Location-locatable protective sleeve and method for constructing the same

Abstract

A protective sleeve assembly and method for constructing the same for protecting an electrical component and a wire harness extending therethrough is provided. The sleeve assembly includes a multi-layer tube extending longitudinally along an axis between opposite ends. An end cap is disposed over one of the opposite ends. The end cap has an opening through which the wire harness extends to enable assembly and disassembly of the protective sleeve assembly along the wire harness and around the electrical component. The multi-layer tube includes an inner tube and an outer tube. The inner tube has a semi-rigid tubular wall including a radially extending energy dissipation feature to minimize transmission of impact forces to the electrical component. The outer tube is a textile tube disposed around the inner tube.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 122,797, filed on December 8, 2020, and U.S. Utility Patent Application No. 17 / 544,577, filed on December 7, 2021, the entire disclosure of which is hereby incorporated by reference in its entirety.

Background Art

[0002] 1. Technical Field The present invention relates to a protective sleeve having an integral positioning feature that enables a sleeve to be positionable and releasably secured along an elongated article to be protected against impact, wear, and cutting, and a method of constructing the same.

[0003] 2. Related Art Sensors used in automotive applications, such as oxygen sensors that provide data for controlling the operation and performance of an engine, are often mounted in the engine compartment of a vehicle, where they are exposed to a harsh environment including strong radiant heat, sources of shock, sources of wear, and steady vibrations during vehicle operation. Considering the harsh environment, it is advantageous to cover relatively delicate sensors and electrical components such as wire harnesses connected thereto with a protective sleeve that can attenuate vibrations, protect against impact forces and wear, and reflect and shield radiant heat. Such sleeves often include an elongated flexible and relatively soft textile tube having an inner attenuation layer of a non - woven material, such as polyester felt. The inner attenuation layer is typically surrounded by a reflective layer of an aluminum foil layer laminated with a reinforcing layer such as a woven scrim of polymer filaments or a polymer sheet material.

[0004] Due to the properties of the protective sleeve and its environment, attaching the sleeve to the sensor in a way that ensures it is securely fixed in the desired position and easily removable for sensor installation and maintenance is difficult. Adhesives, tapes, and friction fittings are used for attachment, but all of these methods have various drawbacks. Attaching the sensor with adhesive is fairly reliable, but it permanently attaches the sleeve. As a result, this method makes it difficult to easily remove the sleeve for sensor repair or sleeve reuse. Furthermore, considering the heat and vibration that the sensor and its protective sleeve experience in the engine compartment, tape and friction fittings are unreliable and may be impractical. In addition, due to the relatively soft nature of the tube, protection against impact forces and resistance to cut are generally low. [Overview of the project]

[0005] The present invention provides a protective sleeve assembly for protecting electrical components extending through a protective sleeve assembly from exposure to contamination, impact forces, abrasion, and vibration. The protective sleeve assembly includes a semi-rigid multilayer tube extending longitudinally along an axis between opposing ends, and an end cap positioned above one of the ends. The end cap includes at least one finger extending radially inward substantially toward the axis. The at least one finger is elastically flexible in the opposite axial direction to allow assembly and disassembly of the protective sleeve assembly around the electrical components to be protected. The semi-rigid multilayer tube includes an inner tube and an outer tube. The inner tube has a semi-rigid tubular wall with energy-dissipating features that act to minimize the transmission of impact forces to the electrical components, while also providing enhanced cut resistance and protection against contamination ingress. The outer tube is a textile tube positioned around the inner tube and provides cut resistance and abrasion resistance to the protective sleeve assembly.

[0006] According to another aspect of the present invention, the end cap may be provided as a separate member fastened to at least one of the inner tube and / or outer tube.

[0007] According to another aspect of the present invention, the end cap can be fastened to the pipe by fasteners such as staples, screw fasteners, or rivets.

[0008] According to another aspect of the present invention, the fastener may be in the form of an adhesive.

[0009] According to another aspect of the present invention, the fastener may be in the form of a welded joint.

[0010] According to another aspect of the present invention, the welded joint may be in the form of an ultrasonic welded joint.

[0011] According to another aspect of the present invention, the inner tube is formed from a solid, impermeable tubular polymer wall.

[0012] According to another aspect of the present invention, the inner tube may have ribs to enhance energy dissipation.

[0013] According to another aspect of the present invention, the ribs of the inner tube can form an open pocket, also called a gap, between the inner tube and the outer tube, thereby enhancing energy dissipation, impact resistance, vibration reduction, and protection against contamination intrusion into the central void bounded by the protective sleeve assembly.

[0014] According to another aspect of the present invention, the end cap can be manufactured from a solid, semi-rigid nonmetallic material.

[0015] According to another aspect of the present invention, the finger may be substantially triangular.

[0016] According to another aspect of the present invention, the outer tube may be woven, woven or braided with any number of monofilaments and / or multifilaments.

[0017] According to another aspect of the present invention, monofilaments and / or multifilaments may include wires to enhance break resistance.

[0018] According to another aspect of the present invention, a method is provided for constructing a protective sleeve assembly to protect electrical components extending through the protective sleeve assembly from exposure to contamination, impact forces, abrasion, and vibration. The method comprises forming a semi-rigid multilayer tube extending longitudinally along an axis between opposing ends, and providing an end cap having at least one finger positioned above one end, extending radially inward substantially toward the axis, the at least one finger being elastically flexible in the opposite axial direction to allow assembly and disassembly of the protective sleeve assembly around the electrical components to be protected. The method further comprises constructing a semi-rigid multilayer tube including an inner tube and an outer tube, and constructing an inner tube having a semi-rigid tubular wall including an energy dissipation mechanism that acts to dissipate energy and minimize the transmission of impact forces to the electrical components, while also enhancing cut resistance and protection against contamination ingress. The method further comprises constructing the outer tube as a textile tube positioned around the inner tube to provide cut resistance and abrasion resistance to the protective sleeve assembly.

[0019] According to another aspect of the present invention, the method further comprises constructing the inner tube as a solid tubular polymer impermeable wall.

[0020] According to another aspect of the present invention, the method further includes constructing an inner tube having ribs to enhance energy dissipation.

[0021] According to another aspect of the present invention, the method further includes constructing the ribs of the inner tube to extend radially outward from the impermeable wall to form a circumferentially bounded pocket facing radially outward, also referred to as a gap, thereby forming a sealed chamber between the inner tube and the outer tube to enhance energy dissipation, impact resistance, vibration reduction, and protection against the intrusion of contaminants into the central void bounded by the protective sleeve assembly.

[0022] According to another aspect of the present invention, the method further comprises leaving no solid matter in the encapsulation chamber, thereby acting as an individual cushion against impact force while reducing the weight of the protective sleeve assembly and enhancing the thermal protection for the electrical member extending through the cavity of the protective sleeve assembly by providing an encapsulation chamber filled only with air.

[0023] According to another aspect of the present invention, the method further comprises filling the open pockets with a solid material including any suitable continuous or discrete foam, elastomer, rubber, gel, or non-woven material.

[0024] According to another aspect of the present invention, the method further comprises constructing ribs on the inner tube that extend radially inwardly from the impermeable wall.

[0025] According to another aspect of the present invention, the method further comprises constructing ribs that extend radially inwardly and longitudinally between opposing ends of the inner tube.

[0026] According to another aspect of the present invention, the method further comprises braiding, weaving, or knitting an outer tube of any number and material type of monofilaments and / or multifilaments.

Brief Description of the Drawings

[0027] These and other features and advantages of the present invention will be more readily understood when considered in connection with the following detailed description of the presently preferred and best modes, the appended claims, and the accompanying drawings. [Figure 1] A schematic side view of a protective sleeve assembly for protecting an electrical member according to a presently preferred embodiment of the present invention. [Figure 2] An assembled perspective view of a protective sleeve assembly according to one presently preferred embodiment of the present invention. [Figure 2A]This is a schematic partial cross-sectional view of the protective sleeve assembly, cut laterally with respect to its central axis and viewed along the direction of the central axis. [Figure 2B] This figure is similar to Figure 2A, illustrating an aspect according to another embodiment of the present disclosure. [Figure 3] Figure 2 is a perspective view of the inner tube and end cap of the protective sleeve assembly. [Figure 4] This is a similar diagram to Figure 3, viewed from the opposite end. [Figure 5] This is a perspective view of various non-limiting forms of end caps intended herein. [Figure 6] This is a perspective view of various non-limiting forms of end caps intended herein. [Figure 7] This is a perspective view of various non-limiting forms of end caps intended herein. [Figure 8] This is a perspective view of various non-limiting forms of end caps intended herein. [Modes for carrying out the invention]

[0028] Referring more closely to the drawings, Figure 1 shows a schematic side view of a protective sleeve assembly 10 by one currently preferred structure used to position, maintain, or hold a first elongated member, referred to as a multilayer tube or sleeve assembly 12, over an electrical component, such as a sensor 14 (as found in the engine compartment of a vehicle, for example) and a wire harness 16 connected thereto, which is represented here as impact-resistant, cut-resistant, abrasion-resistant, sound-damping, vibration-damping, and thermal protective shielding. In this example, the sleeve assembly 12 comprises an elongated tube assembly including an inner tubular shield, also referred to herein as an inner tube 18 (Figures 3 and 4), the inner tubular shield having a central void, also referred to as a bore 19, the central void being sized to at least partially accommodate a sensor 14 therein. The bore 19 extends along a central axis A from one open end 20 to the opposite open end 22 of the sleeve assembly 12. The inner tube 18 is constructed as a semi-rigid tubular inner wall 24, which acts to minimize the transmission of impact forces to the electrical components 14, 16 and includes energy dissipation features (described in more detail below) that enhance cut resistance and protection against contamination ingress. The sleeve assembly 12 further comprises an outer tubular shield, also referred to herein as an outer tube 26 (Figure 2). The outer tube 26 is constructed as a textile tube, also referred to as an outer wall 28, positioned around the inner tube 18, and provides enhanced cut resistance and enhanced abrasion resistance to the protective sleeve assembly 10. The sleeve assembly 12 further comprises an end cap 30 positioned on one of the ends 22. The end cap 30 includes at least one finger, indicated as a plurality of fingers 32, the fingers extending radially inward to a free end 34 substantially toward the central axis A, the free end 34 fencing an opening 35 sized to receive a wire harness 16, the opening 35 preferably sized so that the wire harness 16 is slightly tight-fitted. The fingers 32 are elastically flexible in opposite axial directions to allow assembly and disassembly of the protective sleeve assembly 10 along and around the electrical components 14, 16 to be protected.

[0029] A sensor 14 (e.g., an oxygen sensor) is connected to a microprocessor (not shown) via a wire harness 16, through which the sensor 14 provides data used by the microprocessor to control the engine's operation and performance. Preferably, the wire harness 16 is covered by a second elongated member, such as an elongated protective harness sleeve 36 extending substantially along the length of the wire harness 16. The harness sleeve 36 can be manufactured by extrusion, molding, or other means from any material or fabric such as a polymer material, and is shown here as an example having an annular corrugation C extending circumferentially around the harness sleeve 36 to provide radial rigidity and bendability.

[0030] During use, the harness sleeve 36 is positioned through the opening 35, preferably with a slight interference fit, and received into the bore 19 of the protective sleeve assembly 10. The protective sleeve assembly 10 is moved longitudinally along the harness sleeve 36 and positioned to surround the sensor 14 and wire harness 16, providing protection to the sensor 14 and wire harness 16, such as protection against impact, abrasion, heat, and other shielding. The end cap 30, also called a positioning device, is moved by sliding the protective sleeve assembly 10 longitudinally along the outer surface of the harness sleeve 36 by applying sufficient axial force to overcome the slight interference fit between the harness sleeve 36 and the inner circumference of the opening 35, such as defined by the free end 34 of the finger 32, not limited to, for example. As a result of the slight interference fit, the positioning device 30 maintains the sleeve assembly 12 in place along the harness sleeve 36. It should be noted that the positioning device 30 can be fixed to the sensor sleeve 12 at any point during the process, and therefore the end cap 30 can be fixed to the end 22 by means of fasteners, i.e., staples or rivets, adhesives, and / or welded joints, after the sleeve assembly has been positioned around the harness sleeve 36 and sensor 14, or in some cases, before positioning, depending on how the positioning device 30 is fixed to the sleeve assembly 12. Thus, the protective sleeve assembly 10 is intended to be assembled as a single assembly or as separate components, as desired for the intended application. When fasteners or welded joints are used, ideally the protective sleeve assembly 10 is intended to be assembled as a single assembly.

[0031] The inner tube 18 can be formed as a solid, impermeable, semi-rigid (meaning having significant structural integrity to maintain the “shape constructed in use”) tubular polymer inner wall 24. The wall 24 of the inner tube 18 may have outer ribs 40 extending radially outward from the wall 24 away from axis A to increase strength and energy dissipation, and inner ribs 38 extending radially inward from the wall 24 toward axis A to increase strength, the inner ribs 38 further increase strength and energy dissipation. The inner ribs 38 are shown to extend substantially parallel to axis A between opposing ends 20, 22 and may extend from one end 20 to the opposite end 22. The outer ribs 40 are shown to provide a rib 40a extending in the longitudinal direction and a rib 40b extending in the circumferential direction. The longitudinally extending rib 40a is shown extending substantially parallel to axis A between opposing ends 20, 22, and can extend from one end 20 to the opposite end 22, while the circumferentially extending rib 40b extends between the longitudinally extending ribs 40a in an interconnected relationship with them. Thus, the outer ribs 40a, 40b of the inner tube 18 form an open, circumferentially bounded pocket 42 facing radially outward, also called a gap, which forms a plurality of sealed chambers 44 (Figure 2A) between the inner tube 18 and the outer tube 26, enhancing energy dissipation, impact resistance, vibration reduction, and protection against contamination intrusion into the central cavity 19 bounded by the protective sleeve assembly 10. As shown in Figure 2A, the sealing chamber 44 can be made free of solid material, thereby providing a sealing chamber filled only with air, which acts as an individual cushion against impact forces, reducing the weight of the protective sleeve assembly 10 while enhancing thermal protection for the electrical components 14, 16 that pass through and extend into the cavity 19 of the protective sleeve assembly 10.Otherwise, as shown in Figure 2B, according to another aspect of the present disclosure, the open pocket 42 may be filled with a solid material 43, which may be any suitable open-cell or closed-cell foam, elastomer, rubber, gel, or nonwoven material, hot-melt material, or other type of adhesive (such as one used to secure the outer tube 26 to the inner tube 18), before forming or positioning the outer tube 26 around the inner tube 18 to close and seal the chamber 44 in order to achieve enhanced buffering and thermal protection for the intended application.

[0032] The inner tube 18 can be formed from any desired polymer material suitable for the intended application, including high-temperature resistant and high-strength polymer materials, such as thermoplastic or thermosetting materials (e.g., nylon, polypropylene, polyethylene, polyvinyl chloride, polyethylene terephthalate). The inner tube 18 can be formed by any suitable molding technique for cost-effectiveness, although other manufacturing methods, including machining operations, are also contemplated herein.

[0033] The end cap 30 can be provided as a material piece integral with the inner tube 18, or as a separate member fastened to at least one of the inner tube 18 and / or the outer tube 26, as shown fastened to the inner tube 18. The end cap 30 can be fastened to the inner tube 18 by fasteners such as staples, screw fasteners, or rivets. According to a further aspect of the present disclosure, the fasteners can be in the form of adhesives or welded joints such as ultrasonic welded joints. The end cap 30 is formed from a flexible elastic material such as a heat-resistant polymer containing the material described above for the inner tube 18, for example. The fingers 32 shown in Figures 2 and 3 are, as mere examples, wedge-shaped or substantially piping-shaped, and directly adjacent fingers 32 have different lengths from each other. Every other finger 32 is shown to be the same length. Thus, every other finger 32a has a first length, the intermediate finger 32b has a second length, and the first length is longer than the second length. Of course, it should be noted that the fingers 32 can be provided in any appropriate number depending on the application, and can be in shapes other than the approximate pie shape, such as rectangles, curves, or other shapes.

[0034] The end cap 30 can provide an edge 46 that extends radially outward from the outer rib 40. The edge 46 acts as a positive stop for the outer tube 26 to prevent it from being pushed axially beyond the edge 46, such as when assembling the outer tube 26 onto the inner tube 18 during manufacturing and use, and thus acts to maintain the outer tube 26 in its intended position around the inner tube 18.

[0035] The finger 32 is fixed as a cantilever spring to the annular outer portion of the end cap 30 at the end opposite to the free end 34. The cantilever action is advantageous because it allows the finger end 34 to elastically flex in the opposite axial direction substantially along the direction of the central axis A, thereby allowing the end cap 30 to move in the opposite axial direction along its length relative to the wire harness 16. In any embodiment, the force applied to move the end cap 30 must be sufficient to overcome the resistance between the finger 32 and any elongated component with which the finger 32 engages, such as the wire harness 16 or harness sleeve 36 when provided around the wire harness 16. The resistance to the flexure applied by the finger 32 can be modified by adjusting the length, size, number, and type and / or thickness of the finger.

[0036] Figure 5 shows an alternative embodiment of the end cap 132, which is substantially similar to the end cap 30, but in which the fingers 132 are spaced apart from each other around the circumference of the end cap 130, defining a wedge-shaped space 48 between them. In the illustrated embodiment, the wedge-shaped space 48 is shown as being similar in size and shape to the wedge-shaped fingers 132, but may be larger or smaller depending on the desired performance criteria for the intended application. This embodiment further shows a substantially cylindrical portion 49 which can be sized to be in close contact with the inside or periphery of the inner tube 18.

[0037] Figure 6 shows an alternative embodiment of the end cap 230, which is substantially similar to the end cap 30, but in which the fingers 232 are arranged adjacent to each other, and thus the space between adjacent fingers 232 is substantially eliminated. Instead, adjacent fingers 232 are spaced circumferentially apart from each other by slits 50 having substantially uniform width along their length.

[0038] Figure 7 shows another alternative embodiment of the end cap 330. The end cap 330 comprises an elongated cylindrical or tapered band 52 to which a plurality of fingers 332 are attached. The fingers 332 are arranged adjacent to each other circumferentially around the band 52 as in Figure 6, but they can also be arranged at intervals as in the embodiment of Figure 5.

[0039] Figure 8 shows another alternative embodiment of the end cap 430. The end cap 430 has fingers 432 as described for the end cap 130, but does not have a substantially cylindrical portion and is formed rather as a flat disc. The fingers 432 are shown spaced apart from each other, but can also be formed adjacent to each other, as shown in Figure 6. The end cap 430 is preferably fixed to the end 22 of the inner tube 18 via one of the fixing mechanisms described above.

[0040] The outer tube 26 may be woven (as shown by example K in the exemplary patch of Figure 2, where it should be understood that the entire outer tube 26 is woven), braided (as shown by example W in the exemplary patch of Figure 2, where it should be understood that the entire outer tube 26 is braided), or braided (as shown by example B in the exemplary patch of Figure 2, where it should be understood that the entire outer tube 26 is braided). The monofilaments and / or multifilaments may include wires to improve cut resistance and to provide protection against electromagnetic interference (EMI), radio frequency interference (RFI), and / or electrostatic discharge (ESD). The monofilaments and / or multifilaments may further include natural organic fibers and / or inorganic fibers. The outer tube 26 may be fastened to the inner tube 18 via any preferred fastening mechanism, including mechanical fasteners, adhesives, and / or welded joints.

[0041] Clearly, many modifications and variations of the present invention are possible in light of the above teachings. It is intended that all features of all claims and all embodiments can be combined with each other, provided that such combinations do not contradict each other. Therefore, it should be understood that the present invention may be implemented in ways other than those specifically described within the appended claims.

Claims

1. A protective sleeve assembly for protecting electrical components and wire harnesses extending through them, The semi-rigid multilayer tube extends longitudinally along the axis of the semi-rigid multilayer tube between opposing ends, An end cap positioned on one of the opposing ends, the end cap having at least one finger extending radially inward substantially toward the axis, the at least one finger being elastically flexible in the opposite axial direction to allow assembly and disassembly of the protective sleeve assembly along the wire harness and around the electrical component, The semi-rigid multilayer tube includes an inner tube and an outer tube, the inner tube having a semi-rigid tubular wall including a radially extending energy dissipation mechanism to minimize the transmission of impact force to the electrical component, and the outer tube being a textile tube arranged around the inner tube. The radially extending energy dissipation mechanism includes a plurality of ribs extending radially outward, The plurality of ribs comprises a plurality of longitudinally extending ribs extending substantially parallel to the axis, and a plurality of circumferentially extending ribs extending between the plurality of longitudinally extending ribs, forming a plurality of individual pockets. The individual pockets form a protective sleeve assembly that contains a sealed chamber between the inner tube and the outer tube.

2. The protective sleeve assembly according to claim 1, wherein the inner tube is a solid, impermeable polymer wall.

3. The protective sleeve assembly according to claim 1, wherein the rib extends so as to abut against the outer tube.

4. The protective sleeve assembly according to claim 1, wherein the radially extending energy dissipation mechanism includes ribs extending radially inward.

5. The protective sleeve assembly according to claim 2, wherein the end cap is made of a solid, semi-rigid nonmetallic material.

6. The protective sleeve assembly according to claim 2, wherein the outer tube is braided, woven, or woven.

7. The protective sleeve assembly according to claim 2, wherein the radially extending energy dissipation mechanism includes ribs extending radially inward.

8. The protective sleeve assembly according to claim 7, wherein the radially inwardly extending ribs extend substantially parallel to the axis.

9. A protective sleeve assembly for protecting electrical components and wire harnesses extending through them, The semi-rigid multilayer tube extends longitudinally along the axis of the semi-rigid multilayer tube between opposing ends, The end cap is positioned on one of the opposing ends and has an opening for receiving the wire harness, enabling assembly and disassembly of the protective sleeve assembly along the wire harness and around the electrical component, The semi-rigid multilayer tube includes an inner tube and an outer tube, the inner tube being a solid, impermeable polymer wall including a plurality of radially outward-extending ribs that extend in contact with the outer tube to form a plurality of sealing chambers between the inner tube and the outer tube, The plurality of radially outward-extending ribs comprises a plurality of longitudinally-extending ribs extending substantially parallel to the axis, and a circumferentially-extending rib extending between the plurality of longitudinally-extending ribs, forming a plurality of individual pockets. The individual pockets form a protective sleeve assembly that contains a sealed chamber between the inner tube and the outer tube.

10. The protective sleeve assembly according to claim 9, wherein the outer tube is a textile tube.

11. The protective sleeve assembly according to claim 10, wherein the inner tube has a plurality of ribs extending radially inward.

12. A method for constructing a protective sleeve assembly to protect an elongated member extending through the protective sleeve assembly, To form the semi-rigid multilayer tube that extends longitudinally along the axis of the semi-rigid multilayer tube between opposing ends, To provide an end cap having at least one finger positioned on one of the opposing ends and extending radially inward substantially toward the axis, wherein the at least one finger is elastically flexible in the opposite axial direction, The semi-rigid multilayer tube comprising an inner tube and an outer tube is constructed, and the inner tube having a semi-rigid tubular polymer impermeable wall including ribs extending radially outward, The outer tube is constructed as a textile tube arranged around the inner tube, A method comprising constructing a radially outward-extending rib, wherein the radially outward-extending rib comprises a plurality of longitudinally-extending ribs extending substantially parallel to the axis and a circumferentially-extending rib extending between the plurality of longitudinally-extending ribs, forming a plurality of individual pockets, the individual pockets forming a sealed chamber between the inner tube and the outer tube.

13. The method according to claim 12, further comprising ensuring that no solid material remains in the individual sealing chambers, thereby providing the sealing chambers filled only with air.

14. The method according to claim 12, further comprising providing the sealing chamber filled with a solid material.

15. The method according to claim 12, further comprising forming the inner tube having ribs extending radially inward.

16. The method according to claim 15, further comprising forming a rib extending radially inward and substantially parallel to the axis.

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