U.S. patent application number 14/043663 was filed with the patent office on 2015-04-02 for wrappable laminated textile sleeve with enhanced flexibility and method of reducing cracking in a foil layer of a wrappable textile sleeve.
This patent application is currently assigned to Federal-Mogul Powertrain, Inc.. The applicant listed for this patent is Federal-Mogul Powertrain, Inc.. Invention is credited to David A. Harris, Aleksandr Ilyin, Cassie M. Malloy, Alexa Woodruff.
Application Number | 20150093556 14/043663 |
Document ID | / |
Family ID | 51842806 |
Filed Date | 2015-04-02 |
United States Patent
Application |
20150093556 |
Kind Code |
A1 |
Woodruff; Alexa ; et
al. |
April 2, 2015 |
WRAPPABLE LAMINATED TEXTILE SLEEVE WITH ENHANCED FLEXIBILITY AND
METHOD OF REDUCING CRACKING IN A FOIL LAYER OF A WRAPPABLE TEXTILE
SLEEVE
Abstract
A wrappable textile sleeve and method of reducing cracking in a
foil layer of a wrappable textile sleeve are provided. The 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
includes a textile layer, a polymeric film layer fixed to the inner
textile layer and a metal foil layer fixed to the polymeric film
layer. The polymeric film layer has a first thickness and the metal
foil layer has a second thickness, wherein the second thickness is
greater than the first thickness.
Inventors: |
Woodruff; Alexa; (Bryn Mawr,
PA) ; Malloy; Cassie M.; (Blue Bell, PA) ;
Harris; David A.; (Coatsvile, PA) ; Ilyin;
Aleksandr; (Chester Springs, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Federal-Mogul Powertrain, Inc. |
Southfield |
MI |
US |
|
|
Assignee: |
Federal-Mogul Powertrain,
Inc.
Southfield
MI
|
Family ID: |
51842806 |
Appl. No.: |
14/043663 |
Filed: |
October 1, 2013 |
Current U.S.
Class: |
428/213 ;
156/60 |
Current CPC
Class: |
B32B 1/08 20130101; D03D
15/0094 20130101; H02G 3/0481 20130101; B32B 5/24 20130101; B32B
5/024 20130101; Y10T 428/2495 20150115; D10B 2401/041 20130101;
B32B 37/00 20130101; Y10T 156/10 20150115 |
Class at
Publication: |
428/213 ;
156/60 |
International
Class: |
B32B 5/02 20060101
B32B005/02; B32B 37/00 20060101 B32B037/00 |
Claims
1. A wrappable textile sleeve, comprising: an elongate wall
extending along a longitudinal axis between opposite ends with
lengthwise extending edges extending along said longitudinal axis
between said opposite ends; said wall including a textile layer, a
polymeric film layer fixed to said inner textile layer and a metal
foil layer fixed to said polymeric film layer; and said polymeric
film layer having a first thickness and said metal foil layer
having a second thickness, said second thickness being greater than
said first thickness.
2. The wrappable textile sleeve of claim 1 wherein said first
thickness is between about 0.0001 inches and 0.0004 inches and said
second thickness is between about 0.00035 inches and 0.0010
inches.
3. The wrappable textile sleeve of claim 2 wherein said first
thickness is between about 0.0002 inches and 0.0003 inches and said
second thickness is between about 0.0005 inches and 0.0009
inches.
4. The wrappable textile sleeve of claim 1 wherein said metal foil
layer is soft aluminum.
5. The wrappable textile sleeve of claim 1 wherein said polymer
film is a preshrunk polymer film.
6. The wrappable textile sleeve of claim 5 wherein said polymer
film is polyethylene terephthalate.
7. The wrappable textile sleeve of claim 1 wherein said polymer
film layer and said metal foil layer are bonded together by an
adhesive.
8. The wrappable textile sleeve of claim 7 wherein said polymer
film layer is bonded to said textile layer by an adhesive.
9. The wrappable textile sleeve of claim 1 wherein said textile
layer has interlaced filaments.
10. The wrappable textile sleeve of claim 9 wherein said textile
layer is woven.
11. The wrappable textile sleeve of claim 10 wherein said textile
layer has a plurality of discrete circumferentially extending
annular bands formed from circumferentially extending weft yarns
with adjacent bands having weft yarns with different diameters from
one another.
12. The wrappable textile sleeve of claim 10 wherein said first
thickness is between about 0.0001 inches and 0.0003 inches and said
second thickness is between about 0.00035 inches and 0.0010
inches.
13. The wrappable textile sleeve of claim 1 further including a
closure tape, said closure tape having a woven scrim and a metal
foil layer bonded to one another, said woven scrim having a side
facing away from said metal foil layer of said closure tape, with
an adhesive thereon for attachment to said metal foil layer of said
wall.
14. A method of reducing cracking in a foil layer of a wrappable
textile sleeve, comprising: providing a textile layer; providing a
polymeric film layer having a first thickness; providing a metal
foil layer having a second thickness and a polymeric film layer
with one another; bonding the polymeric film layer to the textile
layer; bonding the metal foil layer to the polymeric film layer;
and providing the second thickness of the metal foil layer with a
greater thickness than the first thickness of the polymeric film
layer.
15. The method of claim 14 further including providing the first
thickness between about 0.0001 inches and 0.0004 inches and
providing the second thickness between about 0.00035 inches and
0.0010 inches.
16. The method of claim 14 further including providing the metal
foil layer as soft aluminum.
17. The method of claim 14 further including providing the polymer
film as a preshrunk polymer film.
18. The method of claim 14 further including providing the textile
layer as a woven layer.
19. The method of claim 18 further including providing the textile
layer having a plurality of discrete circumferentially extending
annular bands formed from circumferentially extending weft yarns
with adjacent bands having weft yarns with different diameters from
one another.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] This invention relates generally to protective textile
sleeves for protecting elongate members, and more particularly, to
wrappable textile sleeves having an outer foil layer.
[0003] 2. Related Art
[0004] It is known to utilize textile sleeves to protect elongate
members from a variety of external environmental conditions,
including braided, knit or woven textile structures. It is further
known to form the sleeve having wrappable walls. With wrappable
walls, it is further known to utilized closure tape to maintain
opposite lengthwise extending edges of the wall in secured,
overlapped relation with one another. In some applications it is
desirable to have the elongate members contained within the sleeve
against thermal environmental conditions, such as high heat, for
example. In these applications, it is known to provide the textile
sleeve with an outer reflective foil layer, and further, to provide
the closure tape having a reflective outer foil layer. Typically
the foil layers of the sleeve and closure tape are adhered to an
outer surface of the textile sleeve wall and to an outer surface of
the foil layer of the sleeve wall, respectively.
[0005] Unfortunately, in use, when the sleeve wall and closure tape
are exposed to high heat, such as in an automotive exhaust pipe
application, the foil layer of the sleeve wall can be prone to
cracking. Cracking has been found to be particularly troubling in
the region of the closure tape. If the foil layer of the sleeve
wall becomes cracked, the useful life of the sleeve is generally
diminished, and can also be unsightly.
SUMMARY OF THE INVENTION
[0006] In accordance with one aspect of the invention, a wrappable
textile sleeve is provided. The 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 includes a textile layer, a
polymeric film layer fixed to the inner textile layer and a metal
foil layer fixed to the polymeric film layer. The polymeric film
layer has a first thickness and the metal foil layer has a second
thickness, wherein the second thickness is greater than the first
thickness.
[0007] In accordance with another aspect of the invention, the
first thickness is between about 0.0001 inches and 0.0004 inches
and the second thickness is between about 0.00035 inches and 0.0010
inches.
[0008] In accordance with another aspect of the invention, the
first thickness is between about 0.0002 inches and 0.0003 inches
and the second thickness is between about 0.0005 inches and 0.0009
inches.
[0009] In accordance with another aspect of the invention, the
metal foil layer is soft aluminum.
[0010] In accordance with another aspect of the invention, the
polymer film is a preshrunk polymer film.
[0011] In accordance with another aspect of the invention, the
polymer film is polyethylene terephthalate.
[0012] In accordance with another aspect of the invention, the
polymer film layer and the metal foil layer are bonded together by
an adhesive.
[0013] In accordance with another aspect of the invention, the
polymer film layer is bonded to the textile layer by an
adhesive.
[0014] In accordance with another aspect of the invention, the
textile layer has interlaced filaments.
[0015] In accordance with another aspect of the invention, the
textile layer is woven.
[0016] In accordance with another aspect of the invention, the
textile layer has a plurality of discrete circumferentially
extending annular bands formed from circumferentially extending
weft yarns with adjacent bands having weft yarns with different
diameters from one another.
[0017] In accordance with another aspect of the invention, the
first thickness is between about 0.0001 inches and 0.0003 inches
and the second thickness is between about 0.00035 inches and 0.0010
inches.
[0018] In accordance with another aspect of the invention, the
sleeve includes a closure tape having a woven scrim and a metal
foil scrim bonded to one another. The woven scrim has a side facing
away from the metal foil scrim with an adhesive thereon for
attachment to the metal foil layer of the sleeve wall.
[0019] In accordance with another aspect of the invention, a method
of reducing cracking in a foil layer of a wrappable textile sleeve
is provided. The method includes providing a textile layer;
providing a polymeric film layer having a first thickness;
providing a metal foil layer having a second thickness and a
polymeric film layer with one another; bonding the polymeric film
layer to the textile layer; bonding the metal foil layer to the
polymeric film layer; and providing the second thickness of the
metal foil layer with a greater thickness than the first thickness
of the polymeric film layer.
[0020] In accordance with another aspect of the invention, the
method further includes providing the first thickness of the
polymeric film layer between about 0.0001 inches and 0.0004 inches
and providing the second thickness of the foil layer between about
0.00035 inches and 0.0010 inches.
[0021] In accordance with another aspect of the invention, the
method further includes providing the metal foil layer as soft
aluminum.
[0022] In accordance with another aspect of the invention, the
method further includes providing the polymer film as a preshrunk
polymer film.
[0023] In accordance with another aspect of the invention, the
method further includes providing the textile layer as a woven
layer.
[0024] In accordance with another aspect of the invention, the
method further includes providing the textile layer having a
plurality of discrete circumferentially extending annular bands
formed from circumferentially extending weft yarns with adjacent
bands having weft yarns with different diameters from one
another.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] 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:
[0026] FIG. 1 is a perspective view of a wrappable textile sleeve
constructed in accordance with one aspect of the invention shown
wrapped about an elongate member;
[0027] FIG. 2 is an enlarged cross-sectional view of the textile
sleeve of FIG. 1;
[0028] FIG. 3 is a partially broken away plan view of a flattened
wall of the textile sleeve of FIG. 1; and
[0029] FIG. 4 is an enlarged cross-sectional view of a closure tape
of the textile sleeve of FIG. 1.
DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS
[0030] Referring in more detail to the drawings, FIG. 1 illustrates
a wrappable textile sleeve 10 constructed in accordance with one
aspect of the invention wrapped about an elongate member 12 (e.g.
flexible wire harness or other flexible member) to be protected.
The sleeve 10 has an elongate wall 14 that extends along a
longitudinal axis 16 between opposite ends 18, 20 with lengthwise
extending edges 22, 24 extending along the longitudinal axis 16
between the opposite ends 18, 20. The wall 14 includes an inner
textile layer 26, an outer reflective layer, such a metal layer of
aluminum 28, and an intermediate polymer film layer 30 sandwiched
between the inner and outer layers 26, 28. The film layer 30 has a
first thickness and is fixed to the textile layer 26, and the metal
foil layer 28 has a second thickness and is fixed to the polymer
film layer 30. The second thickness of the foil layer 28 is greater
than the first thickness of the film layer 30, which has been
discovered to provide an optimal performance of the sleeve 10,
particularly when being routed about bends and around corners. With
the film layer 30 having a reduced thickness relative to the foil
layer 28, the wall 14 is able to retain a relatively smooth arc,
and not kink, and further, the foil layer 28 is inhibited from
cracking, and as such, the performance and useful life of the
sleeve 10 is enhanced. One theory for this phenomenon is attributed
to the reduced contribution of the film layer 30 from hardening and
causing the foil layer from kinking and cracking, particularly at
high temperatures, such as those encountered within an engine
compartment or near an exhaust system, by way of example and
without limitation.
[0031] The textile layer 26 can be woven, knit or braided, and is
preferably woven from at least one lengthwise extending warp yarn
32 and a plurality of circumferentially extending weft yarns 34.
The weft yarns 34 can be woven to form a plurality of discrete
annular bands A, B extending and alternating in adjacent relation
with one another along the longitudinal axis 16 with immediately
adjacent bands A, B having weft yarns with different diameters from
one another. As shown, the bands A are woven from weft yarns 34
having a first diameter and the bands B are woven from weft yarns
34 having a second diameter, wherein the first and second diameters
are different from one another, represented as the first diameter
being smaller than the second diameter. As such, the textile layer
26 is formed having varying physical properties along the length of
the sleeve 10 due to the different diameters of the weft yarns 28
in the bands A, B. The bands A, having the very fine diameter
monofilament weft yarns 34, provide the sleeve 10 with enhanced
flex regions that result in an enhanced ability of the sleeve 10 to
flex and bend around corners, including corners of 90 degrees or
more, without kinking and without forming openings or gaps between
the overlapping edges 22, 24. Meanwhile, the bands B, having the
larger diameter monofilament weft yarns 34, such as between about
0.38 and 0.48 mm, and provide the sleeve 10 with stiff, rigid
regions relative to the bands A, thereby providing the wall 14 with
enhanced hoop strength to prevent the wall 14 from being flattened
or crushed. As such, the elongate member 12 contained within the
sleeve 10 is protected against damage from being crushed.
[0032] The weft yarns 34 are provided as monofilament yarn within
both bands A, B, and can be provided at least in part as
heat-settable monofilament yarn, if desired to heat- set the wall
14 into a thermally formed, self-wrapping wall, or other polymeric
and/or mineral fiber yarn, depending on the application. The
alternating bands A, B, as discussed above, have differently sized
monofilaments, thereby providing the sleeve with increased flex
bands A and increased hoop strength bands B. In accordance with one
aspect of the invention, the weft yarns 28 in the flexible bands A
are about 1/3 the diameter of the weft yarns 28 in the more rigid
bands B. Accordingly, a ratio of about 3:1 in weft yarn diameters
for the relative bands B, A has been found to provide the sleeve 10
with excellent bending and crush strength performance. The bands A,
B are sized in axially extending widths relative with one another
to provide the desired amount of flex and hoop strength, while at
the same time preventing the wall 14 from kinking and forming
openings/gaps along the seam between the overlapping edges 22, 24.
If the relative widths between the bands A, B is not maintained,
the wall 14 can either sacrifice the needed hoops strength, such as
if the bands A are too wide relative to the bands B, or the wall
can be too stiff and inflexible, thereby kinking and forming
openings/gaps along the seam between the edges 22, 24, such as if
the bands B are too wide relative to the bands A. Accordingly, it
should be recognized that a balance needs to be maintained between
the respective widths of the bands A, B to provide the sleeve 10
with the ability to flex without kinking and forming openings/gaps,
while also retaining the desired hoop strength without being too
stiff.
[0033] The warp yarn 32 can be provided of any suitable yarn
material, including monofilament or multifilament yarn, and in any
suitable number of ends. Preferably the warp yarn 32 is provided at
least in part of multifilament yarn to enhance the coverage
protection provided by the wall 14 to the enclosed elongate member
12. The density of the warp yarn 32 has an influence on the
flexibility of the sleeve wall 14, and as such, it has been
discovered that a reduced warp density of about 14 ends per inch is
optimal to provide the sleeve wall 14 with the flexibility desired,
though the warp density could be increased if optimal flexibility
is unnecessary.
[0034] The foil layer 30 is provided as a flexible layer, and
preferably from dead soft aluminum (aluminum that is annealed, such
as at about 600 degrees Fahrenheit, to reduce strength and
hardness). Other types of foil and grades of foil have been tested,
however, they were found to be too stiff and to have too little
elongation, thereby being more prone to tearing and cracking. The
thickness of the foil layer 30 is between about 0.00035 inches and
0.0010 inches.
[0035] The film layer 30 is provided as an impervious polymeric
layer, such as from preshrunk polyethylene terephthalate (PET). By
being preshrunk, further shrinkage in use is minimized, thereby
reducing the likelihood of delamination from the textile and foil
layers 26, 28. The film layer 30 is provided having a thickness
ranging between about 0.0001 inches and 0.0004 inches.
[0036] In one presently preferred construction of the sleeve 10,
the textile layer 26 was formed having alternating bands A, B in a
weaving process, as discussed above. Further, a lamination of the
foil layer 28 and the film layer 30 was formed by adhering the two
layers 28, 30 to one another via an adhesive that is able to
withstand high temperatures without delaminating. In several tests
to determine optimal strength and flexibility of the sleeve 10, the
film layer 30 was provided having a constant thickness, while the
thickness of the foil layer 28 was varied between 0.000035 inches
to 0.001 inches. Upon completion of the testing, an optimal
thickness of the foil layer 28 was found to be about 0.0007 inches,
wherein the number of cracks formed in the foil layer 28 upon being
bent decreased as the thickness of the foil layer 28 was increased,
however, at a thickness greater than 0.001 inches, the flexibility
of the sleeve 10 was significantly reduced. Further testing was
performed using a constant thickness foil layer 28, and the
thickness of the film layer 30 was varied between 0.00025 inches to
0.002 inches. During this testing, it was found that an optimal
thickness of the film layer 30 was found to be about 0.00025
inches, and when the film layer 30 increased in thickness, the
number of cracks in the foil layer 28 increased as a result of the
film layer 30 becoming increasingly brittle with increased
thickness. This said, a sample with no film layer 30 was tested,
and it performed poorly, as the foil layer 28 was unsupported and
thus, was subject to tearing easily.
[0037] In accordance with another aspect of the invention, a
closure tape 36 is provided to maintain the opposite edges 22, 24
of the sleeve wall 12 in overlapped, closed relation with one
another. The closure tape 36 has a high temperature textile
lattice, also referred to as scrim 38, such as a woven, knit or
braided layer 38, and a metal foil layer 40, having a thickness
equal to or substantially equal to that of the foil layer 28 on the
sleeve 10, bonded to one another via an adhesive 41. The woven
scrim 38 has a side 42 facing away from the metal foil layer 40
with an adhesive 44 thereon for bonded attachment to the metal foil
layer 28 of the sleeve 10. To enable the closure tape 36 to remain
unused, a release paper 45 can be applied over the adhesive 44
until it is desired to uncover the adhesive 44 for use. Of course,
one end 46 of the closure tape 36 can be adhered to the foil layer
28 of the sleeve 10 during manufacture of the sleeve 10, with the
release paper remaining on the exposed, unbonded portion of the
adhesive layer 44 adjacent an opposite end 48 until it is desired
to wrap the sleeve wall 14 about the elongate member 12 and fix the
opposite ends 18, 20 of the sleeve wall 14 in overlapped relation
with one another.
[0038] The metal foil layer 40 of the closure tape 36 functions to
provide a reflective foil covering about the entirety of the sleeve
10, and to prevent heat from affecting the ability of the adhesive
44 of the closure tape 36 from remaining adhered to the metal foil
layer 28 of the sleeve wall 14. The textile scrim 38 of the closure
tape 36 can be woven, knit or braided from any suitable high
temperature yarn, including basalt, silica, fiberglass and the
like. Further, the closure tape 36 can be formed having any
suitable length sufficient to be adhered to the opposite edges 22,
24 of the wall 14, but is generally provided having a length equal
to about 1/3 to 1/2 the wrapped outer circumference of the sleeve
10. With the closure tape 36 having the textile scrim 38, as
compared to that of a polymeric film layer, the flexibility and
crack resistance of the sleeve wall 14 is optimized. Testing has
found that the flexibility and crack resistance to be nearly
doubled for the textile scrim containing closure tape 36 compared
to that of a closure tape including a polymeric scrim layer. The
reason attributed to this is based largely on the elimination of
the polymeric film that has been found to contribute to a
diminished flexibility and crack resistance as a result of
hardening when exposed to heat.
[0039] Many modifications and variations of the present invention
are possible in light of the above teachings. 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.
* * * * *