METHOD OF CONSTRUCTION THEREOF

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application Serial No. 62/408,962, filed October 17, 2016, U.S. Provisional Application Serial No. 62/286,106, filed January 22, 2016, and U.S. Utility Application Serial No. 15/411,080, filed January 20, 2017, which are incorporated herein by way of reference in their entirety.

BACKGROUND OF THE INVENTION

1. Technical Field

[0002] This invention relates generally to textile sleeves for protecting elongate members, and more particularly to braided textile sleeves.

2. Related Art

[0003] Tubular textile sleeves are known for use to provide protection to internally contained elongate members, such as wire harnesses, fluid or gas conveying tubes, or cables, for example. It is further known to braid tubular textile sleeves for protecting elongate members contained therein. Modern vehicle applications for such sleeves are requiring greater protection to the elongate members, such as against increased environmental temperatures and increased resistance to abrasion. These increased demands require the sleeves to pass various test parameters, such as exposure to increased temperatures and exposure to specifically defined abrasion test specifications, such as abrasion tools being passed along both the length of the sleeve and transversely to the length of the sleeve without abrading through the full braided layer of the sleeve or causing any damage to the elongate member contained therein. Known braided sleeve constructions, under some test parameters, are unable to meet the test specifications, and thus, further development is needed. Of course, it is to be appreciated that the resulting sleeves must not only meet the various thermal and abrasion resistant test requirements, but also must be economical in manufacture; have a relatively small envelope and remain flexible to facilitate installation over meandering paths, which tend to be contrary to the ability to form a sleeve that meets increasingly stringent test parameters.

[0004] A braided sleeve constructed in accordance with this invention is able to meet the increasingly demanding temperature and abrasion resistant test parameters discussed above, while also having a relatively small envelope and remaining flexible, while other benefits may become readily recognized by those possessing ordinary skill in the art.

SUMMARY OF THE INVENTION

[0005] A textile sleeve having a seamless, flexible, abrasion resistant tubular wall of braided yarns is provided. The yarns of the wall are braided to withstand elevated temperatures, such as up to about 17S °C, and to resist abrasion through the full wall thickness under specified test parameters, while also remaining sufficiently flexible such that the sleeve can be routed about meandering paths including sharp bends without kinking.

[0006] In accordance with another aspect of the invention, a protective textile sleeve is provided having a flexible, tubular wall of braided yarns. At least some of the yarns are provided as a plurality of monofilaments and at least some of the yarns are provided as a plurality of multifilaments. The plurality of multifilaments are braided in a plurality of separate bundles. Each of the bundles includes at least two multifilaments, wherein the flexible, tubular wall has an outer surface density of between about 500-700g/m ² ,

[0007] In accordance with another aspect of the invention, the multifilaments have a denier of between about 1000-1200dTex.

[0008] In accordance with another aspect of the invention, the multifilaments have a tenacity between about 60-85 cN/tex.

[0009] In accordance with another aspect of the invention, the multifilaments are polyester. [0010] In accordance with another aspect of the invention, the monofilaments have a diameter between about 0.35-0.40mm.

[001 1] In accordance with another aspect of the invention, the monofilaments have a tenacity between about 40-55 cN/tex.

[0012] In accordance with another aspect of the invention, the monofilaments have a Young's Modulus of about 3GPa.

[0013] In accordance with another aspect of the invention, the plurality of multifilaments and the plurality of monofilaments are braided in a respective ratio of about 2: 1 ,

[0014] A protective textile sleeve constructed in accordance with another aspect of the invention has a flexible, tubular wall of braided yarns, with at least some of the yarns being provided as a plurality of monofilaments and at least some of the yarns being provided as a plurality of multifilaments. The plurality of multifilaments are braided as a plurality of separate bundles, with each of the bundles including at least two multifilaments. Further, the monofilaments have a tenacity between about 40-55 cN/tex, thereby being embedded into the multifilaments to lock the multifilaments in an "as braided" location to enhance the abrasion resistance of the sleeve wall.

[0015] A protective textile sleeve constructed in accordance with another aspect of the invention has a flexible, tubular wall of braided yarns, with at least some of the yarns being provided as a plurality of monofilaments and at (east some of the yarns being provided as a plurality of multifilaments. The plurality of multifilaments are braided in a plurality of separate bundles, with each of the bundles including at least two multifilaments, wherein the monofilaments have a Young's Modulus of about 3GPa, thereby being embedded into the multifilaments to lock the multifilaments in an "as braided" location to enhance the abrasion resistance of the sleeve wall. [0016] In accordance with another aspect of the invention, a method of constructing a protective textile sleeve is provided. The method includes braiding a flexible, tubular wall from a plurality of monofilaments having a tenacity between about 40-55 cN/tex and a plurality of multifilaments having a denier of between about 1000-1200dTex. The plurality of multifilaments are braided as a plurality of separate bundles, with each of the separate bundles including at least two multifilaments. The method includes embedding the plurality of monofilaments into the plurality of multifilaments during the braiding process to effectively lock the plurality of multifilaments in place.

[0017] In accordance with another aspect of the invention, the method further includes providing the multifilaments having a tenacity between about 60-83 cN/tex.

[0018] In accordance with another aspect of the invention, the method further includes providing the monofilaments having a diameter between about 0.35-0.40mm.

[0019] In accordance with another aspect of the invention, the method further includes providing the monofilaments having a Young's Modulus of about 3GPa.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] These and other aspects, features and advantages of the invention 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, appended claims, and accompanying drawings, in which:

[0021] Figure 1 is a schematic perspective view of a braided protective textile sleeve constructed in accordance with one aspect of the invention shown protecting an elongate member extending therethrough;

[0022] Figure 2 is an enlarged fragmentary plan view of a wall of the sleeve of Figure 1 ;

[0023] Figure 3 is a schematic end view illustrating a braid structure of the sleeve of Figure I depicting a ratio of bundled multifilaments and individual monofilaments; [0024] Figure 4 is a schematic partial end view illustrating a braid structure of the sleeve of Figure 1 with an abrasion test tool arranged for contact therewith;

[0025] Figures SA and SB illustrate abrasion tests performed on a sleeve to determine if the sleeve meets predetermined specification requirements; and

[0026] Figure 6 is a table listing different braid sleeve structures constructed in accordance with various aspects of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0027] Referring in more detail to the drawings, Figure 1 illustrates a braided tubular textile sleeve 10 constructed according to one aspect of the invention. The sleeve 10 includes a plurality of multifilament yarns, referred to hereafter as simply as multifilaments 1 1, braided with a plurality of monofilament yarns, referred to hereafter simply as monofilaments 12, to form a tubular wall 14 of the sleeve 10. The wall 14 is braided in seamless fashion and thus, has a circumferentially continuous, uninterrupted outer surface 16 and an inner surface 18 defining an inner tubular cavity 20 extending axial ly along a central longitudinal axis 22 between opposite ends 24, 26 of the sleeve 10. The cavity 20 is sized for receipt of an elongate member 28 to be protected, such as a wire harness, fluid or gas conveying conduit, cable or the like. The synergies created between the multifilaments I I and the monofilaments 12 provide the sleeve 10 with an outer surface density as low as about S00 g/m ² , resulting in a cost effective sleeve and a highly flexible wall 14, while at the same time providing the wall 14 with a tough outer surface 16 that is highly resistant to abrasion, such that the wall 14 of the sleeve 10 is able to protect the elongate member 28 contained therein against damage. Evidence of such toughness under elevated temperatures has been empirically verified in abrasion testing, discussed in more detail below.

[0028] The wall 14 can be constructed having any suitable length and diameter and is braided having a tight braid structure to increase the impermeability of the wall 14 against the ingress of external fluid and/or debris into the cavity 20 without need for a secondary coating of any kind. Accordingly, the sleeve 10 is made cost effective given its ability to provide protection to the elongate member 28 without need for multiple wall layers or a secondary coating material. Tn accordance with one aspect of the invention, the wall 14 is formed with bundled, dual strands or ends of the multifilaments 1 1 in side-by-side, mirrored relation and with single strands or ends of the monofilaments 12, wherein the bundled multifilaments 1 1 are braided with the single monofilament strands 12. Figure 3 illustrates the individual bundles of dual strands DS of multifilaments I I, shown schematically, in relation to the single strands SS of monofilaments 12, shown schematically. As such, if an equal number of carriers are used to braid the wall 14, such as 36 carriers for the multifilaments 1 1 and 36 carriers for the monofilaments 12, by way of example and without limitation, each of the carriers of the multifilaments 1 1 has 2 ends of the multifilaments 11, while each of the carriers of the monofilaments 12 has a single end of the monofilaments 12. Accordingly, the multifilaments 11 and monofilaments 12 are braided with one another in a respective ratio of 2: 1 ends. As such, it should be recognized the two ends of multifilaments 1 1 on each carrier are braided in side-by-side, mirrored relation with one another as though they are a single, common yarn.

[0029] The monofilaments 12 play in important role in the performance of the sleeve 10 and provide the sleeve 10 with its ability to resist abrasion, and function in part to lock the bundled multifilaments 1 1 in their "as braided" location during use, thereby enhancing the abrasion resistance of the wall 14 provided by the "locked and fixed" high tenacity multifilaments 1 1. The multifilaments of polyester are provided having a linear density of between about 1000-1200 dTex, and in one exemplary embodiment were provided having an 1 100 denier and a count-related yarn tenacity between about 60-85cN/tex, wherein cN/tex yarn ^∞ cN/tex fiber (x) substance utiIization% (/) 100, and in particular, were provided as high tenacity PET sold under the tradename Diolen®, by way of example and without limitation. The ability of the monofilaments 12 to lock the multifilaments 1 1 in position is due in part to the diameter of the monofilaments, which is provided between about 0.35- 0.40mm, and also the high modulus and rigidity in the radial direction (lack of ability to be radially deformed elastically) of the monofilaments (it is to be understood that although the monofilaments 112 are rigid in the radial direction that they remain flexible along their length, thereby allowing the sleeve 10 to remain highly flexible), having a relatively high Young's Modulus of elasticity, such as about 3GPa, and a tenacity between about 40-55 cN/tex, and in one particularly preferred embodiment, by way of example and without limitation, high tenacity thermoplastic polyamide, such as high tenacity nylon. With the monofilaments 12 having a relatively high Young's Modulus, they are able to be embedded into the multifilaments 1 1, thereby acting to lock the multifilaments 1 1 in place in an "as braided" location. To the contrary, if the monofilaments were provided having a relatively low Young's Modulus, the monofilaments would be more elastic, both axially and radially, and as such, would not be embedded into the multifilaments to the degree needed to lock the multifilaments in an "as braided" location. As such, with a relatively low Young's Modulus monofilament, an increased surface area density of the wall would be needed, such as about 900g/m ² , to provide the degree of abrasion resistance needed to pass the abrasion test and to protect the elongate member against damage. Of course, it should be recognized that an increased surface area would come at an increased cost, add bulk, and further, would reduce the flexibility of the sleeve.

[0030] Tests used to validate the abrasion resistance of the sleeve 10 include a tool 30, having an applied mass of 200g, that is oriented with the length of the tool 30 extending generally transversely to the longitudinal axis 22 of the sleeve 10 (5A and 5B). In accordance with one test, the tool 30 is moved along the length of the sleeve 10 at a frequency of 10Hz, such as shown in Figure SA, and in another test, the tool 30 is moved at a frequency of lOHz in a sawing type motion, transversely to the length of the sleeve, across the width of the sleeve 10, such as shown in Figure SB. The number of cycles for a new sleeve test is 144,000. A sleeve 10 constructed in accordance with the invention, as described above, is able to pass the test having a rating of 4 or higher on a scale of 0-5. Passing the test requires only a partial wearing of the underlying braided yarns take place during testing, without breaking through the thickness or severing of any of the underlying braided yarns, and of course, no damage to an elongate member contained in the sleeve 10 can result. The abrasion resistance test procedure performed on a sleeve constructed in accordance with the invention, which passed the test with a score of no less than 4, is as follows:

[0031] During construction of the sleeve 10, including braiding the bundled multifilaments 1 1 and single monofilaments 12 with one another, as discussed above, the desired length of the sleeve 10 is preferably cut to length in the braiding process. Cutting the desired finished length of the sleeve 10 in the braiding process has been found to facilitate maintaining the round outer peripheral shape of the sleeve 10, thereby facilitating insertion of the elongate member 28 through the cavity 20.

[0032] The table illustrated in Figure 6 shows six (6) different samples produced in accordance with various aspects of the invention, by way of example and without limitation, with the mean sleeve diameter listed in column B; the various types of multifilament and monoftlament yarns listed in columns C and D, respectively, along with the number of carriers and ends of respective yarns; the braid wall mass listed in column E; and the braid wall density listed in column F.

[0033] It is to be understood that the above detailed description is with regard to some presently preferred embodiments, and that other embodiments readily discernible from the disclosure herein by those having ordinary skill in the art are incorporated herein and considered to be within the scope of any ultimately allowed claims.