CA2122733A1 - Shaped fabric products and methods of making same - Google Patents
Shaped fabric products and methods of making sameInfo
- Publication number
- CA2122733A1 CA2122733A1 CA002122733A CA2122733A CA2122733A1 CA 2122733 A1 CA2122733 A1 CA 2122733A1 CA 002122733 A CA002122733 A CA 002122733A CA 2122733 A CA2122733 A CA 2122733A CA 2122733 A1 CA2122733 A1 CA 2122733A1
- Authority
- CA
- Canada
- Prior art keywords
- product
- tubular
- filamentary
- fill
- resiliently
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
- F16L57/06—Protection of pipes or objects of similar shape against external or internal damage or wear against wear
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D1/00—Woven fabrics designed to make specified articles
- D03D1/0035—Protective fabrics
- D03D1/0043—Protective fabrics for elongated members, i.e. sleeves
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D13/00—Woven fabrics characterised by the special disposition of the warp or weft threads, e.g. with curved weft threads, with discontinuous warp threads, with diagonal warp or weft
- D03D13/002—With diagonal warps or wefts
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D3/00—Woven fabrics characterised by their shape
- D03D3/02—Tubular fabrics
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C5/00—Shaping or stretching of tubular fabrics upon cores or internal frames
- D06C5/005—Shaping or stretching of tubular fabrics upon cores or internal frames of articles, e.g. stockings
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C7/00—Heating or cooling textile fabrics
- D06C7/02—Setting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
- F16L57/02—Protection of pipes or objects of similar shape against external or internal damage or wear against cracking or buckling
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
- H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
- H02G3/02—Details
- H02G3/04—Protective tubing or conduits, e.g. cable ladders or cable troughs
- H02G3/0462—Tubings, i.e. having a closed section
- H02G3/0481—Tubings, i.e. having a closed section with a circular cross-section
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S139/00—Textiles: weaving
- Y10S139/01—Bias fabric digest
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
- Y10T156/10—Methods of surface bonding and/or assembly therefor
- Y10T156/1002—Methods of surface bonding and/or assembly therefor with permanent bending or reshaping or surface deformation of self sustaining lamina
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1328—Shrinkable or shrunk [e.g., due to heat, solvent, volatile agent, restraint removal, etc.]
- Y10T428/1331—Single layer [continuous layer]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
- Y10T428/1362—Textile, fabric, cloth, or pile containing [e.g., web, net, woven, knitted, mesh, nonwoven, matted, etc.]
Abstract
Disclosed are flexible, kink-resistant shaped fabric products which are particularly well adapted for protecting and/or covering elongate substrates, such as cables, conduits, wiring and the like. The shaped fabric products include a wall portion comprising a filament resiliently set in a spiral configuration with respect to the longitudinal axis of the shaped product. The wall portion may also preferably comprise a filament in the form of circumferential hoops substantially conforming in shape and size to the cross-sectional configuration of the shaped product. Also disclosed are methods for forming such shaped product.
Description
~93/09281 PCT/GB92/02003 S~APED FABRIC PRODUCTS AND METHODS OF MARING SAME
The present invention ic directed to tubular products, and more particular~y to tubular fabrics whieh are particularly well adapted for bundling and prstecting elongated articles, such as wires, cables, hoses and conduits.
The use of fabric sleeves for encasing cables, hoses and other elongated flexible articles is well-known in t~e art. Examples of such sleeving are available from the ~`
Bentley-Harris Manufacturing Company under the registered trademark EXPANDO. The EXPANDO~ sleeving is lightweight and provides tough physical protection for cable assemblies, wire harnesses and the like. The open construction of ~his type o~
product is of advantage over solid material in that it breathes and prevents the entrapment of moisture. In addition, this type of sleeving ma'ntains the bundled, elongated articles in clean, compact condition.
While sleeving of the type employed by the EXPANDO~
~product has achieved significant success and possesses certain advantageous characteristics, a need for flexi~le, kink- -resis~ant woven tubular products continues to exist. U.S.
Patent No. 4,223,824 - Evans et al., for example, recognizes the difficult~ of providing woven tubular products which resist kinking when curved or ben~. Evans et al. teaches that this di~ficulty may be overcome by providing a hose having a reinforcement structure comprised of plied warp yarns formed o~ filamen~s of high modulus material which resists longitudinal extension of the hose. The warp elements of Evans et al are said to have a high degree of twist in the WO93~092B1 212 2 7 3 3 - 2 - PCT/GB92/0200~
filaments in order to provide stability to the hose wall when compressed during curving of the hose. Furthermore, Evans et al. illustrates the w~rp elements as extending along the length of the hose in a direction substantially parallel to the axis of ~he hose.
U.S~ Pa~ent No. 4,652,263 - Herwic~ et al. is directed to woven fabric tubes especially adapted for use as prosthases in biomedical applications. Herwick et al. note that such woven fabric tubes are preferably capable of returning to t~eir original shape after being stretched, compressed or bent. Herwick et al. also note that such tubular products should also ~e resistan~ to kinking or radi21 eollapse. Elasticity is impar~ed to the tubes of Herwick et al. by proYiding the woven tubular products with axially-oriented warp threads forming loops extending radially outward between circumferential fill threads. The loops are set to return to th~ loop configuration upon rele se of tension applied axially to the tube.
U.S. Paten~ No. ~,015,641 - Goff et al. recognizes the difficulty associated with providing s~ape retaining woven tubular products. In particular, Goff et al. notes that tubular fabrics have heretofore been filled with foam ~aterial so that the product will have a cushioned, shape retaining characteristic. Goff et al. suggest that a similar effect can be obtained by forming a woven tubular produot using monof ilament f illiny yarns in both layers of the fabric and alternately and interm~ttently weaving monofilament warp yarns between the layers to connect the two layers together.
While the products mentioned above may have achieved some degree of success, they also posse5s certain drawbacks.
For example, potentially costly and somewhat unusual manufacturing techniques are required to produce the products of the ~ype described above. Moreover, the products described in Goff et al. 5uffer from the disadvantage of requiring the presence of structural members spanning the hollow portion Of the tubular product. The presence of such struckural members limits the usefulness of the tu~ular product for encasing ~93/09281 212 2 7 3 3 PCT/GB92/02003 elongate substrates.
Thusl Applicants have recognized a need ~or shaped-fabric products, and particularly for tubular fabrics, which are at once shape-retaining, ~ink-resistant and flexible.
Furthermore, Applicants have recognized the failure of the prior art to provide methods for manufacturing woven tubular products which possess these characteristics.
Furthermore, while the abrasion-resistance of the heretofore used protective fabric coverings has been acceptable in many applications, applicants have found that tremendous improvement in abrasion resistance is possible.
Such improvement in abrasion resis~ance is highly desir~ble for obvious reasons, such as increas~ng the useful life of the protective fabric cover. ~-Accordingly, it is an object of the present invention to provide flexible, kink-resist~nt fa~ric covers.
It is a further object to the present invantion to provide relatively low-cost protective fabric covers.
It is yet a further object of the present invention ::-to provide flexible, kink-resistant fabric covers with excellent abrasion resistance.
S~ARY OF TRE INVENT~ON
The present invention provides flexible, kink-resistant shaped fabric products which are particularly well adapted for protecting and/or covering elongate substrates, such as cables, conduits, wiring and t~e 'ike. The shaped fabric produc~s are preferably elongate tubular products having a l~ngitudinal dimension which is substantially greater than the width, diameter or girth of tne product. According to important aspects of the present invention, the shaped ~abric products include a wall portion comprising a filament resiliently set in a spiral conîiguration with respect to the longitudinal axis of the shaped product. Applicants have fsund that tubular products comprising fabrics, and preferably woven fabric5, haYing ~uch spirally set filaments generally possess excellent flexibili~y and exceptional kin~- and abrasion-resistance.
WO~3/09281 212 2 7 3 3 PCT/GB92/02003 The wall portion of the tubular product also preferably comprises a filament in the form of circumferential hoops substantially conforming in shape and size to the cross-sectional configuration of the shaped product. For the preferred cylindrically shaped tubular products, the circumferential hoops are substantially circular hoops having a diameter equal to about the diameter of the cylinder.
According to preferred aspects of ~he present invention, the shaped fabric product comprises a woven tubular fabric having a fill end t~ereof in the form of hoops which lie in a plane substantially perpendicular to the axis of the tube and warp ends thereof resiliently set in a spiral configuration with respect to the longitudinal axis of the tube.
The present invention also provides methods of forming flexible, kink-resistant tubular fabrics. The methods comprise: (l) providing a shaped fabric product comprising a wall portion comprising interlaced, resiliently settable filaments and (2) resiliently setting at least a portion of the resiliently settable filaments in a spiral configuration with respect to the longitudinal axis of the tubular product.
According to certain preferred embodiments, t~e providing step comprises providing a woven tubular fabric and the setting step romprises heat setting the resiliently set~able filaments.
~RIEF DESCRIPTION OF THE ~RAWINGS
Fig. l is a perspe~ive view of a woven tubular product according to a first embodiment of the present invention.
Fig, 2 is a plan view of a woven tubular product according to a first embodimen~ of the present inventîon.
Flg. 3 is a perspective view of a woven tubular product which is radially discontinuous according to a second embodiment of the present invention.
Fig. 4 is a perspective view of a radially discontinuous woven tubular product of the present invention encasing an elongate substra~e, WO 93/09281 212 2 7 3 3 PCI`/GB92/0200~s DETAILED DESCRIPT~ON O~ PREFERRED EMBODIMENq~S
The present invention is directed to shaped products, and more particularly to shaped fabric products. As the term is used herein, "fabric" refers to any material comprised of interlaced filamentary components. As will be appreciated by those skilled in the art, many classes of fabric material exist, and it is contemplated that all such materials may be adaptable for use in connection with the present invention. In particular, it is contemplated that the shaped fabric products may comprise knitted products, ~r?ided products or woven products, with woven products being preferred. The preferred woven products comprise fill and warp threads in~erlaced according to any one of the well~known weave patterns. In general, however, applicants have found that a ~will pattern, and preferably a 2-2 twill pattern, .
produces acceptable results.
Furthermore, it is gPnerally preferred that the shaped fabric products are preferably characterized by an open construction. That is, it is generally preferred t~at t~
filamentary materials comprising the wall portion of the shaped fabric are relatively loosely interlaced. In this way, the shaped fabric products of the present invention breath and prever,_ entrapment or moisture.
The presen~ shaped fabric products are particularly well adapted for protecting and/or co~ering substrates, especially elongate substrates. The particular s~ape of the present fabric will thus typically depend upon the shape of the substrate being covered or protected. In all cases, however, the shaped fabric product will provide a wall portion for covering the substrate and a chamber or open area internal to the wal~ portion for containing at ieast a portion o the subs~rate.~~.Thus, the shaped rabric products will preferably possess a hollow portion defined by a wall portion having a shape corresponding generally to the shape of the subs~rate to be pro~ected, thereby providing a chamber or cavity f or accep~ing the substrate. While all such shapes are within the scope of the present invention, it is contemplated that the WO93/0~281 212 2 7 3 3 - 6 - PCT/GB92/02003 shaped fabrics of the present invention will fr~quently and typically be in tubular form. As used herein, the term ~tubular~' refers to an elongate article having an internal chamber running substantially along the leng~ thereof. While it is expected that the tubular products of the present invention will typically have a circular cross-sectiona}
configuration, it is contemplated that other cross-sectional configurations, such as triangular, square and ellipsoidal, may also be used.
Acc~rding to important aspects of t~e present invention, the shaped fabric products comprise filaments in the wall portion thereof resiliently set in a spiral configuration relative to the longitudinal axis of the shaped fabric. For embodiments comprising tubul~r products, for ~:
example, the fabric product includes filaments resiliently set in a spiral pattern with respect to the axis of the tube. As the term is used herein, "resilient set" refers to the incorporation of a permanent set or a bias in a resilient filamentary material. Thus, a filamentary material which has been resiliently set in a given configuration tends to remain in that configuration under ambient temperature conditions and in the ab~ence of external stress. However, such material readily deforms upon the application of externally applied stress but returns to substantially its original "set"
position upon the release of the stress.
It is contemplated that the pitch of the resiliently set spiral filaments may vary widPly within th~ scope hereof, depending upon such factors as the particular filamentary material being used, the cost of the product and the degree of flexibility and kink-resistance which is desired. In general, however, it is preferred 'hat for tubular fabric products the resiliently~s.ét spir~l filaments have a pitch of no greater than about 0.4 turns pe~ ls~gitudinal inch of tubular product, and even more preferably a pitch of from about 0.2 to about 0~3 turns per inch. Applicants have found that tubular fabric products, and especially woven tubular products having a circular cross-section and an inner diameter of from about WO93/0928l 212 2 7 3 3 PCT/GB92/0200~
3/16 to about 4 inches, possess high levels of bot~
flexibility and kink-resistance when the spiral filaments have a pitch within the range described herein. Furthermore, Applicants have found that such tubular products possess an unexpectedly hiyh de~ree of abrasion resistance.
~ ccording to preferred embodiments of the present invention, the shaped fabric products include a wall portion comprising filaments resiliently set in a spiral configuration relative to the longitudinal axis o~ the shaped fabric such that the tubul~r product has an abrasion resistan~ of at least about 25,000 cycles and evPn more preferably of from about 30,000 ~o about 60,000 cycles of the ARP test. As the term is used herein, the ARP test refers to`the abrasion test o~tlined hereinafter in the Example section of the present specification.
According to certain preferred aspects of the present invention, the wall portion of the shaped fabric product also comprises resiliently set circumferential hoops substantially conforming in shape and size to the cross-sectional configuration of the shaped product. As us~d herein, the term "cross-sectional configuration" refers to the configuration of a shaped product in a plane which is subs~antially normal with respert to the longitudinal axis of the product. For example, the wall portion of cylindrically shaped tubular fabrics preferably includes resiliently set circular filaments forming hoops having approximately the diameter of the cylinder. According to especially preferred embodiments, the shaped product is a woven product in ~hich a substantial portion o, the fill threads, and even more preferably substantially all of the fill threads, are resiliently set in the form of circumferential hoops and wherein a subs~antial por~ion of the warp ends, and even more preferably substantially al~ of the warp ends, are resiliently set in a spiral configuration with respect to the longitudinal axis o~ ~he shaped product.
As is known t~ thosD skilled in the art, many ~ilamentary ma~erials of cons~ruction are capable of being W093/09281 21 2 2 7 ~ 3 - 8 - PCT/GB92/02003 provided with a resilient set. Thus, it is contemDlated that a large number of materials are adaptable for use in forming the resiliently settable filaments hereof. For example, many structural meta~s and engineering plastics will assume a permanent set when stressed above their elastic limit at room temperature. In general, however, it is expected that the filamentary material of the present invention will be provided with a resilient set or bias by the application of heat, pressure, irradiation, chemical reagents and combinations of these.
While it is contemplated that metals and natural fibers ~ay be used for the resiliently settabl~ filaments hereof, it is generally preferred t~at such filaments comprise synthetic fibers, and even more preferably synthetic fibers constructed from the class of materials known as thermoplastic resins. In general, thermoplastic resins are polym~ric materials that soften or melt at elevated temperatures, thus allowing them to be processed into shapes and products that, when cooled, recover the physical and chemical properties of the original resin. In addition, this class of materials generally has a good balance of high tensile properties, compress~ve and shear strength, as well as imoa~t resistance.
Exemplary thermoplastic resins are polyamides, polyesters, and polyolefins, with polyamides and polyesters being pre~erred.
Filaments comprised of thermoplastic resins of ~he type described may be cause to take a resilient, permanent set by fprming a product comprised of the plastic material to a specific geometry, for exampl~, a circular or spiral shape, and then modifying the properties of the material. As mentioned above, this is usually accomplished by the application o~ heat to raise its temperature to a point either above the-g~ass transition temDerature or above the softening point. The shaped product is then cooled so as to recrystallize or "set" the f1lamentary material. The product thereafter has a resilien~ set or bias (sometimes called an "elastic memory"J in the shape in which it was formed, as is well recoqnized by those of ordin ry skill in the art.
_ g _ ~
Although the application of heat is the usu~l and most widely employed met~od of producing the set or bias, it should also be recognized that other, eg., chemical or physical, methods may sometimes be employed. For example, such a set may be provided to filamentary material comprising polyethylene by irradiating the shaped product so as to cross-link the polyethylene chains. Such cross-linking may be accelerated or enhanced by the inclusion of cross-linking promoters in the polymeric material.
It is contemplated that ~he resiliently settable filaments used in the fabrics of the present invention may vary widely both as to type and dimension. In par~icular, it is contemplated that the resiliently settable filaments may include multi-filament yarns and threads, monofilament yarns and threads or mixtures of these types of filaments, with monofilaments being preferred.
It will be appreciated that filamentary material other than the resiliently settable mat~rial described above may be included with advantage in the shaped fabrics of the present invention. ~or example, it may be beneficial to include filaments comprised of fluorocarbon polymer resin to impart lcw friction characteristics t~ the shaped products.
Moreover, combinations of engineering plastic materials and yarns or strands or filaments comprised of me~als or mineral materials may be used. T~us, it is contemplated that the present fabrics may comprise, in addition to the resiliently settable filaments hereof, other natural and synthetic filaments which contribute but do not detract from the properties of the present shaped products.
A first embodiment of shaped-fabric product of the present invention will now be described in connection with Figs. 1 an ~2. The shaped fabric product, desi~na~ed generally as lO, comprises a woven tubular product having a circular cross-section. The tubular product comprises a wall portion 11 forming a hollow chamber 12. In use, the hollow chamber 12 is filled by an elonga~e substrate which is t~ be pro~ected by the shaped fa~ric 10. Wall portion ll of sAaped product 10 comprises fill ends 13 interlaced with warp ends 14. Fill ends 13 are in the shape of circular hoops or bands having a diameter equivalent to about the diameter of the wall portion 11 of tubular product 10. Warp ends 14 are resiliently set in a spiral configuration with respect to the longitudinal axis z of tubular product 10.
It will be appreci~ted that numerous and varisd methods may be employed to obtain a tubular product of the type disclosed in Figs. 1 and 2, and the use of all such methods is within the scope hereof. According to the method aspects of the present invention, however, the tubular product is constructed by first providin~ a woven tubular product in which the fill ends lie in a plane which is substantially perp ndicular to the axis of the tube and in which the warp ends lie in a plane which is substantially parallel to the axis of the tube. Numerous techniques are available for providing such a product, and all such techniques are within t~e scope hereof. For example, such a tubular product may be provided by first providing a rectangular sheet of woven fabric in whic~ the fill ends are substantially parallel to the short odge of the sheet and the warp ends are sub-~tantially parallel to the long edge of the woven sheet.
The long edges of this woven rectangular sheet are then joined according to any one of several well-known techniques, such as sewing, to form a woven product which is continuous along its short edge. It will be appreciated that other methods and techni~ues are ~nown and available for forming woven fabrics which arP continuous along their short edge. For example, certain weaving equipment, such as narrow fabric needle looms, are readily adapted to produce such woven products. The woven products can then be formed into a tubular confiquration by, for example, placing the product sver a cylindrical mandrel.
It will be appreciated that the ~ormation of tubular products using narrow fabri~ needle looms as indicated herein produces woven tubular products in which a single fill end is knitted to itsel~ to form interconnected resilient hoops disposed in a plane which ~s substantially perpendicular to WO~3~09281 212 2 7 3 3 PCT~GB92J0200~
the axis of the tube.
The me~hods of the present invention further comprise resiliently setting the warp ends of the provided tubular product in a spiral configuration relative to the axis of the tube. This step preferably comprises rotating a first portion of the tubular product about its longitudinal axis while preventing a second portion of the tubular prcduct from rotating. In this way, the warp ends of the woven produc~ are twisted into a spiral configuration with respect to the axis of the tube. Once in the spiral configuration, the ~arp ends may be resiliently set according to techniques of the type described above tc retain the spiral configuration. Ac~ording to especially preferred embodiments, the fill nds 13 are also comprised of resiliently settable material, and the step of resiliently setting the warp ends in the spiral configuration will also provide the preferred step of resiliently setting the fill ends in the form of a circular hoop.
The present invention is not limited t~ continuous tubular pr~ducts of the type illustrated in Fig. 1. For example, a second embodiment of the present invention provides tubular products which are discontinuous in the circumferential direction as illustrated in ~i~. 3. It will be appreciated by those skilled in the art that tubular products of the present invention which are discontinuous in the circumferential direction have cerlain advantages, especially when the wall portion of the tubular product includes resiliently set fill ends in the form of hoops or bands. For example, the discontinuity imparted to products of the type illustrated in Fig. 3 permits the tubular produc~ to be readily opened in the circumferential direction, thereby providing easy assembly of the protectiYe cover around the substrate to~be protected. Furthermore, because of the resiliently set circumferential hoops provided by fill ends 13, such a tubular product will return resiliently to its relatively closed configuration, thereby providing protection ~o the enclosed substrate, as illustrated in Fig. ~.
The present invention ic directed to tubular products, and more particular~y to tubular fabrics whieh are particularly well adapted for bundling and prstecting elongated articles, such as wires, cables, hoses and conduits.
The use of fabric sleeves for encasing cables, hoses and other elongated flexible articles is well-known in t~e art. Examples of such sleeving are available from the ~`
Bentley-Harris Manufacturing Company under the registered trademark EXPANDO. The EXPANDO~ sleeving is lightweight and provides tough physical protection for cable assemblies, wire harnesses and the like. The open construction of ~his type o~
product is of advantage over solid material in that it breathes and prevents the entrapment of moisture. In addition, this type of sleeving ma'ntains the bundled, elongated articles in clean, compact condition.
While sleeving of the type employed by the EXPANDO~
~product has achieved significant success and possesses certain advantageous characteristics, a need for flexi~le, kink- -resis~ant woven tubular products continues to exist. U.S.
Patent No. 4,223,824 - Evans et al., for example, recognizes the difficult~ of providing woven tubular products which resist kinking when curved or ben~. Evans et al. teaches that this di~ficulty may be overcome by providing a hose having a reinforcement structure comprised of plied warp yarns formed o~ filamen~s of high modulus material which resists longitudinal extension of the hose. The warp elements of Evans et al are said to have a high degree of twist in the WO93~092B1 212 2 7 3 3 - 2 - PCT/GB92/0200~
filaments in order to provide stability to the hose wall when compressed during curving of the hose. Furthermore, Evans et al. illustrates the w~rp elements as extending along the length of the hose in a direction substantially parallel to the axis of ~he hose.
U.S~ Pa~ent No. 4,652,263 - Herwic~ et al. is directed to woven fabric tubes especially adapted for use as prosthases in biomedical applications. Herwick et al. note that such woven fabric tubes are preferably capable of returning to t~eir original shape after being stretched, compressed or bent. Herwick et al. also note that such tubular products should also ~e resistan~ to kinking or radi21 eollapse. Elasticity is impar~ed to the tubes of Herwick et al. by proYiding the woven tubular products with axially-oriented warp threads forming loops extending radially outward between circumferential fill threads. The loops are set to return to th~ loop configuration upon rele se of tension applied axially to the tube.
U.S. Paten~ No. ~,015,641 - Goff et al. recognizes the difficulty associated with providing s~ape retaining woven tubular products. In particular, Goff et al. notes that tubular fabrics have heretofore been filled with foam ~aterial so that the product will have a cushioned, shape retaining characteristic. Goff et al. suggest that a similar effect can be obtained by forming a woven tubular produot using monof ilament f illiny yarns in both layers of the fabric and alternately and interm~ttently weaving monofilament warp yarns between the layers to connect the two layers together.
While the products mentioned above may have achieved some degree of success, they also posse5s certain drawbacks.
For example, potentially costly and somewhat unusual manufacturing techniques are required to produce the products of the ~ype described above. Moreover, the products described in Goff et al. 5uffer from the disadvantage of requiring the presence of structural members spanning the hollow portion Of the tubular product. The presence of such struckural members limits the usefulness of the tu~ular product for encasing ~93/09281 212 2 7 3 3 PCT/GB92/02003 elongate substrates.
Thusl Applicants have recognized a need ~or shaped-fabric products, and particularly for tubular fabrics, which are at once shape-retaining, ~ink-resistant and flexible.
Furthermore, Applicants have recognized the failure of the prior art to provide methods for manufacturing woven tubular products which possess these characteristics.
Furthermore, while the abrasion-resistance of the heretofore used protective fabric coverings has been acceptable in many applications, applicants have found that tremendous improvement in abrasion resistance is possible.
Such improvement in abrasion resis~ance is highly desir~ble for obvious reasons, such as increas~ng the useful life of the protective fabric cover. ~-Accordingly, it is an object of the present invention to provide flexible, kink-resist~nt fa~ric covers.
It is a further object to the present invantion to provide relatively low-cost protective fabric covers.
It is yet a further object of the present invention ::-to provide flexible, kink-resistant fabric covers with excellent abrasion resistance.
S~ARY OF TRE INVENT~ON
The present invention provides flexible, kink-resistant shaped fabric products which are particularly well adapted for protecting and/or covering elongate substrates, such as cables, conduits, wiring and t~e 'ike. The shaped fabric produc~s are preferably elongate tubular products having a l~ngitudinal dimension which is substantially greater than the width, diameter or girth of tne product. According to important aspects of the present invention, the shaped ~abric products include a wall portion comprising a filament resiliently set in a spiral conîiguration with respect to the longitudinal axis of the shaped product. Applicants have fsund that tubular products comprising fabrics, and preferably woven fabric5, haYing ~uch spirally set filaments generally possess excellent flexibili~y and exceptional kin~- and abrasion-resistance.
WO~3/09281 212 2 7 3 3 PCT/GB92/02003 The wall portion of the tubular product also preferably comprises a filament in the form of circumferential hoops substantially conforming in shape and size to the cross-sectional configuration of the shaped product. For the preferred cylindrically shaped tubular products, the circumferential hoops are substantially circular hoops having a diameter equal to about the diameter of the cylinder.
According to preferred aspects of ~he present invention, the shaped fabric product comprises a woven tubular fabric having a fill end t~ereof in the form of hoops which lie in a plane substantially perpendicular to the axis of the tube and warp ends thereof resiliently set in a spiral configuration with respect to the longitudinal axis of the tube.
The present invention also provides methods of forming flexible, kink-resistant tubular fabrics. The methods comprise: (l) providing a shaped fabric product comprising a wall portion comprising interlaced, resiliently settable filaments and (2) resiliently setting at least a portion of the resiliently settable filaments in a spiral configuration with respect to the longitudinal axis of the tubular product.
According to certain preferred embodiments, t~e providing step comprises providing a woven tubular fabric and the setting step romprises heat setting the resiliently set~able filaments.
~RIEF DESCRIPTION OF THE ~RAWINGS
Fig. l is a perspe~ive view of a woven tubular product according to a first embodiment of the present invention.
Fig, 2 is a plan view of a woven tubular product according to a first embodimen~ of the present inventîon.
Flg. 3 is a perspective view of a woven tubular product which is radially discontinuous according to a second embodiment of the present invention.
Fig. 4 is a perspective view of a radially discontinuous woven tubular product of the present invention encasing an elongate substra~e, WO 93/09281 212 2 7 3 3 PCI`/GB92/0200~s DETAILED DESCRIPT~ON O~ PREFERRED EMBODIMENq~S
The present invention is directed to shaped products, and more particularly to shaped fabric products. As the term is used herein, "fabric" refers to any material comprised of interlaced filamentary components. As will be appreciated by those skilled in the art, many classes of fabric material exist, and it is contemplated that all such materials may be adaptable for use in connection with the present invention. In particular, it is contemplated that the shaped fabric products may comprise knitted products, ~r?ided products or woven products, with woven products being preferred. The preferred woven products comprise fill and warp threads in~erlaced according to any one of the well~known weave patterns. In general, however, applicants have found that a ~will pattern, and preferably a 2-2 twill pattern, .
produces acceptable results.
Furthermore, it is gPnerally preferred that the shaped fabric products are preferably characterized by an open construction. That is, it is generally preferred t~at t~
filamentary materials comprising the wall portion of the shaped fabric are relatively loosely interlaced. In this way, the shaped fabric products of the present invention breath and prever,_ entrapment or moisture.
The presen~ shaped fabric products are particularly well adapted for protecting and/or co~ering substrates, especially elongate substrates. The particular s~ape of the present fabric will thus typically depend upon the shape of the substrate being covered or protected. In all cases, however, the shaped fabric product will provide a wall portion for covering the substrate and a chamber or open area internal to the wal~ portion for containing at ieast a portion o the subs~rate.~~.Thus, the shaped rabric products will preferably possess a hollow portion defined by a wall portion having a shape corresponding generally to the shape of the subs~rate to be pro~ected, thereby providing a chamber or cavity f or accep~ing the substrate. While all such shapes are within the scope of the present invention, it is contemplated that the WO93/0~281 212 2 7 3 3 - 6 - PCT/GB92/02003 shaped fabrics of the present invention will fr~quently and typically be in tubular form. As used herein, the term ~tubular~' refers to an elongate article having an internal chamber running substantially along the leng~ thereof. While it is expected that the tubular products of the present invention will typically have a circular cross-sectiona}
configuration, it is contemplated that other cross-sectional configurations, such as triangular, square and ellipsoidal, may also be used.
Acc~rding to important aspects of t~e present invention, the shaped fabric products comprise filaments in the wall portion thereof resiliently set in a spiral configuration relative to the longitudinal axis of the shaped fabric. For embodiments comprising tubul~r products, for ~:
example, the fabric product includes filaments resiliently set in a spiral pattern with respect to the axis of the tube. As the term is used herein, "resilient set" refers to the incorporation of a permanent set or a bias in a resilient filamentary material. Thus, a filamentary material which has been resiliently set in a given configuration tends to remain in that configuration under ambient temperature conditions and in the ab~ence of external stress. However, such material readily deforms upon the application of externally applied stress but returns to substantially its original "set"
position upon the release of the stress.
It is contemplated that the pitch of the resiliently set spiral filaments may vary widPly within th~ scope hereof, depending upon such factors as the particular filamentary material being used, the cost of the product and the degree of flexibility and kink-resistance which is desired. In general, however, it is preferred 'hat for tubular fabric products the resiliently~s.ét spir~l filaments have a pitch of no greater than about 0.4 turns pe~ ls~gitudinal inch of tubular product, and even more preferably a pitch of from about 0.2 to about 0~3 turns per inch. Applicants have found that tubular fabric products, and especially woven tubular products having a circular cross-section and an inner diameter of from about WO93/0928l 212 2 7 3 3 PCT/GB92/0200~
3/16 to about 4 inches, possess high levels of bot~
flexibility and kink-resistance when the spiral filaments have a pitch within the range described herein. Furthermore, Applicants have found that such tubular products possess an unexpectedly hiyh de~ree of abrasion resistance.
~ ccording to preferred embodiments of the present invention, the shaped fabric products include a wall portion comprising filaments resiliently set in a spiral configuration relative to the longitudinal axis o~ the shaped fabric such that the tubul~r product has an abrasion resistan~ of at least about 25,000 cycles and evPn more preferably of from about 30,000 ~o about 60,000 cycles of the ARP test. As the term is used herein, the ARP test refers to`the abrasion test o~tlined hereinafter in the Example section of the present specification.
According to certain preferred aspects of the present invention, the wall portion of the shaped fabric product also comprises resiliently set circumferential hoops substantially conforming in shape and size to the cross-sectional configuration of the shaped product. As us~d herein, the term "cross-sectional configuration" refers to the configuration of a shaped product in a plane which is subs~antially normal with respert to the longitudinal axis of the product. For example, the wall portion of cylindrically shaped tubular fabrics preferably includes resiliently set circular filaments forming hoops having approximately the diameter of the cylinder. According to especially preferred embodiments, the shaped product is a woven product in ~hich a substantial portion o, the fill threads, and even more preferably substantially all of the fill threads, are resiliently set in the form of circumferential hoops and wherein a subs~antial por~ion of the warp ends, and even more preferably substantially al~ of the warp ends, are resiliently set in a spiral configuration with respect to the longitudinal axis o~ ~he shaped product.
As is known t~ thosD skilled in the art, many ~ilamentary ma~erials of cons~ruction are capable of being W093/09281 21 2 2 7 ~ 3 - 8 - PCT/GB92/02003 provided with a resilient set. Thus, it is contemDlated that a large number of materials are adaptable for use in forming the resiliently settable filaments hereof. For example, many structural meta~s and engineering plastics will assume a permanent set when stressed above their elastic limit at room temperature. In general, however, it is expected that the filamentary material of the present invention will be provided with a resilient set or bias by the application of heat, pressure, irradiation, chemical reagents and combinations of these.
While it is contemplated that metals and natural fibers ~ay be used for the resiliently settabl~ filaments hereof, it is generally preferred t~at such filaments comprise synthetic fibers, and even more preferably synthetic fibers constructed from the class of materials known as thermoplastic resins. In general, thermoplastic resins are polym~ric materials that soften or melt at elevated temperatures, thus allowing them to be processed into shapes and products that, when cooled, recover the physical and chemical properties of the original resin. In addition, this class of materials generally has a good balance of high tensile properties, compress~ve and shear strength, as well as imoa~t resistance.
Exemplary thermoplastic resins are polyamides, polyesters, and polyolefins, with polyamides and polyesters being pre~erred.
Filaments comprised of thermoplastic resins of ~he type described may be cause to take a resilient, permanent set by fprming a product comprised of the plastic material to a specific geometry, for exampl~, a circular or spiral shape, and then modifying the properties of the material. As mentioned above, this is usually accomplished by the application o~ heat to raise its temperature to a point either above the-g~ass transition temDerature or above the softening point. The shaped product is then cooled so as to recrystallize or "set" the f1lamentary material. The product thereafter has a resilien~ set or bias (sometimes called an "elastic memory"J in the shape in which it was formed, as is well recoqnized by those of ordin ry skill in the art.
_ g _ ~
Although the application of heat is the usu~l and most widely employed met~od of producing the set or bias, it should also be recognized that other, eg., chemical or physical, methods may sometimes be employed. For example, such a set may be provided to filamentary material comprising polyethylene by irradiating the shaped product so as to cross-link the polyethylene chains. Such cross-linking may be accelerated or enhanced by the inclusion of cross-linking promoters in the polymeric material.
It is contemplated that ~he resiliently settable filaments used in the fabrics of the present invention may vary widely both as to type and dimension. In par~icular, it is contemplated that the resiliently settable filaments may include multi-filament yarns and threads, monofilament yarns and threads or mixtures of these types of filaments, with monofilaments being preferred.
It will be appreciated that filamentary material other than the resiliently settable mat~rial described above may be included with advantage in the shaped fabrics of the present invention. ~or example, it may be beneficial to include filaments comprised of fluorocarbon polymer resin to impart lcw friction characteristics t~ the shaped products.
Moreover, combinations of engineering plastic materials and yarns or strands or filaments comprised of me~als or mineral materials may be used. T~us, it is contemplated that the present fabrics may comprise, in addition to the resiliently settable filaments hereof, other natural and synthetic filaments which contribute but do not detract from the properties of the present shaped products.
A first embodiment of shaped-fabric product of the present invention will now be described in connection with Figs. 1 an ~2. The shaped fabric product, desi~na~ed generally as lO, comprises a woven tubular product having a circular cross-section. The tubular product comprises a wall portion 11 forming a hollow chamber 12. In use, the hollow chamber 12 is filled by an elonga~e substrate which is t~ be pro~ected by the shaped fa~ric 10. Wall portion ll of sAaped product 10 comprises fill ends 13 interlaced with warp ends 14. Fill ends 13 are in the shape of circular hoops or bands having a diameter equivalent to about the diameter of the wall portion 11 of tubular product 10. Warp ends 14 are resiliently set in a spiral configuration with respect to the longitudinal axis z of tubular product 10.
It will be appreci~ted that numerous and varisd methods may be employed to obtain a tubular product of the type disclosed in Figs. 1 and 2, and the use of all such methods is within the scope hereof. According to the method aspects of the present invention, however, the tubular product is constructed by first providin~ a woven tubular product in which the fill ends lie in a plane which is substantially perp ndicular to the axis of the tube and in which the warp ends lie in a plane which is substantially parallel to the axis of the tube. Numerous techniques are available for providing such a product, and all such techniques are within t~e scope hereof. For example, such a tubular product may be provided by first providing a rectangular sheet of woven fabric in whic~ the fill ends are substantially parallel to the short odge of the sheet and the warp ends are sub-~tantially parallel to the long edge of the woven sheet.
The long edges of this woven rectangular sheet are then joined according to any one of several well-known techniques, such as sewing, to form a woven product which is continuous along its short edge. It will be appreciated that other methods and techni~ues are ~nown and available for forming woven fabrics which arP continuous along their short edge. For example, certain weaving equipment, such as narrow fabric needle looms, are readily adapted to produce such woven products. The woven products can then be formed into a tubular confiquration by, for example, placing the product sver a cylindrical mandrel.
It will be appreciated that the ~ormation of tubular products using narrow fabri~ needle looms as indicated herein produces woven tubular products in which a single fill end is knitted to itsel~ to form interconnected resilient hoops disposed in a plane which ~s substantially perpendicular to WO~3~09281 212 2 7 3 3 PCT~GB92J0200~
the axis of the tube.
The me~hods of the present invention further comprise resiliently setting the warp ends of the provided tubular product in a spiral configuration relative to the axis of the tube. This step preferably comprises rotating a first portion of the tubular product about its longitudinal axis while preventing a second portion of the tubular prcduct from rotating. In this way, the warp ends of the woven produc~ are twisted into a spiral configuration with respect to the axis of the tube. Once in the spiral configuration, the ~arp ends may be resiliently set according to techniques of the type described above tc retain the spiral configuration. Ac~ording to especially preferred embodiments, the fill nds 13 are also comprised of resiliently settable material, and the step of resiliently setting the warp ends in the spiral configuration will also provide the preferred step of resiliently setting the fill ends in the form of a circular hoop.
The present invention is not limited t~ continuous tubular pr~ducts of the type illustrated in Fig. 1. For example, a second embodiment of the present invention provides tubular products which are discontinuous in the circumferential direction as illustrated in ~i~. 3. It will be appreciated by those skilled in the art that tubular products of the present invention which are discontinuous in the circumferential direction have cerlain advantages, especially when the wall portion of the tubular product includes resiliently set fill ends in the form of hoops or bands. For example, the discontinuity imparted to products of the type illustrated in Fig. 3 permits the tubular produc~ to be readily opened in the circumferential direction, thereby providing easy assembly of the protectiYe cover around the substrate to~be protected. Furthermore, because of the resiliently set circumferential hoops provided by fill ends 13, such a tubular product will return resiliently to its relatively closed configuration, thereby providing protection ~o the enclosed substrate, as illustrated in Fig. ~.
2 1 2 2 7 3 3 - l2 - PCT/GB92/0200~
It will be appreciated that tubular products which are àiscontinuous in the circumferential direction may be prepared according to various techniques, and all such ~echniques are within the scope of the present invention. For example, tubular products of the type disclosed in Fig. 3 may be prepared by providing a longituàinal cut or slit in the wall portion 12 of the tubular product, thereby producing a tubular product having adjacent longitudinal edges. While such a cut or slit will provide the advantages described above, it may also have disadvantages in some applications.
For example, the simple provision of a cut or a slit longitudinally of the tube may leave a small gap or opening in the tube wall. This small gap or opening may be a disadvan~age for applications whic~. require that the enclosed substrate be completely ~echanically isolated from the environment. According to certain embodiments of the present invention, therefore, it is preferred that the longitudinal edges 15 and 16 of the discontinuous tubular product overlap one ansther in the radial direction, as illustrated in-Fig. 3.
This overlap may be pr~vided using any one of several processing techniques. In general, Aowever, it is contemplated that the tubular product will be radially compressed so as to provide overlap between edges 15 and 16 and subse~uently heat set in this compressed position. For exampie, ~he discontinuous tubular product may be provided to a folder of well a known design and heated, preferably simultaneously heated, to provide edges '~ and 16 in a heat s t, ove_lapped position. As an alternative example, the discontinuous tubular product may be wrapped around a mandrel having a diameter smaller ~han ~he inner diameter of the discontinuous tube such tha~ overlap of the longitudinal edges occurs . The ~ overlapped conr iguralion is then set into ~Ae tube, suc;r~ as by the application Oc heat to the mandre'.
While it is cor.templa~ed that the tubular produ-ts of ~he present invention may be provided in a wide variety of shapes and siz~s, it is gen rally preferred that tubula-producls are subs~an.ially ~i cular in cross-seclion an- have `~093~0~281 21 2 2 7 3 3 PCT/GB92/0200~
an inner diameter of about 0.25 inch to about 4 inches.
Furthermore, it is generally preferred that the warp and fill threads of the present invention are monofilaments having a diameter of from about 5 to about 15 mil with about 8 to about 10 mil being preferred.
Shaped fabric products, particularly tubular fabrics for use in casing and covering elongated substrates, according to the present invention exhibit exceptional and altogether unexpected results. For example, one important characteristic of the shaped articles of t~e present invention is the excellent abrasion resistance thereof. The following examples, which are set forth by way of illustration but not by way of limitation, describe the improvements in abrasion resistance which are achieved according'to t~e present invention as compared to typical prior art produc~s. In each of the examples which follows, abrasion tests were performed utilizing established standard test criteria for the evaluation of chaff guards intended to provide from abrasion and chaffing of hose assemblies and adjacent components, as set forth by the Society of Automotive Engineers, Inc.
according to "Aerospace Recommended Practice" (ARP 15-36A), issued December 1978, revised February lg81, which are incorporated herein by reference. In particular, each tubular fabric being tested was installed over a stainless stee mandrel, approximately 1~ ~nches iong. The mandrel and tubular product were res~rained by suitable clamps and fittings according to the specified criteria. The tests were operated under ambien. temperature conditions. An abrasive element comprising a 0.50 inch precision ground drill rod (QQ-T-580) with a ~pecific hea- ~realment of 60-64 HRC hardness and a sur~ace finish of R 1D ~ in (0.40 ~m~ was applied to the ou~er surfac~ of the ~ubula- fabric with a total force of about ~ pounds. The abrasi~ force was then reciprocated longitudi~ally across the tubular product at a rate of about 200 cycles per minu~e through a total stroke of about 3 inch.
In the ~cest results, failure of the protective cover is established as a we2-ing through o' ~he cover by the abrasion WO93/09281 2 1 2 2 7 3 3 - 14 - PCT~GB92/0200~
element. Such a ~ailure is determined by t~e abrasive element contacting t~e metal reinforcement of the h~se assembly after wear through of the fabric product, thus closing an electrical circuit which stops the tester.
COMPP~RATIVE EXlU~PI.E 1 A braided tubular product having an inner diameter of about Q.5 inch comprising polyester monofilament having a diameter of about .010 inch and a braid pattern of one over, one under was subjec~ to an abrasion test according to the procedure described above. The. tubular product was substantially circular in cross-section and had an inner diame~er of abuut 0.5 inch. Such a product is gener~lly available under the trade designation EXPANDV~. A series of three tests of the type described above ~ere carried out. The results of this test are desc-ibed in connection with Table 1 below~
Table 1 ~un #Cvcles to Failure 1 13,800 2 9,700 3 14,600 Avg. 12,700 EXAMP~E 1 A woven tubular product according to the present invention was su~ject to an abrasion test according to the procedure desczibed above. The woven product comprised polyester monofilament fill threads having a diameter of about O.OOg inch and polyester monof~lament warp threads having a diameter of about .010 inch in a 2-2 twill pattern. The tubular product was substantially circular in cross-sPction and had an inner diameter of about 0.5 inch. The fill threads _ were all resiliently set by the application of heat in the form of a substantially circular hoop having a diameter of about 0.52 inch. The warp threads were all resiliently set by the application of h~at in a spiral configuration having a pitCh of about 0.2 turns per inch. A series of three tests of the type described above were farried 9Ut. The results Oc '~O 93/09281 212 2 7 3 3 PCr/GB92/0200~
this test are described in connection with Table 2 below.
Table 2 Run #Cvcles to Failure 56, 500 2 50, 400 3 62, 600 Avg. ~6, 500 _
It will be appreciated that tubular products which are àiscontinuous in the circumferential direction may be prepared according to various techniques, and all such ~echniques are within the scope of the present invention. For example, tubular products of the type disclosed in Fig. 3 may be prepared by providing a longituàinal cut or slit in the wall portion 12 of the tubular product, thereby producing a tubular product having adjacent longitudinal edges. While such a cut or slit will provide the advantages described above, it may also have disadvantages in some applications.
For example, the simple provision of a cut or a slit longitudinally of the tube may leave a small gap or opening in the tube wall. This small gap or opening may be a disadvan~age for applications whic~. require that the enclosed substrate be completely ~echanically isolated from the environment. According to certain embodiments of the present invention, therefore, it is preferred that the longitudinal edges 15 and 16 of the discontinuous tubular product overlap one ansther in the radial direction, as illustrated in-Fig. 3.
This overlap may be pr~vided using any one of several processing techniques. In general, Aowever, it is contemplated that the tubular product will be radially compressed so as to provide overlap between edges 15 and 16 and subse~uently heat set in this compressed position. For exampie, ~he discontinuous tubular product may be provided to a folder of well a known design and heated, preferably simultaneously heated, to provide edges '~ and 16 in a heat s t, ove_lapped position. As an alternative example, the discontinuous tubular product may be wrapped around a mandrel having a diameter smaller ~han ~he inner diameter of the discontinuous tube such tha~ overlap of the longitudinal edges occurs . The ~ overlapped conr iguralion is then set into ~Ae tube, suc;r~ as by the application Oc heat to the mandre'.
While it is cor.templa~ed that the tubular produ-ts of ~he present invention may be provided in a wide variety of shapes and siz~s, it is gen rally preferred that tubula-producls are subs~an.ially ~i cular in cross-seclion an- have `~093~0~281 21 2 2 7 3 3 PCT/GB92/0200~
an inner diameter of about 0.25 inch to about 4 inches.
Furthermore, it is generally preferred that the warp and fill threads of the present invention are monofilaments having a diameter of from about 5 to about 15 mil with about 8 to about 10 mil being preferred.
Shaped fabric products, particularly tubular fabrics for use in casing and covering elongated substrates, according to the present invention exhibit exceptional and altogether unexpected results. For example, one important characteristic of the shaped articles of t~e present invention is the excellent abrasion resistance thereof. The following examples, which are set forth by way of illustration but not by way of limitation, describe the improvements in abrasion resistance which are achieved according'to t~e present invention as compared to typical prior art produc~s. In each of the examples which follows, abrasion tests were performed utilizing established standard test criteria for the evaluation of chaff guards intended to provide from abrasion and chaffing of hose assemblies and adjacent components, as set forth by the Society of Automotive Engineers, Inc.
according to "Aerospace Recommended Practice" (ARP 15-36A), issued December 1978, revised February lg81, which are incorporated herein by reference. In particular, each tubular fabric being tested was installed over a stainless stee mandrel, approximately 1~ ~nches iong. The mandrel and tubular product were res~rained by suitable clamps and fittings according to the specified criteria. The tests were operated under ambien. temperature conditions. An abrasive element comprising a 0.50 inch precision ground drill rod (QQ-T-580) with a ~pecific hea- ~realment of 60-64 HRC hardness and a sur~ace finish of R 1D ~ in (0.40 ~m~ was applied to the ou~er surfac~ of the ~ubula- fabric with a total force of about ~ pounds. The abrasi~ force was then reciprocated longitudi~ally across the tubular product at a rate of about 200 cycles per minu~e through a total stroke of about 3 inch.
In the ~cest results, failure of the protective cover is established as a we2-ing through o' ~he cover by the abrasion WO93/09281 2 1 2 2 7 3 3 - 14 - PCT~GB92/0200~
element. Such a ~ailure is determined by t~e abrasive element contacting t~e metal reinforcement of the h~se assembly after wear through of the fabric product, thus closing an electrical circuit which stops the tester.
COMPP~RATIVE EXlU~PI.E 1 A braided tubular product having an inner diameter of about Q.5 inch comprising polyester monofilament having a diameter of about .010 inch and a braid pattern of one over, one under was subjec~ to an abrasion test according to the procedure described above. The. tubular product was substantially circular in cross-section and had an inner diame~er of abuut 0.5 inch. Such a product is gener~lly available under the trade designation EXPANDV~. A series of three tests of the type described above ~ere carried out. The results of this test are desc-ibed in connection with Table 1 below~
Table 1 ~un #Cvcles to Failure 1 13,800 2 9,700 3 14,600 Avg. 12,700 EXAMP~E 1 A woven tubular product according to the present invention was su~ject to an abrasion test according to the procedure desczibed above. The woven product comprised polyester monofilament fill threads having a diameter of about O.OOg inch and polyester monof~lament warp threads having a diameter of about .010 inch in a 2-2 twill pattern. The tubular product was substantially circular in cross-sPction and had an inner diameter of about 0.5 inch. The fill threads _ were all resiliently set by the application of heat in the form of a substantially circular hoop having a diameter of about 0.52 inch. The warp threads were all resiliently set by the application of h~at in a spiral configuration having a pitCh of about 0.2 turns per inch. A series of three tests of the type described above were farried 9Ut. The results Oc '~O 93/09281 212 2 7 3 3 PCr/GB92/0200~
this test are described in connection with Table 2 below.
Table 2 Run #Cvcles to Failure 56, 500 2 50, 400 3 62, 600 Avg. ~6, 500 _
Claims (27)
1. A flexible, abrasion- and kink-resistant tubular product for protecting conduit, cable and like elongated substrates comprising a woven tube having a substantially circular cross-sectional configuration, an ARP
abrasion resistance of at least about 25,000 cycles and a wall portion comprising:
(a) a filamentary fill end comprising interconnected resiliently set hoops disposed in a plane substantially perpendicular to the axis of the tube; and (b) a filamentary warp end interwoven with said fill end and heat set in a spiral configuration having a pitch of from about 0.2 to about 0.3 turns per longitudinal inch of tubular product.
abrasion resistance of at least about 25,000 cycles and a wall portion comprising:
(a) a filamentary fill end comprising interconnected resiliently set hoops disposed in a plane substantially perpendicular to the axis of the tube; and (b) a filamentary warp end interwoven with said fill end and heat set in a spiral configuration having a pitch of from about 0.2 to about 0.3 turns per longitudinal inch of tubular product.
2. The tubular product of claim 1 wherein said filamentary fill end and said filamentary warp end each comprise a synthetic monofilament.
3. The tubular product of claim 1 wherein said tubular product is discontinuous in the circumferential direction.
4. The tubular product of claim 1 wherein said fill ends and said warp ends each comprise filament formed of thermoplastic resin.
5. The tubular product of claim 1 wherein said filamentary fill end and said filamentary warp end each comprise a monofilament of thermoplastic resin selected from the group consisting of polyamides, polyesters and combinations of these.
6. The tubular product of claim 1 wherein said wall portion consists essentially of one or more of said filamentary fill ends and one or more of said filamentary warp ends.
7. A tubular fabric product for protecting conduit, cable and like elongate substrates, said product comprising a wall portion comprising first filamentary material resiliently set in the form of a plurality of hoops disposed in a plane substantially perpendicular to the longitudinal axis of the tube and second filamentary material interlaced with said first filamentary material and resiliently set in a spiral configuration with respect to the axis of the tube.
8. The tubular fabric product of claim 7 comprising a woven tubular product.
9. The tubular fabric product of claim 7 comprising a tubular product having a substantially circular cross-section with an inner diameter of from about 0.25 inch to about 4 inches.
10. The tubular fabric of claim 7 wherein said second filamentary material has a pitch of no greater than 0.4 turns per inch of longitudinal length.
11. The tubular fabric product of claim 7 wherein first and second filamentary materials each comprise thermoplastic filaments.
12. The tubular fabric product of claim 11 wherein said first and second filamentary material each comprise monofilament.
13. A flexible, abrasion- and kink-resistant shaped fabric product comprising a wall portion comprised of filamentary material resiliently set in a spiral configuration with respect to the longitudinal axis of the shaped product.
14. The shaped fabric product of claim 13 comprising a woven product.
15. The shaped fabric product of claim 13 comprising a woven tube having a substantially circular cross-sectional configuration.
16. The shaped fabric product of claim 13 wherein said product has an ARP abrasion resistance of at least about 25,000 cycles.
17. The shaped fabric product of claim 13 wherein said product is a woven product and said spirally set filamentary material comprises a filamentary warp end of said product,
18. The shaped fabric product of claim 17 wherein said woven product consists essentially of one or more warp ends and one or more fill ends and wherein substantially all of said warp ends are spirally set filamentary material.
19. The shaped fabric product of claim 18 wherein said one or more fill ends are resiliently set in the form of a plurality of hoops disposed in a plane substantially perpendicular to the longitudinal axis of the shaped fabric.
20. The shaped fabric product of claim 19 wherein said one or more fill ends consist essentially of a single fill end in the form of interconnected resiliently set hoops, each hoop being substantially disposed in a plane substantially perpendicular to the axis of the shaped product.
21. A method of making a tubular product comprising:
(a) providing a fabric of interlaced filamentary material, at least a portion of said filamentary material being resiliently settable; and (b) resiliently setting at least a portion of said settable filaments in the form of a spiral configuration with respect to the longitudinal axis of the tube.
(a) providing a fabric of interlaced filamentary material, at least a portion of said filamentary material being resiliently settable; and (b) resiliently setting at least a portion of said settable filaments in the form of a spiral configuration with respect to the longitudinal axis of the tube.
22. The method of claim 21 wherein said providing step comprises providing a woven product.
23. The method of claim 21 wherein said providing step comprises providing a woven tubular product having a substantially circular cross-sectional configuration.
24. The method of claim 21 wherein said setting step comprises forming said filament in said spiral configuration and then heat setting said filament in said configuration.
25. The method of claim 21 wherein:
(a) said providing step comprises providing a woven tubular product consisting essentially of substantially longitudinal warp filaments and one or more circumferential fill filaments; and (b) said setting step comprises:
(i) twisting said tubular product to place said warp filaments in a spiral configuration relative to the axis of the tube; and (ii) heat setting said warp filaments in said spiral configuration.
(a) said providing step comprises providing a woven tubular product consisting essentially of substantially longitudinal warp filaments and one or more circumferential fill filaments; and (b) said setting step comprises:
(i) twisting said tubular product to place said warp filaments in a spiral configuration relative to the axis of the tube; and (ii) heat setting said warp filaments in said spiral configuration.
26. The method of claim 25 wherein said providing step comprises providing a circumferentially discontinuous tubular product having first and second longitudinal edges and said setting step comprises: (i) radially compressing said tubular product to provide radial overlap of said longitudinal edges; and (ii) heat setting said resiliently settable fill filaments in said overlapped configuration.
27. The method of claim 21 wherein said fill filaments comprise resiliently settable filaments and said setting step comprises heat setting said resiliently settable fill filaments in the form of a plurality of hoops disposed in a plane substantially perpendicular to the longitudinal axis of the shaped fabric.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/787,900 US5413149A (en) | 1991-11-05 | 1991-11-05 | Shaped fabric products and methods of making same |
| US07/787,900 | 1991-11-05 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2122733A1 true CA2122733A1 (en) | 1993-05-13 |
Family
ID=25142866
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002122733A Abandoned CA2122733A1 (en) | 1991-11-05 | 1992-11-02 | Shaped fabric products and methods of making same |
Country Status (9)
| Country | Link |
|---|---|
| US (2) | US5413149A (en) |
| EP (1) | EP0611404B1 (en) |
| JP (1) | JP2718571B2 (en) |
| KR (1) | KR940702956A (en) |
| CA (1) | CA2122733A1 (en) |
| DE (1) | DE69219785T2 (en) |
| ES (1) | ES2101125T3 (en) |
| MX (1) | MX9206347A (en) |
| WO (1) | WO1993009281A1 (en) |
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- 1992-11-02 EP EP92922758A patent/EP0611404B1/en not_active Expired - Lifetime
- 1992-11-02 ES ES92922758T patent/ES2101125T3/en not_active Expired - Lifetime
- 1992-11-02 WO PCT/GB1992/002003 patent/WO1993009281A1/en active IP Right Grant
- 1992-11-02 CA CA002122733A patent/CA2122733A1/en not_active Abandoned
- 1992-11-02 DE DE69219785T patent/DE69219785T2/en not_active Expired - Fee Related
- 1992-11-02 KR KR1019940701456A patent/KR940702956A/en not_active IP Right Cessation
- 1992-11-04 MX MX9206347A patent/MX9206347A/en unknown
-
1995
- 1995-04-06 US US08/418,076 patent/US5556495A/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| EP0611404B1 (en) | 1997-05-14 |
| WO1993009281A1 (en) | 1993-05-13 |
| JPH07500882A (en) | 1995-01-26 |
| DE69219785T2 (en) | 1997-12-18 |
| ES2101125T3 (en) | 1997-07-01 |
| US5413149A (en) | 1995-05-09 |
| US5556495A (en) | 1996-09-17 |
| JP2718571B2 (en) | 1998-02-25 |
| EP0611404A1 (en) | 1994-08-24 |
| KR940702956A (en) | 1994-09-17 |
| MX9206347A (en) | 1993-10-01 |
| DE69219785D1 (en) | 1997-06-19 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |