CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 62/795,999, filed January 23, 2019, and U.S. Utility Patent Application Serial No. 16/749,725, filed January 22, 2020, the entire disclosures of which is incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

1. Technical Field

[0002] This invention relates generally to textile sleeves, and more particularly to braided textile sleeves and to their method of construction.

2. Related Art

[0003] It is known to protect temperature sensitive elongate members, such as wires and temperature sensitive sensors connected thereto with heat resistant tubular members, such as solid polymeric or metal tubing. Although known tubing can provide protection to wires extending therethrough against high heat, such tubing is generally stiff and inflexible, and thus, the ability to route the wires along meandering paths is limited. Some attempts to provide more flexible tubular members, such as via braiding, have been made; however, the heat resistance of such braided tubular members, also referred to a sleeves or sheaths, is generally limited to temperatures below about 280 degrees Fahrenheit. In addition, the resistance to abrasion provided by braided sleeves is generally low, and thus, the sleeves can be worn over time, thereby subjecting the wire(s) therein to damage.

[0004] Accordingly, what is needed is a protective sleeve that provides protection to an elongate member extending therethrough against high heat, such as temperatures above 280 degrees Fahrenheit, that is flexible, is abrasion resistant and is resistant to fraying. SUMMARY OF THE INVENTION

[0005] In accordance with one aspect of the invention, a protective textile sleeve includes a seamless, circumferentially continuous, tubular braided wall extending lengthwise along a central longitudinal axis between opposite ends. The wall includes a plurality of yams braided with one another, with a plurality of the yams being high temperature, non-heat- shrinkable yam and a plurality of the yams being heat-shrinkable yams. The heat-shrinkable yams are shrinkable at a temperature that does not cause the high temperature, non-heat- shrinkable yams to shrink, or at least does not cause the high temperature, non-heat- shrinkable yams to shrink substantially. Accordingly, by way of example and without limitation, the heat-shrinkable yams may shrink lengthwise greater than 10 percent of their original length, such as between about 10-90 percent of their original length or more, while the non-heat-shrinkable yam may shrink about 2 percent of their original length or less when the sleeve is exposed to a heat-shrink, heat treatment process.

[0006] In accordance with another aspect of the invention, the heat-shrinkable and non heat-shrinkable yams are braided with one another such that the heat-shrinkable yams, upon being shrank, cause the non-heat-shrinkable yams to be axially compressed (gathered, bunched, warped) such that the thickness of the braided wall of the sleeve is increased by between about 25-90 percent relative to the thickness prior to heat-shrinking the heat- shrinkable yams, with the increased wall thickness providing an increased resistance to abrasion, an increased resistance to fraying, an increased resistance to the ingress of contamination, an increased level of thermal insulation and an increased level of protection against high temperature thermal conditions.

[0007] In accordance with another aspect of the invention, upon heat-shrinking the heat- shrinkable yams, the non-heat-shrinkable yams are axially compressed and bunched between the heat-shrink yams, thereby increasing the density of the wall, which in turn increases the resistance to abrasion, increases the thermal insulation and increases the level of protection against high temperature thermal conditions, increases the resistance to the ingress of contamination, and increases the resistance to fraying of the yams upon cutting the sleeve wall to length and fraying of the ends of the sleeve while in use.

[0008] In accordance with another aspect of the invention, the non-heat-shrinkable yam and the heat-shrinkable yam can be provided in an equal number of ends braided with one another, thereby providing a uniform appearance and a uniform level of protection about the entirety of the sleeve.

[0009] In accordance with another aspect of the invention, the non-heat-shrinkable yam and the heat-shrinkable yam can be braided in a respective 1 : 1 braid pattern, with the non heat-shrinkable yam and the heat-shrinkable yam alternating with one another in opposite S and Z helical directions.

[0010] In accordance with another aspect of the invention, the non-heat-shrinkable yam can be provided as a monofilament and/or multifilament, as desired, to provide the sleeve with the desired type of abrasion resistance protection, coverage and flexibility.

[0011] In accordance with another aspect of the invention, the non-heat-shrinkable yam can be provided as aramid multifilament, thereby enhancing the resistance of the sleeve to degradation when exposed to high temperatures, such as in excess of 280 degrees Fahrenheit.

[0012] In accordance with another aspect of the invention, the heat-shrinkable yam can be provided as poly ether ether ketone (PEEK) monofilament.

[0013] In accordance with another aspect of the invention, a protective braided sleeve includes a seamless, circumferentially continuous, flexible tubular wall extending lengthwise along a central longitudinal axis between opposite ends, with the wall including a first plurality of yams braided with a second plurality yams, wherein the first plurality of yams and the second plurality of yams have different heat-shrink ratios from one another. The wall has a first thickness prior to exposing the wall to a predetermined temperature and a second thickness after exposing the wall to the predetermined temperature, with the second thickness being between about 25-90 percent greater than the first thickness, thereby increasing the abrasion resistance, increasing the resistance to the ingress of contamination, and increasing the heat-resistance of the wall.

[0014] In accordance with another aspect of the invention, the wall has a first length prior to exposing the wall to the predetermined temperature and a second length after exposing the wall to the predetermined temperature, the second length being less than the first length, thereby contributing to the increased abrasion resistance, the increased resistance to the ingress of contamination, and the increased heat-resistance of the wall.

[0015] In accordance with another aspect of the invention, the second length is at least 10 percent less than the first length.

[0016] In accordance with another aspect of the invention, the first plurality of yams shrink lengthwise at least 10 percent of an as braided length upon exposing the wall to the predetermined temperature and the second plurality of yams shrink lengthwise less than 2 percent of an as braided length upon exposing the wall to said predetermined temperature, thereby contributing to the increased thickness of the wall upon exposing the wall to the predetermined temperature, thus, increasing the abrasion resistance, the increased resistance to the ingress of contamination, and the increased heat-resistance of the wall.

[0017] In accordance with another aspect of the invention, the first plurality of yams can be provide as monofilaments and the second plurality of yams can be provided as multifilaments.

[0018] In accordance with another aspect of the invention, the wall can be braided including only the first plurality of yams and the second plurality of yams. [0019] In accordance with another aspect of the invention, a method of constructing a protective textile sleeve includes braiding a plurality of non-activatable, non-heat-shrinkable yams with a plurality of activatable, heat-shrinkable yams to form a seamless tubular wall extending lengthwise along a central longitudinal axis, with the resulting braided wall being in a first, non-heat-treated state. Further, heat-treating the braided wall to a second, heat- treated state and causing the activatable, heat-shrinkable yams to become activated and shrink lengthwise, while not causing the non-activatable, non-heat-shrinkable yams to shrink lengthwise substantially, and causing the non-activatable, non-heat-shrinkable yams to become bunched to take on a serpentine, meandering shape along the length of the shrunken yams.

[0020] In accordance with another aspect of the invention, the method can further include braiding the non-heat-shrinkable yams and the heat-shrinkable yams in alternating relation with one another in a 1 : 1 braid pattern to provide the sleeve with a substantially balanced content and uniform distribution of the non-heat-shrinkable yams and heat- shrinkable yams.

[0021] In accordance with another aspect of the invention, the method can further include increasing a first thickness of the braided wall from when the wall is in the first, non-heat- treated state to a second thickness when the wall is in the second, heat-treated state, such as being greater than 25 percent, and preferably being greater than 50 percent, and more preferably being greater than 75 percent of the first thickness, thereby increasing the resistance of the wall to abrasion and increasing the thermal insulation properties of the wall to provide the elongate member bounded by the wall with enhanced protection against the ingress of contamination and against high temperature external environmental thermal conditions, such as above 280 degrees Fahrenheit. [0022] In accordance with another aspect of the invention, the method can further include increasing a first density of the braided wall from when the wall is in the first, non-heat- treated state to a second density when the wall is in the second, heat-treated state, such that the second density is significantly greater than the first density, such as being greater than 25 percent, and preferably being greater than 50 percent, and more preferably being greater than 75 percent of the first density, thereby significantly increasing the resistance of the wall to abrasion, increasing the thermal insulation properties of the wall to provide the elongate member bounded by the wall with enhanced protection against high temperature external environmental thermal conditions, increasing the resistance to the ingress of contamination, and further increasing the resistance of the yams to fraying while being cut and while in use.

[0023] In accordance with another aspect of the invention, a method of constructing a protective textile sleeve can include braiding a plurality of first yams with a plurality of second yams to form a seamless tubular wall extending lengthwise along a central longitudinal axis, with the resulting seamless tubular wall having a first thickness. Further, exposing the braided wall to a predetermined temperature and causing the first yams to shrink lengthwise and causing the second yams to become axially bunched under a force imparted by the shrunken first yams causing the seamless tubular wall to expand to a second thickness that is greater than the first thickness.

[0024] In accordance with another aspect of the invention, the method can further include increasing the first thickness between about 25-90 percent to the second thickness upon exposing the braided wall to the predetermined temperature.

[0025] In accordance with another aspect of the invention, the method can further include increasing the first thickness between about 50-90 percent to the second thickness upon exposing the braided wall to the predetermined temperature. [0026] In accordance with another aspect of the invention, the method can further include increasing the first thickness between about 70-90 percent to the second thickness upon exposing the braided wall to the predetermined temperature.

[0027] In accordance with another aspect of the invention, the method can further include causing the first yams to shrink lengthwise at least 10 percent upon exposing the braided wall to the predetermined temperature and causing the second yams to shrink lengthwise less than 2 percent upon exposing the braided wall to the predetermined temperature, thereby causing the first yams to impart an axially directed force on the second yams and causing the second yams to be bunched to increase the thickness of the braided wall.

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] These and other aspects, features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description of presently preferred embodiments and best mode, appended claims and accompanying drawings, in which:

[0029] Figure 1 is a schematic perspective view of a tubular braided sleeve constructed in accordance with one embodiment of the invention shown in a deactivated, as initially braided, non-heat-treated, first state with an elongate member to be protected disposed in a cavity thereof;

[0030] Figure 1A is a view similar to Figure 1 with the tubular braided sleeve shown in an activated, heat-treated, second state;

[0031] Figure 2 is an enlarged schematic view of a portion of a wall of the tubular braided sleeve of Figure 1 shown in a deactivated, as initially braided, non-heat-treated, first state;

[0032] Figure 2A is an enlarged schematic view of a portion of the wall of the tubular braided sleeve of Figure 1A shown in an activated, heat-treated, second state; [0033] Figure 3 is a side view of a non-heat-shrinkable, high temperature yam braided in the wall of the tubular braided sleeve, with the non-heat-shrinkable, high temperature yam shown prior to subjecting the tubular braided sleeve to a heat treatment process; and

[0034] Figure 3A is a view similar to Figure 3 of the non-heat-shrinkable, high temperature yam shown after subjecting the tubular braided sleeve to a heat treatment process.

DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS

[0035] Referring in more detail to the drawings, Figures 1-2 A illustrate a tubular braided protective textile sleeve, referred to hereafter as sleeve 10, constmcted in accordance with one aspect of the invention. The sleeve 10, as braided in a single, continuous braiding process, has a braided, circumferentially continuous, seamless tubular wall 12 bounding a through passage, also referred to as cavity 13, extending lengthwise along a central longitudinal axis 14 between open opposite ends 16, 18, wherein the cavity 13 receives an elongate member 15 to be protected, such as a wire harness, conduit, pipe, or the like. The wall 12 is braided including a plurality of ends (end, as understood in the art is a single yam filament, whether a monofilament or a multifilament) of yam braided with one another, with a plurality of the yams being non-heat-shrinkable, high temperature yams 20 (Figures 3 and 3A; high temperature meaning able to withstand temperatures in excess of 280 degrees Fahrenheit without being altered in material property or length) and a plurality of the yams being heat-shrinkable yams 22 (a cross-linked heat-shrinkable yam meaning that the yams 22 can be activated to shrink 10% or more, up to 90%, of their original, non-activated length; Figures 1 and 1A). The heat-shrinkable yams 22 are shrinkable at a temperature in a heat- treatment process that does not cause the high temperature yams 20 to shrink, or at least does not cause the high temperature yams to shrink substantially. Accordingly, by way of example and without limitation, the heat-shrinkable yams 22 may shrink lengthwise (axially) greater than 10 percent of their original length, such as between about 10-90 percent, while the non-heat-shrinkable, high temperature yam 20 may shrink about 2 percent, or less, of their original length when the sleeve 10 is exposed to the heat treatment process. Accordingly, upon the sleeve 10 being heat-treated, the heat-shrinkable yams 22 are shrunken lengthwise between about 10-90 percent, while the non-heat-shrinkable, high temperature yam 20 remain substantially non-shrunk. As such, as shown in Figure 3A, the non-heat- shrinkable, high temperature yam 20 are caused to taken on a meandering, serpentine configuration along their length as a result of being axially compressed, also referred to as axially gathered, axially warped or axially bunched, such that the effective thickness of the braided wall 12 of the sleeve 10 is increased, such as by at least 25 percent, and more preferably between about 50-90 percent from a first thickness tl (Figure 2; illustrating a portion of the wall 12, with it to be recognized that the remaining unseen portion of the wall 12 is the same as the portion shown) before heat-shrinking the heat-shrinkable yams 22, to a second thickness t2 (Figure 2A; illustrating a portion of the wall 12, with it to be recognized that the remaining unseen portion of the wall 12 is the same as the portion shown) after heat- shrinking the heat-shrinkable yams 22, and the density of the wall 12 is increased from a first density dl before heat-shrinking the heat-shrinkable yams 22 (Figure 2) to a second density d2 after heat-shrinking the heat-shrinkable yams 22 (Figure 2A), wherein d2 is greater than 25 percent of dl, and preferably being greater than 50 percent, and more preferably being greater than 75 percent of dl. The increased wall thickness t2 and the increased density d2 provide synergies including an increased resistance to abrasion; an increased level of thermal insulation, an increased thermal protection against high temperature thermal conditions, and an increased resistance to fraying of the yams 20, 22 upon cutting the sleeve wall 12 to length and fraying of the ends 16, 18 of the sleeve 10 while in use (Figure 2A). [0036] The braided yams 20, 22 forming the entirety of the wall 12, or substantially entirety if other yams are included, can be provided in a desired number of relative ends (an end is known as a single yam) alternated with one another about the circumference of the sleeve 10 in the opposite S and Z helical directions (S and Z directions illustrated in the Figures, as would be understood by a skilled artisan in the textile arts upon viewing the disclosure herein) in any desired respective ratio of ends of high temperature yam 20 to heat- shrinkable yam 22, such as 1 :1 (Figures 2 and 2A), to provide the sleeve 10 with a substantially circumferentially balanced content of the yams 20, 22 and a uniform thickness and density about the circumference and along the length of the sleeve 10.

[0037] In accordance with another aspect of the disclosure, the heat-shrinkable yam 22 can be provided as any suitable heat-shrinkable monofilament and/or multifilament. In one example, wherein a ¼ inch diameter sleeve was produced, by way of example and without limitation, the heat-shrinkable yam 22 was provided as a monofilament of PEEK having a diameter of about 0.26mm and a heat-shrink ratio of about 15 percent at a heat-treat temperature of about 280 degrees Fahrenheit, by way of example and without limitation. Further, in the example embodiment, the non-heat-shrinkable yam 20 was provided as a multifilament of aramid having a diameter of about 0.13mm and a heat-shrink ratio of about 0.5 percent at a heat-treat temperature of about 280 degrees Fahrenheit, by way of example and without limitation. Upon heat-treating the exemplary wall 12, such as at a temperature between about 250-320 degrees Fahrenheit for between about 0.5-3 minutes, by way of example and without limitation, the length shrink ratio was about 19 percent, such that the length LI of the sleeve 10 (Figure 1) prior to being heat-treated was reduced to a length L2 (Figure 1A; LI x 81%), while the thickness tl of the wall 12 (Figure 2) increased about 80 percent to t2 (Figure 2A; caused by the axial bunching and meandering of the non-heat- shrinkable yam 20, as shown in Figure 3, prior to the wall 12 being heat-treated and in Figure 3 A after the wall 12 being heat-treated). The resulting sleeve 10 was provided with an increased resistance to an ingress of contamination, an increased resistance to abrasion and increased thermal properties allowing it to withstand and protect an electrical member contained therein against an external environmental temperature up to about 320 degrees Fahrenheit for up to about 40 hours, with the sleeve 10 retaining high flexibility and diametrically expansive properties. It is contemplated herein that any desired diameter sleeve can be produced using a suitably sized diameter non-heat-shrinkable yam 20 and heat- shrinkable yam 22 and number of ends thereof, as will be understood by a person possessing ordinary skill in the art.

[0038] In accordance with another aspect of the disclosure, a method of constructing a braided textile sleeve 10 is provided. The method includes braiding a plurality of yams 20, 22 with one another to form a seamless tubular wall 12 extending lengthwise along a central longitudinal axis 14 in a first non-heat-treated state, with at least some of the yams being provided as non-activatable, non-heat-shrinkable yams 20 and at least some of the yams being provided as activatable, heat-shrinkable yams 22. Then, heat-treating the braided wall at a first temperature to cause the activatable, heat-shrinkable yams 22 to shrink lengthwise, while not causing the non-activatable, non-heat-shrinkable yams 20 to shrink or shrink substantially at the first temperature.

[0039] In accordance with another aspect of the disclosure, the method can further include braiding the non-heat-shrinkable yams 20 and the heat-shrinkable yams 22 in alternating relation with one another in a 1 : 1 braid pattern to provide the sleeve 10 with a substantially balanced content of the non-heat-shrinkable yams 20 and heat-shrinkable yams 22

[0040] In accordance with another aspect of the disclosure, the method can further include heat-treating the braided wall 12 to cause the heat-shrinkable yams 22 to shrink lengthwise between about 10-90 percent, while maintaining the non-heat-shrinkable yams 20 in a non-heat-shrunk or substantially non-heat-shrunk state, such that the length of the non heat-shrinkable yams 20 remains within about 98 percent of their original, as braided, length.

[0041] In accordance with another aspect of the disclosure, the method can further include increasing a first thickness tl of the braided wall 12 from when the wall 12 is in a first, non-heat-treated state to a second thickness t2 upon completing the heat-treating process, wherein the first thickness tl is increased generally between about 25-90 percent to the second thickness t2, and preferably between about 50-90, and more preferably between about 70-90 percent, and in one embodiment, by about 80 percent, thereby increasing the abrasion resistance, density, thermal resistance and end-fray resistance of the wall 12.

[0042] Many modifications and variations of the present invention are possible in light of the above teachings. In addition, it is to be recognized that a braided tubular wall constructed in accordance with the various aspects of the invention can take on a multitude of uses, including that of a protective or bundling member, by way of example and without limitation. It is, therefore, to be understood that the invention may be practiced otherwise than as specifically described, and that the scope of the invention is defined by any ultimately allowed claims.