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CN102667964B - 织物套管的构造方法及其形成的管状织物套管 - Google Patents

织物套管的构造方法及其形成的管状织物套管 Download PDF

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CN102667964B
CN102667964B CN201080054471.0A CN201080054471A CN102667964B CN 102667964 B CN102667964 B CN 102667964B CN 201080054471 A CN201080054471 A CN 201080054471A CN 102667964 B CN102667964 B CN 102667964B
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拉梅什·R·阿乌拉
杰弗里·吉布斯
约翰·巴伯
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Abstract

本发明提供一种织物套管的构造方法及其形成的管状织物套管。该织物套管具有由交织的纱线形成的细长织物壁。采用丙烯酸粘合剂和水性硅树脂的乳液涂在交织的纱线上，该丙烯酸粘合剂可以在低于150℃的温度下防止织物套管产生端部磨损，而硅树脂可以在150-1500℃的温度下防止产生端部磨损。

Description

织物套管的构造方法及其形成的管状织物套管
相关申请的交叉引用
本申请要求于2009年10月7日提交的第61/249,326号美国临时申请的权益，其全部内容通过引用并入此处。
技术领域
本发明主要涉及用于保护细长元件的管状套管，尤其涉及柔性织物套管。
背景技术
众所周知，保护性织物套管中的绕线和线束可以保护电线免受磨损、流体和热量的影响。无论在制造过程中或者实际使用中，织物套管通常首先被编织、辫织或针织，然后成形，织物套管材料均被冷切成期望的长度。可惜的是，当将织物套管材料冷切成期望的长度后，用来构造套管的一根或多根纱线通常会在切口端产生磨损。因此，切口变得不美观，并且进一步地趋于劣化(例如散开)。
为了避免上述不美观的、有问题的冷切现象发生，公知的是：在进行切割操作之前给织物套管涂上一层硅橡胶，使得套管保持柔性且以最小的端部磨损被切割。但是，硅橡胶涂层使得套管不能应用于温度相对较高(例如150摄氏度(℃)以上)的应用中。因此，仍然需要一种可以不用考虑端部磨损进行定长冷切的织物导管，且该套管可以使用在150℃以上的温度下。
发明内容
本发明一方面提供了一种用于导引和保护细长元件的织物套管。该织物套管具有由交织的纱线制成的细长织物壁。丙烯酸粘合剂和水性硅树脂涂层被涂在交织的纱线上，该丙烯酸粘合剂可以在低于150℃的温度下防止织物套管产生端部磨损，而硅树脂可以在大约150-1500℃的温度之间防止织物套管产生端部磨损。
根据本发明另一方面提供了一种柔性织物套管的构造方法。该方法包括将一根或多根热定型的纱线交织以形成织物。该方法进一步包括将水性硅树脂和丙烯酸粘合剂的乳液涂在该织物上。然后，该方法包括在足够的温度下加热涂覆的乳液，以使水分从乳液里蒸发并不会使硅树脂固化。进一步地，该方法包括在一定温度下加热该热定型的纱线，该温度足以将套管壁形成为绕套管的纵轴卷曲的自卷包的管状壁，且该温度不足以使硅树脂固化。
因此，本发明提供一种织物套管，该织物套管在围绕所要保护的细长元件时保持柔性。进一步地，该织物套管可以被冷切而不会造成织物套管的纱线发生磨损。又进一步地，该套管可以经受150℃以上的温度而不会影响套管的保护完整性。此外，在200℃以上的温度下，丙烯酸粘合剂可以被蒸发，硅树脂可以被固化，且所述固化的硅树脂可以保持套管的保护性能。
附图说明
结合下文详细描述的优选实施方案、最佳实施例、所附权利要求和附图，本发明在所述的或者其它方面的特性和优点将更加容易理解，其中：
图1是根据本发明一方面构造的柔性的、自卷包的织物套管的局部原理透视图，示出了其中包含和保护的细长元件；以及
图2是根据本发明一方面的用于构造织物套管的典型流程图。
具体实施方式
更详细地参阅附图，图1示出了根据本发明一方面构造的自卷包织物套管(以下简称套管10)的原理图。套管10具有用于导引和保护细长元件(例如电线或线束14)的细长壁12(例如自卷包的壁)。该细长壁12由至少一根或多根纱线16制成，其中一根或多根纱线交织形成壁12。至少一些在自卷包实施例中的纱线16提供为热定型的纱线，其中，该热定型的纱线被交织之后再被热定型以将壁12偏折成自卷包的管状构形。因此，当壁12处于没有外力作用在非卷包的壁12上使其从自卷包构形展开的松弛状态时，壁12绕着中心纵轴18自卷包以提供封闭或者基本封闭的管状内部型腔20。沿套管10的纵轴18可轻易地进入型腔20，以使得细长元件14可以容易地径向设置入型腔20中，相反地，在例如维修过程中也可以容易地从型腔20中径向取出细长元件。为了使壁12可以在不用考虑纱线16的端部磨损的情况下进行定长冷切，交织的纱线16具有涂有乳液的涂层22，且该乳液包括丙烯酸粘合剂和水性硅树脂，或者由丙烯酸粘合剂和水性硅树脂组成。制成的涂层22使得套管10在高达约200-250℃的温度下保持柔性，并且使得套管10可经受高达约500℃的工作环境温度而不会劣化。因此，套管10可以使用在很多极限温度应用中以保护其中的细长元件14，同时，其制造成本低，且相对于其它高温的非织物管(例如金属管或塑料管)重量更轻。
壁12可以构造为具有任意合适的尺寸(包括长度、直径和壁厚)。壁12具有平行于轴18延伸的相对两侧边24、26，该两侧边24、26终止于例如在制造过程中或者实际使用中冷切成期望长度的相对两端28、29。当壁12为其自卷包的管状构形，且一般不受任何外部施加的作用力时，两侧边24、26优选为至少略微地相互重叠，以周向地完全封闭型腔20。因此，套管10的壁12绕着电线14周向延伸以充分周向地保护型腔20中的电线14。套管10的纵向延伸的两侧边24、26在外部施加的作用力下容易彼此分开延伸，以至少部分打开和显露型腔20。如此一来，在装配过程中电线14可以容易地径向设置入型腔20中，在维修过程中电线14可以容易地从型腔20中径向取出。当解除两侧边24、26的外部施加的作用力后，两侧边24、26在热定型形成的偏折下自动返回到其松弛或基本松弛的、重叠的自卷包位置。
壁12可以由复丝和/或单丝16制成，且至少一根或多根在自卷包实施例中的纱线16被热定型。例如，该一根或多根丝线16可以为热定型聚合物材料(例如聚苯硫醚PPS)，该热定型聚合物材料可以在大约200-225℃之间的温度下被热定型。形成壁12的纱线16可以根据需要采用各种交织工艺(例如编织、针织或辫织)交织，图1中示意性示出的纱线16被编织。
无论采用辫织、针织或编织工艺，在通过交织的纱线16形成织物壁12后，均在纱线16上涂覆乳液，此后，在壁12上形成和/或在纱线16中浸渍成涂层22。涂层22最初涂覆在纱线16上(例如通过喷涂、刷涂、浸渍或辊涂工艺)作为一种乳液的液态涂层。涂层22可以是丙烯酸粘合剂(例如具有按重量计约15-18％含量的羧酸盐弹性聚合物乳液)和水性硅树脂(例如按重量计约15-18％含量的甲基苯基聚硅氧烷乳液)的乳液。当将乳液涂至纱线16上后，通过例如加热处理蒸发乳液中的水分。施加的热量足以将水分蒸发并使得壁12基本干燥，然而，由于热量不足以使硅树脂固化，所以硅树脂保持未固化。因此，壁12保持在未固化的状态下的自由的柔性。
然后，壁12被卷包成管状构形，优选地，相对两侧边24、26相对彼此重叠，采用足够的热量(例如约200-225℃之间的温度)加热壁12，以使至少一些热定型的纱线16被热定型，从而使壁12保持在卷包构形。因此，尽管施加的热量不会使硅树脂固化，但壁12还是呈现出其自卷包的形态。如此一来，壁12保持其自由的柔性且未固化，以便在使用中可以容易地围绕急弯或拐角导引壁12。进一步地，由于涂层22保持未固化，且壁12保持柔性，因此必要时可以通过外部施加的作用力容易地将相对两侧边24、26分开以便对细长元件进行维修。
于是，当将壁16形成为期望的构形后，通过冷切至少一端28可以获得期望的长度，且不会使纱线16产生磨损。不发生磨损直接归因于丙烯酸粘合剂和硅树脂的涂层22。
使用中，在涂层22中的丙烯酸粘合剂被蒸发之前，套管10可以经受约150-200℃之间的温度，然而，涂层22中的硅树脂则保持在套管壁12上，并且甚至可以在更高的温度下固化。虽然，如果硅树脂固化，套管会失去其柔性，但即使硅树脂固化，套管10仍然可用以保护其中的细长元件直到约500℃的温度。因此，套管10能在较宽的温度范围内有效地保护其中的细长元件14，而不会对细长元件14和围绕的表面产生不利影响，该不利影响例如为具有会融化的橡胶涂层的套管所出现的可能情况。
显然，鉴于上述教导，本发明可以有多种修改和变形。因此，应该理解，在所附权利要求的范围内，本发明还可以通过除具体描述的方式以外的其它方式实施。

Claims (2)

1.一种用于导引和保护细长元件的织物套管的构造方法，其特征在于，包括：
将纱线交织以形成细长壁；
将具有丙烯酸粘合剂和水性硅树脂的液态涂层涂在纱线上；
加热液态涂层，以使纱线中的水分蒸发而不会使硅树脂固化且不会将纱线热定型；
将细长壁卷包成沿中心纵轴延伸的卷曲的管状构形；以及
在200-225℃之间的温度下将纱线热定型，以使该壁保持在自卷包的管状构形而不会使硅树脂固化；
其中，所述液态涂层为丙烯酸粘合剂和水性硅树脂的乳液，所述丙烯酸粘合剂为重量计15-18％含量的羧酸盐弹性聚合物乳液，所述水性硅树脂为按重量计15-18％含量的甲基苯基聚硅氧烷乳液。
2.一种根据权利要求1所述的构造方法形成的管状织物套管，其特征在于，包括：
沿所述套管的中心纵轴延伸的具有相对两侧边的壁，所述壁由交织的纱线制成，所述纱线被热定型以使所述壁偏折成自卷包的管状构形，其中所述相对两侧边相互重叠；以及
涂在所述交织的纱线上并干燥的液态涂层，所述涂层具有丙烯酸粘合剂和水性硅树脂，所述水性硅树脂为非固化的水性硅树脂。
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