Self-Wrapping Woven Sleeve Structure for Non-Kinking Corner Bends
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Solution Overview
Problem
Existing textile sleeves for protecting elongate members face limitations, such as rigidity and kinking issues when bent around corners, particularly in braided sleeves, and manufacturing constraints in woven sleeves, which restrict material choices and flexibility.
Innovation Solution
A woven, self-wrapping sleeve with discrete annular bands of weft yarns having varying picks-per-inch (picks-per-centimetre) counts, combined with heat-settable yarns, to provide flexibility and hoop strength, allowing the sleeve to wrap around corners of 90 degrees or more without kinking, while maintaining protection and coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If heat-settable yarns are woven in the circumferential direction to create a self-wrapping structure, then the sleeve gains self-wrapping capability, but the sleeve becomes more rigid and susceptible to kinking when bent around corners
Solution Approach 1:
The sleeve is segmented into multiple zones along its length, with each zone having different weft yarn densities. The first zone has a first density of weft yarns, while the second zone has a second density different from the first. This segmentation allows different portions of the sleeve to have different flexibility characteristics, enabling the sleeve to self-wrap while resisting kinking at bends.
Solution Approach 2:
Different regions of the sleeve are given different local properties through varying weft yarn densities. The zones with lower weft yarn density provide greater flexibility and resistance to kinking, while zones with higher density provide structural support. This local variation in quality allows the sleeve to simultaneously achieve self-wrapping capability and kink resistance.
2Ease of manufacture
If woven sleeves are made with uniform weft yarn density, then manufacturing is simplified, but the sleeve lacks flexibility to bend around corners without kinking
Solution Approach 1:
The manufacturing process is segmented to create zones with different weft yarn densities. The loom is configured to weave the first zone with a first density of weft yarns, then transition to the second zone with a second density. This segmented approach maintains manufacturing simplicity while creating the flexibility variations needed for corner bending.
Solution Approach 2:
The sleeve structure is made dynamic through varying weft yarn densities along its length. The transition from uniform density to variable density allows the sleeve to adapt its flexibility characteristics along its length, enabling it to bend around corners while maintaining overall structural integrity.
3Adaptability or versatility
If braided sleeves are used to achieve non-kinking properties, then flexibility is improved, but material selection and manufacturing options are limited
Solution Approach 1:
The invention changes the key parameter of weft yarn density along the length of the sleeve to achieve flexibility without adopting braided construction. By varying the density parameter in different zones, the sleeve gains the flexibility needed to bend around corners while maintaining the manufacturing advantages of woven construction and broad material selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances flexibility and hoop strength, enabling the sleeve to wrap around sharp corners without kinking, while maintaining protection and coverage, and allows for a variety of yarn types and economical manufacturing.
Implementation Method 1
heat-setting at least some of the weft yarns and imparting a bias on the wall to bring the edges into overlapping relation with one another
Data Source
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AI summary
A wrappable textile sleeve and method of construction thereof is provided. The textile sleeve includes an elongate wall extending along a longitudinal axis between opposite ends with lengthwise extending edges extending along the longitudinal axis between the opposite ends. The wall is woven from lengthwise extending warp yarns and circumferentially extending weft yarns with at least some of the weft yarns being heat-set to impart a self curling bias on the wall to bring the edges into overlapping relation with one another. Further, the weft yarns form a plurality of discrete annular bands that extend circumferentially about the longitudinal axis with adjacent bands having different picks- per-inch from one another to provide the sleeve with enhance regions of flexibility, self- curling bias and hoop strength.