Knitted Protective Sleeve with Integrated Openings

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Solution Overview

Problem

Existing knit tubular sleeves for protecting elongate members face challenges such as complex assembly processes and increased labor and component costs due to closed-wall construction, which requires multiple sleeves or secondary cutting and sewing operations to accommodate protrusions, leading to potential unraveling and reduced useful life.

Innovation Solution

A method of constructing a tubular sleeve using a knitting machine that integrates openings between opposite ends during the knitting process, eliminating the need for secondary operations and ensuring continuous, uncut yarns that prevent unraveling, with options for reverse folding and multiple layers to align openings for enhanced protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a closed-wall construction is used for knit tubular sleeves, then the sleeve structure is simple and continuous, but multiple sleeves are required to accommodate protrusions which complicates assembly and increases labor cost

Engineering Contradiction:

Improvesleeve structureVSAvoidassembly process

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The sleeve wall is segmented by forming openings directly in the knit structure during the knitting process. This allows the sleeve to accommodate protrusions and branched members without requiring multiple separate sleeves, thereby simplifying the assembly process while maintaining structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Openings are formed in advance during the knitting process itself, before the sleeve is assembled onto the exhaust system. This preliminary formation of openings eliminates the need for secondary cutting and sewing operations, reducing assembly complexity and labor costs.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If openings are formed in the closed wall to accommodate protrusions, then assembly is simplified, but the wall must be slit which causes yarn fraying and unraveling

Engineering Contradiction:

Improveassembly processVSAvoidyarn stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Openings are formed in advance during the knitting process with yarns properly terminated and secured. This prevents subsequent fraying and unraveling that would occur if openings were created by slitting the finished sleeve wall.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The potential harm of yarn fraying is converted into a benefit by designing the knitting process to create controlled openings with secured yarn ends. The openings serve their intended purpose of accommodating protrusions while the yarn security prevents the harmful unraveling effect.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If secondary cutting and sewing operations are used to form openings, then yarn unraveling is reduced, but manufacturing cost increases

Engineering Contradiction:

Improveyarn stabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The opening formation operation is merged with the primary knitting process. Both the sleeve construction and opening formation are accomplished in a single continuous knitting operation, eliminating the need for separate secondary cutting and sewing operations, thereby reducing manufacturing cost while maintaining yarn stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Openings are formed in advance during the knitting process with yarns properly terminated and secured. This preliminary formation of openings eliminates the need for secondary cutting and sewing operations, reducing assembly complexity and labor costs.

Inventive Principle:

Principle #10Preliminary action

4Adaptability or versatility

If multiple sleeves are used in combination, then protrusions are accommodated, but the number of components and assembly complexity increases

Engineering Contradiction:

Improveaccommodation of protrusionsVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A single sleeve is designed to perform multiple functions: providing thermal protection and accommodating various protrusions through integrally formed openings. This universal design eliminates the need for multiple specialized sleeves, reducing component count while maintaining adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP2185849B1Method of construction of a protective sleeve with knitted opening

Publication Date: 2017.01.04 FEDERAL MOGUL POWERTRAIN INC

AI summary

A knit tubular protective sleeve and method of construction thereof provides a continuous and seamless tubular wall knit from one or more yams extending between opposite open ends of the sleeve. At least one opening is integrally knit within the tubular wall between the ends. The opening has a circumferentially continuous, knit outer periphery.