Braided textile sleeve with locked yarns and method of construction thereof

Abstract

A protective braided sleeve and method of construction are provided. The braided sleeve includes a seamless, circumferentially continuous, tubular wall extending lengthwise along a central longitudinal axis between opposite ends. The wall includes a plurality of yarns braided with one another. At least one of the yarns is activatable to lock the plurality of yarns in fixed relation with one another to inhibit the expansion of the wall.

Claims

1. A protective braided sleeve, comprising: a seamless, circumferentially continuous, tubular wall extending lengthwise along a central longitudinal axis between opposite ends, said wall including a plurality of yarns braided with one another, said plurality of yarns including a plurality of activatable yarns and a plurality of non-activatable yarns, with all non-activatable yarns being multifilament yarns, at least some of said activatable yarns, when activated, being caused to melt, solidify and lock said plurality of yarns in fixed relation with one another to inhibit the expansion of said wall, said activatable yarns being a solid, single filament yarn.

2. The protective braided sleeve of claim 1, wherein said wall includes non-activatable yarn, with said at least one activatable yarn having a lower melt temperature than said non-activatable yarn.

3. The protective braided sleeve of claim 2, wherein said at least one activatable yarn and said non-activatable yarn are provided in an equal number of ends with one another.

4. The protective braided sleeve of claim 3, wherein said activatable yarns and said non-activatable yarns are braided in a respective 1:1 braid pattern, with said activatable yarns and said non-activatable yarns alternating with one another in opposite S and Z helical directions.

5. The protective braided sleeve of claim 2, wherein said activatable yarns and said non-activatable yarns are braided in a respective 1:2 braid pattern, with said activatable yarns and said non-activatable yarns alternating with one another in opposite S and Z helical directions.

6. The protective braided sleeve of claim 2, wherein said activatable yarns and said non-activatable yarns are braided in a respective 1:3 braid pattern, with said activatable yarns and said non-activatable yarns alternating with one another in opposite S and Z helical directions.

7. The protective braided sleeve of claim 2, wherein said activatable yarns and said non-activatable yarns are braided in a respective 2:1 braid pattern, with said activatable yarns and said non-activatable yarns alternating with one another in opposite S and Z helical directions.

8. The protective braided sleeve of claim 2, wherein said activatable yarns and said non-activatable yarns are braided in a respective 3:1 braid pattern, with said activatable yarns and said non-activatable yarns alternating with one another in opposite S and Z helical directions.

9. The protective braided sleeve of claim 1, wherein at least some of said activatable yarns include heat-shrinkable yarn, said heat-shrinkable yarn being caused to shrink 10% or more of its non-activated length upon being activated.

10. A method of constructing and applying a protective braided sleeve, comprising: braiding a plurality of activatable yarns and a plurality of non-activatable yarns with one another to form a seamless tubular wall extending lengthwise along a central longitudinal axis; providing the plurality of activatable yarns being solid, single filaments and providing all non-activatable yarns being multifilament yarns; disposing the seamless tubular wall about an elongate member to be protected; axially stretching the seamless tubular wall to take on an axially elongated, radially contracted state, such that the seamless tubular is brought into a close fit relation about the elongate member; and activating the activatable yarns in an activation step to cause at least some of the activatable yarns to melt, solidify and lock the yarns of the wall relative to one another.

11. The method of claim 10, further including braiding the activatable yarns and the non-activatable yarns in an equal number of ends with one another.

12. The method of claim 11, further including braiding the activatable yarns and the non-activatable yarns in a respective 1:1 braid pattern, with the activatable yarns and the non-activatable yarns alternating with one another in opposite S and Z helical directions.

13. The method of claim 10, further including braiding the activatable yarns and the non-activatable yarns in a respective 1:2 braid pattern, with the activatable yarns and the non-activatable yarns alternating with one another in opposite S and Z helical directions.

14. The method of claim 10, further including braiding the activatable yarns and the non-activatable yarns in a respective 1:3 braid pattern, with the activatable yarns and the non-activatable yarns alternating with one another in opposite S and Z helical directions.

15. The method of claim 10, further including braiding the activatable yarns and the non-activatable yarns in a respective 2:1 braid pattern, with the activatable yarns and the non-activatable yarns alternating with one another in opposite S and Z helical directions.

16. The method of claim 10, further including braiding the activatable yarns and the non-activatable yarns in a respective 3:1 braid pattern, with the activatable yarns and the non-activatable yarns alternating with one another in opposite S and Z helical directions.

17. The method of claim 10, further including causing at least some of the activatable yarns to shrink 10% or more of its non-activated length upon being activated in the activation step.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) 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:

(2) FIG. 1 is a schematic perspective view of a tubular braided sleeve constructed in accordance with one embodiment of the invention shown in an axially compressed, pre-activated first state;

(3) FIG. 2 is a view similar to FIG. 1 with the tubular braided sleeve shown in an axially extended, activated second state;

(4) FIGS. 3A-3F illustrate plan views of a portion of wall of a tubular braided sleeve in accordance with different aspects of the disclosure;

(5) FIG. 4A is a fragmentary view of an activatable monofilament used in the construction of a tubular braided sleeve in accordance with an aspect of the disclosure; and

(6) FIG. 4B is a fragmentary view of an activatable bi-component filament used in the construction of a tubular braided sleeve in accordance with an aspect of the disclosure.

DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS

(7) Referring in more detail to the drawings, FIGS. 1 and 2 illustrate a tubular braided protective textile sleeve, referred to hereafter as sleeve 10, constructed in accordance with one aspect of the invention. The sleeve 10, as braided in a single, continuing 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. The wall 12 is axially compressible to attain an assembly, nonactivated first state, wherein a plurality (intended to mean more than 1 yarn and equal to or less than the entirety of the yarns) braided yarns, indicated generally at 20, forming the wall 12 are free to shift, also referred to as slide, relative to one another, such that the nonactivated first state provides the wall 12 having an ability to be axially compressed to a decreased length L1 and increased diameter D1 (FIG. 1) via expanded relative movement of the braided yarns 20 and is axially extendible to attain an increased length L2 and decreased diameter D2 (FIG. 2) via contracted relative movement of the braided yarns 20. While the wall 12 is at least partially or fully biased into the axially compressed, assembly friendly first state, the wall 12 is able to be readily assembled about an elongate member 22 to be protected, with the wall 12, and thus, the cavity 13, having an enlarged diameter relative to the elongate member 22, and then, while in the axially extended second state, at least one or more ends (end, as understood in the art is a single yarn filament) of the braided yarns 20 forming the wall 12 is/are provided as activatable yarn 20′, which upon being activated, selectively lock the yarns 20 relative to one another, thereby maintaining and preventing the yarns 20 from shifting relative to one another, and thus, maintaining the wall 12 in its desired assembled configuration (length and diameter) and location relative to the elongate member 22. Accordingly, the sleeve 10 is able to remain in its intended, as assembled location along the elongate member 22 without need for secondary fixation mechanisms, such as tape, tie wraps and the like, thereby enhancing assembly efficiencies, reducing cost, and improving the overall appearance of the assembly over the useful life thereof.

(8) The braided yarns 20 forming the entirety of the wall 12 can be provided entirely as activatable yarn 20′ (FIG. 3A). Otherwise, as few as one or more of the yarns 20, but less than the entirety, forming the wall 12 can be provided as activatable yarn 20′, with the remainder of the yarns 20 being provided as non-activatable yarn 20″. The activatable yarn 20′ is provided as at least one of a heat-fusible yarn, such as from a hot melt material having a melt temperature less than the melt temperature of the non-activatable yarns 20″, and/or from a cross-linked heat-shrinkable yarn (heat-shrinkable is intended to mean yarns that can be activated to shrink 10% or more, up to 90%, of their original, non-activated length). As noted, the yarns 20 forming a portion of the wall 12 can also include non-activatable yarn 20″, and if incorporated, can be provided as any desired type of non-activatable yarn, whether monofilament and/or multifilament, such that the non-activatable yarn 20″ is neither readily heat-fusible (not readily capable of being heated to melt and solidify upon being cooled) nor heat-shrinkable (not capable of being shrunken up 10% of their original length). The activatable yarn 20′ and non-activatable yarn 20″, if non-activatable yarn 20″ yarns are provided, can be provided a desired number of relative ends (an end is known as a single yarn) 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 FIG. 3A, 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 activatable yarn 20′ to non-activatable yarn 20″, such as 1:1 (FIG. 3B); 1:2 (FIG. 3C); 1:3 (FIG. 3D); 3:1 (FIG. 3E); or 2:1 (FIG. 3F), by way of example and without limitation, to provide the sleeve 10 with a substantially circumferentially balanced content of the activatable and non-activatable yarns 20′, 20″, as desired for the intended application and as needed for the desired strength of fixation of the activatable and non-activatable yarns 20′, 20″ with one another, with a higher content of activatable yarns 20′ providing a greater bond of the yarns 20 with one another. The activatable yarns 20′ can be at least one of UV activatable, heat activatable, fluid activatable, or otherwise.

(9) In accordance with another aspect of the invention, the activatable yarn(s) 20′ can be provided as solid, monolithic pieces of a single material filament (FIG. 4A) and/or as bicomponent filament (FIG. 4B) including an inner core 24 (activatable, such as being heat-settable to take on a heat-set shape, or non-activatable) and an activatable outer sheath 26 surrounding the inner core 24, wherein the outer sheath 26 can be a hot melt material having a lower melt temperature than the material of the inner core 24, by way of example.

(10) In use, the sleeve 10, with the activatable yarn 20′ being braided and initially maintained in a non-activated first state, is disposed about the elongate member 22. While disposing the sleeve 10 about the elongate member 22, the yarns 20′, 20″ (if provided), are free to move and shift relative to one another, such that the wall 12 is able to be readily compressed axially and expanded radially to provide an enlarged through cavity 13 for the receipt of the elongate member 22 (FIG. 1). Then, upon locating the sleeve 10 in the desired location about the elongate member 22, the wall 12 can be axially stretched to take on an axially elongated, radially contracted state, such that the wall 12 is brought into snug or close fit relation about the elongate member 22 (FIG. 2). Then, the activatable yarn(s) 20′ can be activated, such as via application of a suitable heat, UV, or chemical, for example, via any desired application process, wherein the activated yarn(s) 20′ is either melted and/or shrunken to lock the entirety of the yarns 20 relative to one another. If melted, the yarns 20 are bonded with one another via melted and solidified material of the yarns 20′, and if shrunken, the friction imparted between the yarns 20 and possibly with the elongate member 22 effectively locks the yarns 20 relative with one another. Accordingly, with the entirety of the yarns 20 being locked relative to one another, the wall 12 is assured of remaining in its intended location on the elongate member 22. Further yet, it bicomponent yarns 20′ are provided, the inner core 24 is heat-set to retain is helical shape, thereby enhancing radial stiffness and providing the sleeve 10 with an enhanced crush and hoop strength, while the outer sheath 26 is melted and solidified to lock the yarns 20 to one another, as discussed above. It is to be recognized that the activation of the bicomponent yarns 20′ can be performed at a single temperature suitable to heat-set the inner core 24 and melt the outer sheath 26.

(11) 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 yarns 20 with one another to form a seamless tubular wall 12 extending lengthwise along a central longitudinal axis 14, with at least some of the yarns 20 being provided as activatable yarns 20′, which, upon being activated, via application of a source of heat, or chemical, or UV radiation, depending on the type of activatable yarn 20′ used, lock the yarns 20 of the sleeve 10 relative to one another, thereby preventing the yarns 20 from slipping and expanding radially. Accordingly, the wall 12 is maintained in its intended configuration and location relative to an elongate member 22 extending therethrough.

(12) The method can include providing at least one or more of the activatable braided yarns 20′ as heat-fusible yarn, such as from a hot melt material. Further, the method can include providing one or more of the activatable yarns 20′ as heat-shrinkable yarns, with the heat-fusible yarn 20′ and/or heat-shrinkable yarns 20′ being oriented relative to non-heat-fusible yarns 20″ (if provided) and/or non-heat-shrinkable yarns 20″ (if provided) to facilitate locking the yarns 20 relative to one another upon the non-heat-fusible yarns 20″ being heated, melted and fused and/or heat-shrinkable yarns 20″ being shrunken. If heat-shrinkable yarns 20′ are provided in combination with heat-fusible yarns 20′, the method can include providing the yarns 20′ such that a common temperature can be used to both activate the shrinking and fusing, thereby simplifying the process, with the non-activatable yarns 20″ being unaffected by the temperature used to shrink and melt the respective yarns 20′

(13) In accordance with another aspect of the disclosure, the method can further include braiding activatable heat-fusible yarn 20′ and/or heat-shrinkable yarns 20′ and non-activatable, non-heat-shrinkable yarns 20″ in alternating relation with one another about the circumference of the sleeve to provide the sleeve 10 with a substantially balanced content of the heat-fusible yarn 20′ and/or heat-shrinkable yarns 20′ and non-heat-shrinkable yarns 20″.

(14) In accordance with another aspect of the disclosure, the method can further include providing the activatable yarns 20′ as at least one of UV activatable yarns, heat-activatable yarns, or otherwise.

(15) In accordance with another aspect of the disclosure, the method can further include providing the activatable yarns 20′ as bicomponent filaments including a non-activatable or activatable (heat-settable, takes on a heat-set shape without melting) core 24 and an activatable outer sheath 26, wherein the outer sheath 26 can be a hot melt, fusible material having a melt temperature lower than the melt temperature of the material of the core 24, wherein the inner core 24 and outer sheath 26 can be activated at the same temperature suitable to both heat-set the inner core 24 and melt the outer sheath 26.

(16) 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.