Wrappable Woven EMI Sleeve with Integrated Abrasion Protection
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Solution Overview
Problem
Existing wrappable woven sleeves for protecting elongate members, such as wires, suffer from abrasion issues and add unnecessary cost and bulk due to the use of additional abrasion-resistant layers, which are not integrated into a single layer design.
Innovation Solution
A single layer wrappable woven sleeve is designed with conductive and non-conductive warp filaments that provide electromagnetic interference (EMI) shielding and abrasion resistance, featuring a flexible, lightweight, and durable construction with internal and external floats to prevent abrasion, and includes a hook-and-loop fastener for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single layer EMI sleeve is used, then cost and bulk are reduced, but abrasion resistance deteriorates
Solution Approach 1:
The patent combines multiple functions (EMI shielding, abrasion resistance, flexibility) into a single integrated sleeve layer. The single layer construction merges the protective functions that traditionally required separate layers, eliminating the need for additional abrasion-resistant sleeves while maintaining both EMI protection and abrasion resistance through the woven structure of conductive and non-conductive filaments.
Solution Approach 2:
The sleeve uses composite material construction with a blend of conductive filaments (for EMI shielding) and non-conductive filaments (for abrasion resistance and flexibility). This composite approach allows a single layer to achieve multiple protective functions simultaneously, providing both electromagnetic interference protection and mechanical abrasion resistance without requiring additional layers.
2Reliability
If additional abrasion resistant sleeve is applied, then abrasion protection is improved, but bulk and weight increase
Solution Approach 1:
The patent merges abrasion protection functionality into the primary EMI sleeve structure itself, eliminating the need for separate abrasion-resistant layers. The single layer design integrates both EMI shielding and abrasion resistance, thereby preventing weight and bulk increase while maintaining protective functionality.
Solution Approach 2:
The sleeve employs local quality differentiation through its filament composition, where non-conductive filaments provide abrasion-resistant properties in specific regions of the weave, while conductive filaments provide EMI shielding. This localized functional distribution allows a single layer to provide both protection types without adding bulk.
3Reliability
If additional abrasion resistant sleeve is applied, then abrasion protection is improved, but sleeve thickness increases
Solution Approach 1:
The patent combines multiple protective functions (EMI shielding and abrasion resistance) into a single integrated layer, eliminating the need for additional thickness from separate abrasion-resistant sleeves. The single layer construction maintains low profile and minimal thickness while providing both protective functions through its woven filament structure.
Solution Approach 2:
The composite material construction with conductive and non-conductive filaments woven together allows a single thin layer to provide both EMI shielding and abrasion resistance. This composite approach achieves multiple protective functions without increasing sleeve thickness, maintaining a low-profile design suitable for tight space applications.
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 sleeve effectively shields against EMI while preventing abrasion to the wires and external components, maintaining a low profile and high durability, suitable for demanding environments like motor vehicles and rail applications.
Implementation Method 1
The wall is woven with warp filaments extending generally parallel to the central longitudinal axis and weft filaments extending generally transversely to the warp filaments. The warp filaments include conductive filaments provided as wire filaments and separate non-conductive warp filaments. The weft filaments include heat-set filaments that are formed to bias the wall into a cylindrical shape and to bias opposite edges into overlapping relation with one another. The weft filaments also include conductive filaments.
Implementation Method 2
The weft filaments include heat-set filaments that are formed to bias the wall into a cylindrical shape and to bias opposite edges into overlapping relation with one another.
Data Source
AI summary
A woven EMI sleeve has a wall with opposite edges extending lengthwise between opposite ends. The wall is wrapped about a central longitudinal axis into a tubular configuration bounding an enclosed cavity sized for receipt of an elongate member therein. The wall is woven with warp filaments extending generally parallel to the central longitudinal axis and weft filaments extending generally transversely to the warp filaments. The warp filaments include conductive filaments provided as wire filaments and separate non-conductive warp filaments. The weft filaments include heat-set filaments that are heat-formed to bias the wall into the tubular configuration and to bias opposite edges into overlapping relation with one another. The weft filaments also include conductive filaments.