspect of the present invention, the warp monofilaments may be provided with a larger diameter relative to the weft yarns to provide increased abrasion protection to the weft yarns.

[0016] According to another aspect of the invention, at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments may have a different diameter than others of the longitudinal monofilaments in the separate bundle, the longitudinal monofilament having a larger diameter providing protection to the longitudinal monofilaments having a smaller diameter.

[0017] According to another aspect of the present invention, at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments may be of a different type of material than others of the longitudinal monofilaments within the separate bundle.

[0018] According to another aspect of the present invention, at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments may have a different diameter and be formed of a different type of material than the others of the longitudinal monofilaments in the separate bundle.

[0019] According to another aspect of the invention, at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments may have a larger diameter, e.g., about 0.25 mm, than the other longitudinal monofilaments in the separate bundle, e.g., having a diameter of about 0.22 mm and formed of, e.g., PET, and may be formed of a different type of material, e.g., nylon, than the other longitudinal monofilaments. The larger diameter monofilament provides increased abrasion resistance from an optimally abrasion-resistant material, thereby providing protection to the smaller, less costly monofilaments, which in turn provide synergistically increased abrasion resistance with the larger diameter monofilaments.

[0020] According to another aspect of the present invention, there is provided a method of constructing a textile sleeve. The method includes weaving an elongated wall constructed to define a cavity extending along a central longitudinal axis of the sleeve, the wall having warp yarns extending parallel to the central longitudinal axis and weft yarns extending transversely relative to the warp yarns. The method further includes weaving the warp yarns in separate bundles of yarns, each bundle having a plurality of monofilament yarns disposed in adjacent abutting relationship with one another, the warp yarns in each separate bundle extending above and below the same weft yarns.

[0021] According to another aspect of the invention, the method may further include weaving a wall having opposing edges extending generally parallel to the central longitudinal axis and wrapping the opposing edges in overlapping relationship to circumferentially define a cavity.

[0022] According to another aspect of the invention, the method may further include weaving the wall as a circumferentially continuous seamless tubular wall.

[0023] In accordance with another aspect of the present invention, the method may further include weaving the bundles over and under a single weft yarn in a repeating manner.

[0024] In accordance with another aspect of the invention, the method may further include heat setting at least some of the weft yarns to urge the opposing edges into overlapping relationship with one another.

[0025] According to another aspect of the invention, the method may further include providing the weft yarn as a monofilament yarn and a multifilament yarn.

[0026] In accordance with another aspect of the invention, the method may further include weaving the weft yarns as monofilament and multifilament yarns in alternating relationship with one another along the length of the sleeve.

[0027] In accordance with another aspect of the present invention, the method may further include weaving the warp and weft yarns in a rib weave pattern.

[0028] According to another aspect of the invention, the method may further include weaving at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments to have a different diameter than others of the longitudinal monofilaments within the separate bundle to further increase the wear resistance of the wall and reduce costs associated with manufacturing the wall.

[0029] According to another aspect of the invention, the method may further include weaving at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments to be of a different type of material than others of the longitudinal monofilaments in the separate bundle to further increase the wear resistance of the wall and reduce costs associated with manufacturing the wall.

[0030] According to another aspect of the invention, the method may further include weaving at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments to have a different diameter and be formed of a different type of material than others of the longitudinal monofilaments in the separate bundle to further increase the wear resistance of the wall and reduce costs associated with manufacturing the wall.

[0031] According to another aspect of the present invention, the method may further include weaving at least one longitudinal monofilament in one or more of the separate bundles of longitudinal monofilaments to have a larger diameter, e.g., about 0.25 mm, than the other longitudinal monofilaments in the separate bundle, e.g., having a diameter of about 0.22 mm and formed of, e.g., PET, and to be formed of a different type of material, e.g., nylon, than the other longitudinal monofilaments in the separate bundle. The larger diameter monofilament provides enhanced abrasion resistance by virtue of the optimally abrasion-resistant material, thereby providing abrasion protection to the smaller, less costly monofilaments, which in turn provide synergistically enhanced abrasion resistance with the larger diameter monofilaments.

[0032] BRIEF DESCRIPTION OF THE DRAWINGS These and other aspects, features and advantages will become readily apparent to those skilled 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 explanation of the drawings]

[0033] [Figure 1] FIG. 1 is a schematic perspective view of a woven wrappable sleeve constructed in accordance with one aspect of the present invention, the sleeve shown carrying and protecting an elongated member therein. [Figure 1A] 1 of a woven circumferentially continuous sleeve constructed in accordance with another aspect of the present invention, the sleeve shown carrying and protecting an elongated member therein. [Figure 2] FIG. 1B is an enlarged schematic plan view of a portion of the wall of the sleeve of FIGS. 1 and 1A constructed in accordance with one embodiment of the present invention. [Figure 2A] 1 and 1A constructed in accordance with another embodiment of the present invention. [Figure 2B] 1 and 1A constructed in accordance with yet another embodiment of the present invention; FIG. [Figure 2C] 1 and 1A constructed in accordance with yet another embodiment of the present invention; FIG. [Figure 2D] 1 and 1A constructed in accordance with another embodiment of the present invention; FIG. 2 is a view similar to FIG. [Figure 2E] 1 and 1A constructed in accordance with another embodiment of the present invention; FIG. 2 is a view similar to FIG. [Figure 2F] 1 and 1A constructed in accordance with another embodiment of the present invention. [Figure 2G]1 and 1A constructed in accordance with another embodiment of the present invention. [Figure 3] 2 is a plan view of the wall of the sleeve of FIG. 1 constructed in accordance with another non-limiting embodiment of the present disclosure, prior to being wrapped into a tubular configuration. DETAILED DESCRIPTION OF THE INVENTION

[0034] Detailed Description of the Preferred Embodiments Referring more particularly to the drawings, Fig. 1 shows a schematic depiction of a woven, wrappable textile sleeve, hereinafter referred to as sleeve 10, constructed in accordance with one aspect of the present invention, while Fig. 1A shows a similar view of a circumferentially continuous sleeve 10' constructed in accordance with another aspect of the present invention. Sleeve 10 has a wrappable, elongated wall 12, while sleeve 10' has a circumferentially continuous, seamless wall 12', each for routing one or more elongated members, such as wires or wiring harnesses 14, and for protecting the elongated members from, for example, exposure to abrasion and the intrusion of contamination, debris, and the like. Other than the wrappable nature of wall 12 and the circumferentially continuous, seamless nature of wall 12', sleeves 10, 10' and the associated yarns used for their construction, discussed below, are similar, and therefore, for simplicity's sake, the following discussion will be directed to sleeve 10, although it should be recognized that the same discussion applies equally to sleeve 10' unless otherwise noted. Elongated wall 12, unlike wall 12', has opposed edges 16, 17 extending generally parallel to central longitudinal axis 18, with edges 16, 17 preferably biased in overlapping relationship relative to one another in a "cigarette wrapped" manner to completely enclose elongated member 14 within central cavity 20 of sleeve 10. Unlike cavity 20' (FIG. 1A), cavity 20 is readily accessible along the entire length of wall 12 due to the separation of opposed edges 16, 17, such that one or more elongated members 14 can be easily positioned radially into cavity 20 relative to axis 18 and, conversely, easily removed from cavity 20, such as during repair. To provide the elongate members 14 with the desired protection against abrasion and to optimize the structural integrity of the walls 12, 12' against wear from abrasion, the walls 12, 12' are woven with separate, distinct warp yarn bundles 22 that extend generally parallel to the central longitudinal axis 18. Each bundle 22 is comprised of a plurality of warp yarns 23 disposed in adjacent, abutting relationship with one another.The bundles 22, having multiple warp yarns 23 in an abutting, side-by-side relationship, minimize yarn movement within the walls 12, 12', preventing significant movement of the individual warp yarns 23 relative to one another, thereby reducing internal friction within the walls 12, 12' and, in turn, reducing wear between the warp yarns 23, even as the walls 12, 12' move against certain external vehicle components, such as, by way of example and not limitation, engine components or frame members. Additionally, the bundles 22 provide an increased surface area of ​​warp yarn 23 material on the exterior surfaces of the walls 12, 12'. The increased surface area of ​​yarn material acts to distribute loads applied on the exterior surfaces evenly and widely over and beyond the densely populated areas of the walls 12, 12', thereby reducing high point loads and, in turn, reducing wear. The walls 12, 12' are further woven with weft yarns. Weft yarns, commonly referred to as fill yarns 24, extend generally circumferentially around the wrapped wall 12 in generally transverse relationship to the warp yarns 23. The fill yarns 24 may be provided at least in part as heat-settable yarns, and, if desired, the wall 12 is biased to self-curl the opposing edges 16, 17 into an overlapping relationship such that when the fill yarns 24 are heat-set, the wall 12 assumes a curled or wrapped configuration. The bias is provided by heat-setting the fill yarns 24, such as heat-settable monofilament yarns, into a curled configuration about the central longitudinal axis 18, thereby rendering the wall 12 self-curled, also referred to as self-wrapping. It should be appreciated that reducing the relative movement between the warp yarns 23 correspondingly reduces relative movement and friction between the warp yarns 23 and fill yarns 24, thereby further reducing internal friction and wear within the walls 12, 12′.

[0035] Depending on the needs of the application, the walls 12, 12' may be configured with any suitable size, including length and diameter. When the wall 12 is in its self-wound tubular configuration and little external force is applied, the edges 16, 17 preferably overlap each other in an at least slightly self-biased manner to completely enclose the cavity 20, thereby providing enhanced protection for the wire 14 housed in the cavity 20. The edges 16, 17 are easily extendable away from each other with the external application of sufficient force to overcome the shape-memory bias imparted by the weft yarns 24 to at least partially open and expose the cavity 20. Thus, the wire 14 can be easily placed into the cavity 20 during assembly or removed from the cavity 20 during repair. Upon release of the externally applied force, the edges 16, 17 automatically return to their shape memory and overlap into a self-wound position under the bias imparted by the heat-set weft monofilament yarns 24.

[0036] The bundles 22 of separate warp yarns, according to one aspect of the present disclosure, may be formed of any suitable monofilament yarns 23. The monofilament warp yarns 23 are bundled in adjacent abutting or substantially abutting relationship to one another, thereby providing enhanced abrasion resistance and, as a result, providing enhanced and optimal surface area coverage to the wall 12. This provides enhanced protection to the elongated member 14 housed within the cavity 20 by inhibiting the ingress of contamination, debris, and the like into the cavity 20. In one exemplary sleeve embodiment (FIG. 2), the bundles 22 are formed of four (4) monofilament warp yarns 23. In another exemplary embodiment (FIG. 2A), the walls 112, 112′ of the sleeves 110, 110′ may include at least one longitudinal monofilament 23′ within the separate bundles 22 of longitudinal monofilaments 23 having a different (larger) diameter than the other longitudinal monofilaments 23 within the separate bundles 22. This provides enhanced abrasion protection for the smaller diameter longitudinal monofilaments 23. In the non-limiting embodiment of Figure 2A (showing only the identified areas in Figure 2, with the remainder of walls 112, 112' repeating that shown in Figure 2), bundles 22 are formed with three (3) monofilament warp yarns 23, although two (2) or more warp yarns 23 may be used. However, it has been found that having at least three (3) warp yarns 23 provides greatly improved abrasion protection. The separate bundles 22 are shown in Figures 2 and 2A, by way of example and not limitation, as woven in a rib-type weave pattern, with each separate bundle 22 extending over and under a common single weft yarn 24 in a repeating manner, although other rib-type weaves are also possible.

[0037] The weft yarns 24 may be provided as any suitable monofilament and / or multifilament material, including heat-settable monofilament and / or multifilament polymeric materials. In the exemplary sleeve embodiment shown in Figures 2 and 2A, the weft yarns 24 are provided as both heat-settable monofilaments 24' (although non-heat-settable monofilaments may be used, particularly in the wall 12') and high-coverage multifilaments 24, spaced apart such that closely adjacent yarns 24, 24' extend above and below the same warp yarns 23 (weft yarn 24 extends above a first warp yarn 23, while closely adjacent weft yarn 24' extends below the first warp yarn 23). The monofilaments and multifilaments of the weft yarns 24 are woven in an alternating manner along the length of the sleeve 10 to provide the wall 12 with increased self-wrapping capability and increased optical coverage, thereby enhancing protection against the ingress of contamination by inhibiting visibility through the wall 12 into the cavity 20. As shown in FIG. 2A , the weft yarns 24, 24′ may be provided with a reduced cross-sectional area (reduced diameter) relative to at least some of the warp yarns 23, which facilitates providing the sleeve 10 with an increased degree of flexibility and reduces abrasion of the weft yarns 24, 24′, where a larger number of closely packed warp monofilaments 23 would be more likely to absorb abrasion. Thus, at least some or all of the warp monofilaments 23′ may be provided with a larger diameter relative to the weft yarns 24, 24′, as shown, to enhance abrasion protection for the weft yarns 24, 24′. However, it has been found that when the weft yarns 24, 24′ are abraded, the closely packed abutting warp yarns 23, 23′ of the bundle 22 are able to maintain the structural integrity of the walls 12, 12′, thereby maintaining protection of the elongated member 14.Additionally, the weft yarns 24 may be provided with a relatively low pick density (picks per inch), which ultimately reduces the cost of manufacturing by increasing the manufacturing run rate (the speed at which the walls 12, 12' are woven) and also reduces the overall material content, thus further reducing the costs associated with manufacturing the sleeve 10.

[0038] The threads 23, 24, 24' may be provided in any desired thermoplastic material, such as, by way of example and not limitation, one or more of polyester, PPS, Nomax, and may further include inorganic materials, such as, by way of example and not limitation, one or more of fiberglass and basalt.

[0039] According to another aspect of the present invention, at least one longitudinal monofilament 23′ in one or more of the separate bundles 22 of longitudinal monofilaments 23 may be of a different type of material than the others of the longitudinal monofilaments 23 within the separate bundles 22.

[0040] 2A , at least one longitudinal monofilament 23′ in one or more of the separate bundles 22 may have a different diameter and be formed of a different type of material than the other longitudinal monofilaments 23 in the separate bundle 22. Thus, synergistic effects may be optimized by providing the longitudinal monofilaments 23, 23′ in the common bundle 22 with different diameters and / or made of different materials, both to enhance abrasion resistance and to improve manufacturing economy and reduce costs. For example, in one exemplary embodiment, at least one longitudinal monofilament 23′ in one or more of the separate bundles 22 of longitudinal monofilaments 23 may have a diameter of, for example, about 0.22 mm, and may have a larger diameter, for example, about 0.25 mm, than the other longitudinal monofilaments 23 in the separate bundle 22, which are formed of, for example, PET, and may be formed of a different type of material, for example, nylon, than the other longitudinal monofilaments 23. The larger diameter monofilament 23' is provided to enhance abrasion resistance from an optimally abrasion resistant material, such as nylon, thereby providing protection to the smaller, less costly monofilament 23, which also provides synergistically enhanced abrasion resistance with the larger diameter monofilament 23'. It should be appreciated that the diameter and material selected for the warp monofilaments 23, 23' may be selected as desired for the intended application.

[0041] According to another aspect of the invention, as shown in FIG. 2B (only the regions identified in FIG. 2 are shown, with the remainder of the walls 212, 212′ repeating those shown in FIG. 2), the walls 212, 212′ of the sleeve 210, 210′ ​​may include weft yarns provided to contain multifilaments 24 and monofilaments 24′ in a bundled, side-by-side relationship. Each weft yarn passage (woven as a single pick) contains both multifilaments 24 and monofilaments 24′, which are either pulled in a parallel relationship, twisted together (they are spirally wound together), or stacked together (one spirally wound around the other). The bundled multifilament and monofilament weft yarns 24, 24′ extend above and below the same warp yarns 23, 23′ in a side-by-side relationship to provide the sleeve with an improved self-wrapping configuration and optimal optical coverage.

[0042] According to another aspect of the present invention, as shown in FIG. 2C (showing only the areas identified in FIG. 2, with the remainder of the walls 312, 312' repeating those shown in FIG. 2), the walls 312, 312' of the sleeve 310, 310' may be constructed in a manner similar to that described above for the walls 212, 212', but the weft may be provided including only multifilaments 24 woven together with the warp yarns 23 and optionally bundles 22 of the warp yarns 23'.

[0043] In accordance with another aspect of the present invention, as shown in FIG. 2D (showing a view similar to FIG. 2), walls 412, 412′ of sleeve 410, 410′ may be constructed in a manner similar to that discussed above for any of walls 12, 12′, 112, 112′, 212, 212′, 312, 312′, except that at least one (shown as all) of the warp yarns in each of bundles 22 may be provided as multifilaments 23″. Thus, the coverage against ingress of contaminants and flexibility of walls 412, 412′ are greatly improved.

[0044] In accordance with another aspect of the present invention, as shown in FIG. 2E (showing a view similar to FIG. 2), walls 512, 512′ of sleeve 510, 510′ may be configured in a manner similar to that discussed above for any of walls 12, 12′, 112, 112′, 212, 212′, 312, 312′, except that at least one of the bundles 22 (shown as alternating bundles 22) may be provided as multifilaments 23″. Thus, alternating bundles 22 include only multifilaments 23″, and alternating bundles 22 include only monofilaments 23. Thus, the coverage against ingress of contaminants and flexibility of walls 512, 512′, as well as resistance to abrasion from monofilaments 23, are greatly increased by multifilaments 23″.

[0045] According to another aspect of the invention, as shown in FIG. 2F (showing a view similar to FIG. 2), the walls 612, 612′ of the sleeve 610, 610′ may be constructed in a manner similar to that discussed above for any of the walls 12, 12′, 112, 112′, 212, 212′, 312, 312′, except that each of the bundles 22 may be provided including multifilaments 23″ and monofilaments 23. In the embodiment shown, the bundles 22 include monofilaments 23 and multifilaments 23″ that abut one another such that the increased surface friction of the multifilaments 23″ acts to secure and lock the alternating monofilaments 23 in place. Thus, the coverage and flexibility of the walls 612, 612′ against ingress of contaminants, as well as the resistance to abrasion by the monofilaments 23, are greatly increased by the multifilaments 23″.

[0046] In accordance with another aspect of the present invention, as shown in FIG. 2G (showing a view similar to FIG. 2), walls 712, 712′ of sleeve 710, 710′ may be constructed in a manner similar to that discussed above for any of walls 12, 12′, 112, 112′, 212, 212′, 312, 312′, except that each of bundles 22 may be provided including multifilaments 23″ and monofilaments 23, as discussed for walls 612, 612′. However, the multifilaments 23″ and monofilaments 23 are arranged differently. In the illustrated embodiment, each of the multifilaments 23″ of bundle 22 is in adjacent abutting relationship with one another. In the illustrated embodiment, a pair of multifilaments 23 ” are disposed in adjacent abutting relationship with one another, with a single monofilament 23 disposed along each side of the abutting pair of multifilaments 23". The increased surface friction of the multifilaments 23" therefore acts to secure and lock the abutting monofilaments 23 in place. Thus, the coverage and flexibility of the walls 712, 712' against the ingress of contaminants, as well as the resistance to abrasion by the monofilaments 23, are greatly increased by the multifilaments 23".

[0047] According to another aspect of the present invention, as shown in FIG. 3 , the wall 812 of the sleeve 810 can be constructed in a manner similar to that discussed above for any of the walls 12, 112, 212, and 312. The wall 812 has opposed edges 816, 817 extending generally parallel to a central longitudinal axis 818. The edges 816, 817 are preferably biased into an overlapping relationship. At least one or both of the edges 816, 817 may include edge regions 816′, 817′ that span a plurality of warp yarns 23 along the entire length of the sleeve 810, such as, by way of example and not limitation, between about 4 and 10 warp yarns 23. The edge regions 816′, 817′ are woven in a plain weave pattern. Thus, the fill yarns 24, 24′ within the edge regions 816′, 817′ are woven with the warp yarns 23 in a plain weave pattern. The inner body region 30, extending between and from one edge region 816' to the opposing edge region 817', is woven in a warp rib weave pattern of weft yarns 24, 24' with warp yarns 23, as discussed above. The opposing edge regions 816', 817' having a plain weave pattern ensures that when bending the sleeve 810 around a sharp corner, the opposing edges 816, 817 remain in their overlapping relationship with one another and avoid separation, which would otherwise occur. Thus, the reduced spreading between the opposing edges 816, 817 provides optimal coverage for the elongated member 14 contained within the sleeve 810.

[0048] 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 woven textile sleeve for routing and protecting an elongated member, comprising:

1. A textile sleeve comprising: an elongated wall configured to define a cavity extending along a central longitudinal axis of the sleeve; the wall woven with warp yarns extending parallel to the central longitudinal axis and weft yarns extending transversely relative to the warp yarns; the warp yarns woven as separate bundles of yarn filaments; each separate bundle of yarn filaments including a plurality of yarn filaments arranged in adjacent abutting relationship with one another; each separate bundle repeatedly extending above and below the weft yarns; and at least one of the yarn filaments in each separate bundle having a larger diameter than the others of the yarn filaments in each separate bundle.

2. The textile sleeve of claim 1 , wherein each said bundle of yarn filaments extends repeatedly over and under a single weft yarn.

3. 10. The textile sleeve of claim 1, wherein the weft yarns comprise monofilaments and multifilaments that alternate with one another along the central longitudinal axis.

4. The textile sleeve of claim 1 , wherein the wall has opposed edges that are biased into overlapping relationship by at least some of the weft yarns that are heat set.

5. The textile sleeve of claim 1 , wherein at least some of the bundles comprise monofilaments.

6. The textile sleeve of claim 5 , wherein at least some of the bundles comprise multifilaments.

7. The textile sleeve of claim 6 , wherein at least some of the bundles include only monofilaments and at least some of the bundles include only multifilaments.

8. The textile sleeve of claim 6 , wherein at least some of the bundles include monofilaments and multifilaments.

9. The textile sleeve of claim 8 , wherein each of the bundles includes monofilaments and multifilaments.

10. The textile sleeve of claim 5 , wherein each of the bundles includes only monofilaments.

11. 6. The textile sleeve of claim 5, wherein the monofilaments have a larger diameter relative to the weft yarns.

12. 6. The textile sleeve of claim 5, wherein at least one of the monofilaments in at least one of the separate bundles has a larger diameter than others of the yarn filaments in the at least one of the separate bundles.

13. 10. The textile sleeve of claim 1, wherein at least one yarn filament in at least one of the separate bundles of warp yarns is a different type of material than others of the yarn filaments in the at least one of the separate bundles.

14. 2. The textile sleeve of claim 1, wherein at least one yarn filament in at least one of the separate bundles of warp yarns has a different diameter and is formed of a different type of material than the others of the yarn filaments in the at least one of the separate bundles.

15. The textile sleeve of claim 1 , wherein at least some of the bundles comprise multifilaments.

16. 16. The textile sleeve of claim 15, wherein at least some of the bundles contain only multifilaments.

17. 17. The textile sleeve of claim 16, wherein each of the bundles includes only multifilaments.

18. A woven textile sleeve for routing and protecting an elongated member, comprising: an elongated wall configured to define a cavity extending along a central longitudinal axis of the sleeve, the wall being woven with warp yarns extending parallel to the central longitudinal axis and weft yarns extending transversely relative to the warp yarns, the warp yarns being woven as separate bundles of monofilaments, each separate bundle of monofilaments including a plurality of monofilaments disposed in adjacent abutting relationship with one another, the weft yarns being comprised of weft monofilaments and weft multifilaments; each separate bundle repeatedly extends over a single weft yarn and under a single weft yarn; the weft monofilaments and the weft multifilaments alternate with one another along the central longitudinal axis; the walls are biased into overlapping relationship with one another by at least some of the weft monofilaments that are heat set; At least one of the monofilaments in each of the separate bundles has a larger diameter than others of the monofilaments in each of the separate bundles.

19. 1. A method of constructing a textile sleeve, comprising: a weaving an elongated wall configured to define a central cavity extending parallel to a central longitudinal axis of the sleeve, the wall having warp yarns extending parallel to the central longitudinal axis and weft yarns extending transversely relative to the warp yarns, the method further comprising: the method includes weaving the warp yarns in separate bundles of yarns, each of the bundles having a plurality of yarn filaments disposed in adjacent abutting relationship with one another, each separate bundle repeatedly extending above and below the weft yarns, at least one of the yarn filaments in each separate bundle having a larger diameter than others of the yarn filaments in each separate bundle, the method further comprising: weaving said weft yarns comprising monofilaments and multifilaments.

20. 20. The method of claim 19, further comprising weaving each of the bundles comprising monofilaments.

21. 21. The method of claim 20, further comprising providing at least one monofilament in each of said separate bundles to have a larger diameter than others of said yarn filaments within said separate bundles.

22. 21. The method of claim 20, further comprising weaving each said bundle comprising multifilaments.

23. 23. The method of claim 22, further comprising weaving each of the monofilaments in the bundle in side-by-side relationship with one of the multifilaments in the bundle.

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