EP-4739828-A1 - TUBULAR PROTECTIVE SLEEVE HAVING A KNITTED DUAL LAYER WALL AND METHOD OF CONSTRUCTION THEREOF

Abstract

A thermal protection tubular sleeve (10) includes a knitted inner wall (14b) having circumferentially continuous outer (16) and inner (18) surfaces. The circumferentially continuous inner surface bounds a cavity (20) that extends lengthwise along a longitudinal central axis (22) between opposite inner ends of the knitted inner wall (14b). The tubular sleeve (10) further includes a knitted outer wall (14a) having circumferentially continuous outer (26) and inner (28) surfaces. The knitted outer wall (14a) extends lengthwise about the longitudinal central axis (22) between opposite outer ends and overlies the knitted inner wall (14b). An intermediate yam (40) extends back and forth between and through knitted loops of the outer wall (14a) and knitted loops (36) of the inner wall (14b) to connect the knitted outer wall (14a) and the knitted inner wall (14b) to one another.

Inventors

• MCFARLAND, SCOTT

Assignees

• Systems Protection Group US LLC

Dates

Publication Date

20260513

Application Date

20240829

Claims (20)

1. 1. A tubular sleeve for providing thermal protection about an elongate member, comprising: a knitted inner wall having a circumferentially continuous outer surface and a circumferentially continuous inner surface, the circumferentially continuous inner surface bounding a cavity extending lengthwise along a longitudinal central axis between opposite inner ends of the knitted inner wall; a knitted outer wall having a circumferentially continuous outer surface and a circumferentially continuous inner surface, the knitted outer wall extending lengthwise about the longitudinal central axis between opposite outer ends, the knitted outer wall overlying the knitted inner wall; and an intermediate yam extending back and forth between the knitted outer wall and the knitted inner wall to connect the knitted outer wall and the knitted inner wall to one another.
2. 2. The tubular sleeve of claim 1, wherein the knitted inner wall is knitted entirely with a first yam forming interlinked inner knitted stitches and the knitted outer wall is knitted entirely with a second yam forming interlinked outer knitted stitches, the inner knitted stitches not knitted to the outer knitted stitches.
3. 3. The tubular sleeve of claim 2, wherein the intermediate yam is the sole connection of the knitted inner wall to the knitted outer wall.
4. 4. The tubular sleeve of claim 3, wherein the intermediate yam is knitted with a tuck stitch.
5. 5. The tubular sleeve of claim 4. wherein the inner knitted stitches and the outer knitted stitches are formed using weft knitted stitches.
6. 6. The tubular sleeve of claim 5, wherein the weft knitted stitches are jersey stitches.
7. 7. The tubular sleeve of claim 2, wherein the first yam and the second yam are multifilaments.
8. 8. The tubular sleeve of claim 7, wherein the first yam and the second yam are different ty pes of material.
9. 9. The tubular sleeve of claim 7, wherein the multifilaments consist of at least one of, fiberglass, ceramic, basalt, silica, slate, slag, aramid and carbon.
10. 10. The tubular sleeve of claim 7, wherein the intermediate yam is a monofilament.
11. 11. The tubular sleeve of claim 10, wherein the monofilament is heat-set to impart a bias on the knitted inner wall and the knitted outer wall to maintain a predetermined shape.
12. 12. The tubular sleeve of claim 1, wherein the opposite inner ends are radially aligned with the opposite outer ends in substantially flush relation.
13. 13. A method of constructing a tubular sleeve for providing thermal protection about an elongate member, the method comprising: knitting an inner wall, and knitting the inner wall having a circumferentially continuous outer surface and a circumferentially continuous inner surface, the circumferentially continuous inner surface bounding a cavity extending lengthwise along a longitudinal central axis between opposite inner ends of the knitted inner wall, on two separate beds of a four-bed weft knitting machine; knitting an outer wall in overlying relation with the inner wall, and knitting the outer wall having a circumferentially continuous outer surface and a circumferentially continuous inner surface, the knitted outer wall extending lengthwise about the longitudinal central axis between opposite outer ends, on two separate beds, different from the two separate beds used to knit the inner wall, of the four-bed weft knitting machine; and knitting an intermediate yam back and forth between the outer wall and the inner wall to connect the outer wall and the inner wall to one another.
14. 14. The method of claim 13, further including knitting the intermediate yam using tuck stitches.
15. 15. The method of claim 13, further including knitting the inner wall and the outer entirely with multifilament yams.
16. 16. The method of claim 15, further including providing the multifilament yams consisting of at least one of, fiberglass, ceramic, basalt, silica, slate, slag, aramid and carbon.
17. 17. The method of claim 15, further including using monofilament yams for the intermediate yam.
18. 18. The method of claim 13, further including knitting the inner wall and the outer entirely with jersey stitches.
19. 19. The method of claim 13, further including knitting the intermediate yam on all four beds of the four-bed knitting machine.
20. 20. The method of claim 13, further including shaping the inner wall and the outer wall to form the cavity having a desired shape, and then heat-setting the intermediate yam to impart a bias on the inner wall and the outer wall to maintain the cavity in the desired shape.

Description

TUBULAR PROTECTIVE SLEEVE HAVING A KNITTED DUAL LAYER WALL AND METHOD OF CONSTRUCTION THEREOF CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This PCT International Patent Application claims the benefit of and priority to U.S. Patent Application Serial No. 18/241,714. filed September 1, 2023. the entire disclosure of which is hereby incorporated by reference in its entirety. BACKGROUND OF THE INVENTION 1. Technical Field [0002] This invention relates generally to tubular protective sleeves for providing protection to elongate members contained therein, and more particularly to knitted tubular protective sleeves and to their method of construction. 2. Related Art [0003] Single wall tubular sleeves are known for protecting elongate members against thermal conditions. The sleeves are commonly constructed from heat resistant yams, such as silica, fiberglass, ceramic, basalt, aramid or carbon, to withstand relatively high temperatures. Although the sleeves are generally effective at providing a thermal barrier, the heat-resistant yam that forms the outer wall of the sleeves is generally susceptible to damage. Accordingly, if protection against abrasion, impact or crush resistance is needed, an additional sleeve(s) is typically disposed in a separate operation about the single wall sleeve. Although this can prove helpful, it is generally labor intensive, bulky' and costly. SUMMARY OF THE INVENTION [0004] In accordance with one aspect of the invention, a tubular sleeve for providing thermal protection about an elongate member, such as a bus bar of an electric vehicle battery pack, contained therein is provided. The tubular sleeve includes a knitted inner wall having a circumferentially continuous outer surface and a circumferentially continuous inner surface. The circumferentially continuous inner surface bounds a cavity that extends lengthwise along a longitudinal central axis between opposite inner ends of the knitted inner wall. The tubular sleeve further includes a knitted outer wall having a circumferentially continuous outer surface and a circumferentially continuous inner surface. The knitted outer wall extends lengthwise about the longitudinal central axis between opposite outer ends and overlies the knitted inner wall. Further, an intermediate yam extends back and forth between the knitted outer wall and the knitted inner wall to connect the knitted outer wall and the knitted inner wall to one another. [0005] In accordance with another aspect of the invention, the knitted inner wall is knitted entirely with a first yam forming interlinked inner knitted stitches and the knitted outer wall is knitted entirely with a second yam forming interlinked outer knitted stitches, the inner knitted stitches not knitted to the outer knitted stitches. [0006] In accordance with another aspect of the invention, the intermediate yam is the sole connection of the knitted inner wall to the knitted outer wall. [0007] In accordance with another aspect of the invention, the intermediate yam is knitted with a tuck stitch. [0008] In accordance with another aspect of the invention, the inner knitted stitches and the outer knitted stitches are formed using weft knitted stitches. [0009] In accordance with another aspect of the invention, the weft knitted stitches are jersey stitches. [0010] In accordance with another aspect of the invention, the first yam and the second yam are multifilaments. [0011] In accordance with another aspect of the invention, the first yam and the second yam can be provide as different types of material to optimized the desired performance attributes of the inner and outer walls. [0012] In accordance with another aspect of the invention, the multifilaments consist of at least one of, fiberglass, ceramic, basalt, silica, slate, slag, aramid and carbon. [0013] In accordance with another aspect of the invention, the intermediate yam is a monofilament. [0014] In accordance with another aspect of the invention, the monofilament is heat-set to impart a bias on both the knitted inner wall and the knitted outer wall to maintain the knitted inner wall and the knitted outer wall, and the cavity bounded by the inner wall, having a predetermined shape. [0015] In accordance with another aspect of the invention, the opposite inner ends are radially aligned with the opposite outer ends in substantially flush relation. [0016] In accordance with another aspect of the invention, a method of constructing a tubular textile sleeve for providing thermal protection about an elongate member is provided. The method includes knitting an inner wall having a circumferentially continuous outer surface and a circumferentially continuous inner surface, with the circumferentially continuous inner surface bounding a cavity extending lengthwise along a longitudinal central axis between opposite inner ends of the knitted inner wall, on two separate beds of a four-bed weft knitting machine. Further, knitting an outer wall in overlying rela