CN215103793U - Fabric innerduct structure and sleeve system - Google Patents

Abstract

The present invention relates to a fabric innerduct structure and a sleeving system, the fabric innerduct structure comprising at least one chamber configured to enclose and carry at least one cable, characterized in that the fabric innerduct structure comprises a plurality of yarns and at least one seam, the seam comprising a plurality of stitches and at least a portion of the yarns located in the seam being fusion bonded together or ultrasonically welded; the sleeve system comprises a sleeve and the fabric innerduct structure.

Description

Fabric innerduct structure and sleeve system

Technical Field

The present invention relates to a fabric innerduct structure and a sleeve system, and more particularly, to a fabric innerduct structure having stitched and ultrasonically welded seams and a sleeve system containing a fabric innerduct structure having stitched and ultrasonically welded seams.

Background

The use of a flexible innerduct structure within the conduit has a number of functions, including isolating individual cables into compartments or channels within the innerduct to maximize the number of cables that can be placed in the conduit, facilitating insertion of the cables into the conduit by preventing friction between the cables, and providing a strap or cord within each compartment of the innerduct to pull the cables into the conduit.

The flexible innerduct structure made of fabric can have various shapes, such as a "common wall construction", "tear-drop construction", and a tube. It is desirable to have a strong seam within the inner catheter structure that prevents unraveling and breakage.

SUMMERY OF THE UTILITY MODEL

To solve the above problems, the present invention provides a fabric innerduct structure comprising at least one chamber configured to enclose and carry at least one cable, characterized in that the fabric innerduct structure comprises a plurality of yarns and at least one seam, the seam comprising a plurality of stitches and at least a portion of the yarns located in the seam being fusion bonded together or ultrasonically welded.

In some embodiments of the fabric innerduct structure, the fabric innerduct structure comprises a woven fabric.

In some embodiments of the catheter-in-fabric structure, the woven fabric is folded about a centrally located longitudinal axis.

In some embodiments of the catheter-in-fabric structure, the fabric is a woven fabric comprising:

a plurality of warp yarns arranged in warp yarn groupings, wherein each grouping contains from 2 to 10 warp yarns; and

a plurality of picks of weft yarn;

wherein in each first weaving zone the pick of weft yarns comprises a repeating first weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein in each partially float weaving zone the pick of weft yarns in said partially float weaving zone comprises a repeating second weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein only a portion of the warp yarns in at least a portion of the warp yarn groupings float over 3 weft yarns, including at least one over-inserted multifilament weft yarn in at least a portion of the weft pattern repeat, and wherein outside of the floats, non-floating warp yarns pass over and under alternating picks of weft yarns in sequence.

In some embodiments of the fabric innerduct structure, the width of the fabric innerduct structure is less than 60 mm.

In some embodiments of the fabric innerduct structure, the width of the fabric innerduct structure is less than 40 mm.

In some embodiments of the fabric innerduct structure, further comprising a drawstring or drawstring located in the fabric innerduct structure.

In some embodiments of the fabric innerduct structure, the fabric innerduct structure is flexible and comprises:

at least one webbing, wherein each webbing comprises a first edge and a second edge and extends in a longitudinal direction,

wherein all of the first and second edges of the respective strips are located in an intermediate region, wherein each strip-like fabric extends outwardly from the intermediate region, folds around a folding axis located in either the first region or the second region and returns to the intermediate region to form a chamber, wherein at least one strip extends from the first region to the second region, wherein the fabric innerduct structure comprises at least one fold in the at least one strip of fabric in the first region and at least one fold in the at least one strip of fabric in the second region, wherein the respective strips are attached together in the intermediate region.

In some embodiments of the fabric innerduct structure, the fabric innerduct structure includes at least two chambers, each chamber designed to enclose at least one cable.

In some embodiments of the fabric innerduct structure, the fabric innerduct structure comprises at least one annular fabric tube and at least one seam.

In some embodiments of the fabric innerduct structure, the fabric innerduct structure includes at least two endless fabric tubes and at least one seam joining the at least two endless fabric tubes together.

In some embodiments of the fabric innerduct structure, the yarns in the seam have a repeating pattern of areas of ultrasonically welded stitches and non-ultrasonically welded stitches.

The utility model also provides a bushing system, a serial communication port, bushing system includes:

a sleeve;

at least one fabric innerduct structure comprising at least one chamber configured to enclose and carry at least one cable, the fabric innerduct structure comprising a plurality of yarns and at least one seam comprising a plurality of stitches and at least a portion of the yarns in the seam being fusion bonded together or ultrasonically welded; the at least one fabric innerduct structure is located within the sleeve.

In some embodiments of the cannula system, the in-fabric catheter structure comprises a woven fabric.

In some embodiments of the cannula system, the woven fabric is folded about a centrally located longitudinal axis.

In some embodiments of the cannula system, the fabric is a woven fabric comprising:

a plurality of warp yarns arranged in warp yarn groupings, wherein each grouping contains from 2 to 10 warp yarns; and

a plurality of picks of weft yarn;

wherein in each first weaving zone the pick of weft yarns comprises a repeating first weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein in each partially float weaving zone the pick of weft yarns in said partially float weaving zone comprises a repeating second weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein only a portion of the warp yarns in at least a portion of the warp yarn groupings float over 3 weft yarns, including at least one over-inserted multifilament weft yarn in at least a portion of the weft pattern repeat, and wherein outside of the floats, non-floating warp yarns pass over and under alternating picks of weft yarns in sequence.

In some embodiments of the cannula system, the cannula has an inner diameter of less than 60 mm.

In some embodiments of the cannula system, the width of the conduit structure within the fabric is less than 60 mm.

In some embodiments of the cannula system, the width of the cannula is less than 40 mm.

In some embodiments of the cannula system, the width of the conduit structure within the fabric is less than 40 mm.

In some embodiments of the sleeve system, further comprising a drawstring or drawstring located in the fabric innerduct structure.

In some embodiments of the cannula system, the in-fabric catheter structure is flexible and comprises:

at least one webbing, wherein each webbing comprises a first edge and a second edge and extends in a longitudinal direction,

wherein all of the first and second edges of the respective strips are located in an intermediate region, wherein each strip-like fabric extends outwardly from the intermediate region, folds around a folding axis located in either the first region or the second region and returns to the intermediate region to form a chamber, wherein at least one strip extends from the first region to the second region, wherein the fabric innerduct structure comprises at least one fold in the at least one strip of fabric in the first region and at least one fold in the at least one strip of fabric in the second region, wherein the respective strips are attached together in the intermediate region.

In some embodiments of the sleeve system, the in-fabric conduit structure comprises at least two chambers, each chamber being designed for enclosing at least one cable.

In some embodiments of the sleeve system, the yarns in the seam have a repeating pattern of areas of ultrasonically welded stitches and non-ultrasonically welded stitches.

Drawings

Fig. 1-7 show different embodiments of the cannula system in which different fabric innerduct structures have sewn and ultrasonically welded seams.

Fig. 8 illustrates one embodiment of a woven fabric.

Detailed Description

The flexible innerduct structure has chambers and is used within a conduit to help isolate individual cables into compartments or channels within the innerduct to maximize the number of cables that can be placed in the conduit, and to facilitate insertion of the cables into the conduit by preventing friction between the cables and providing a band or cord within each compartment of the innerduct.

To form more than one chamber in the innerduct structure, the layers are typically attached together using seams (which may be multiple pieces of fabric, fabric folded onto itself, or a combination of both). Such seams are important and it is preferable to limit or eliminate unraveling and breaking of the seams. One or more seams in the innerduct structure are stitched using stitching yarns and also ultrasonically welded. This ultrasonic welding causes at least a portion of the yarns (yarns from the fabric and/or stitching yarns from the stitching) to at least partially melt, adhere to other yarns, and re-harden to produce yarns that are melt bonded together. The stitching and ultrasonic welding may be performed in any order, but preferably the seam is stitched first and then ultrasonically welded. Once welded, it may be.

Fig. 1 shows a cannula system 10. The cannula 200 (shown in FIG. 1) into which the innerduct structure is inserted may be of any suitable size (inner or outer diameter), material and length, but is preferably a very small cannula with an inner diameter of less than about 75mm, more preferably less than about 60mm, more preferably less than about 50mm, more preferably less than about 40mm, more preferably less than about 35mm, more preferably less than 33mm, more preferably less than 30 mm. A cannula may also be referred to as a conduit, pipe, elongated cylindrical member, etc. In another embodiment, the cannula is preferably of conventional size or even large size. In one embodiment the sleeve is less than about 250mm, in another embodiment the sleeve is preferably from about 35mm to 250mm, in another embodiment the sleeve is preferably less than about 1000mm, more preferably from about 100mm to 900 mm. In another embodiment, the cannula has an outer or inner diameter of between about 10mm and 300 mm. Typically, the sleeve 200 is made of a polymer, but other materials, such as metals, may be used.

The innerduct structure is a fabric innerduct structure having a longitudinal length and a cross-sectional area. In one embodiment, the width of the conduit structure within the fabric is less than about 100mm, more preferably less than about 75mm, and more preferably less than about 50 mm. The width of the duct within the fabric is measured by flattening the duct structure within the fabric (the width appears smaller because sometimes the natural cross-sectional state of the duct is circular or the lobes are slightly rounded), and then the largest measurement over the cross-sectional area is defined as the width. Preferably, the width of the fabric innerduct structure is less than about 35 mm. Preferably, the width of the fabric innerduct structure is less than about 32 mm. Preferably, the width of the fabric innerduct structure is less than about 30 mm. These preferred widths are preferred for all embodiments of the fabric innerduct structure. These small width and specially designed innerduct structures have been shown to increase the number or ease of placement of cables or micro-cables within the conduit in combination with a small conduit. In other embodiments, the fabric innerduct structure is larger, and in one embodiment, the width of the fabric innerduct structure is greater than about 100mm, and more preferably greater than 200 mm. In another embodiment, the width of the fabric innerduct structure is from about 25mm to 500mm, more preferably from about 70mm to 300mm, and more preferably from about 85mm to 225 mm. These preferred width ranges are preferred in some of all the different innerduct structure embodiments disclosed herein.

Referring to fig. 1, one embodiment of an innerduct structure 100 is shown that is three seamless tubes attached together with seams. In fig. 1, the innerduct structure has been placed inside a conduit sleeve 200 and contains a drawable small diameter fiber optic cable 800 and a pull tape or cord 900. For example, the seamless tube may be formed using circular knitting or knitting. The seamless tube may be formed in any suitable width. In one embodiment, the seamless tube has a width of less than about 60mm, more preferably less than about 50mm, and more preferably less than about 40 mm. In another embodiment, the seamless tube has a width of about 30mm to 50mm, more preferably about 40mm to 50 mm. In another embodiment, the seamless tube has a width of about 10mm to 32mm, more preferably about 15mm to 31 mm. In some embodiments, this seamless tube may be preferred because once the tube is formed into the innerduct structure and can be formed into a small width, no further processing of the fabric is required. The seamless tubes may have the same or different widths. Once the tube is attached to the tube using the attachment 300, the tube forms the channels 110, 120, and 130. Fig. 1 shows an innerduct structure 100 that includes three seamless tubes along one side of the tube using an attachment 300. The innerduct structure of fig. 1 shows one of the chambers 130 containing a towable small diameter fiber optic cable 800 and one of the chambers 120 containing a drawstring 900.

The attachment 300 is a stitched and ultrasonically welded seam. A stitched seam is made by stitching together the various layers of fabric with stitching yarns. The ultrasonic welding melts at least a portion of the yarns of the tube structure and/or the stitching yarns within the fabric. The fabric may also have relatively low temperature melting fibers that can melt and allow cooling to fuse the structures together at the attachment. The ultrasonic welding serves to reinforce the seam and prevent the seam from opening or splitting before, during, or after the inner conduit is installed in the sleeve. The stitching and ultrasonic welding may be performed in any order, including both processes being performed substantially simultaneously. Preferably, the attachment 300 is formed by first sewing the seam and then ultrasonically welding the seam. Stitching can be more difficult if the seam is first ultrasonically welded. The attachment member 300 comprises a plurality of stitching yarns, wherein at least portions of the stitching yarns and/or yarns of the innerduct structure are bonded (fused) together. Ultrasonic welding on stitches (ticks) may be applied to one or both sides of the stitches. If the ultrasonic welding is applied on one side only, it is preferred that on the top side, the top side has only one strand (one thread) and the bottom side has two strands. In some embodiments, ultrasonic welding on both sides may be preferred.

In one embodiment, the ultrasonic welding is continuous, meaning that the entire seam is exposed to the ultrasonic welding. The amount of welding applied may be small so that the stitches appear to be almost the same as before the ultrasonic welding, may be medium so that the stitch strands have melted somewhat (it appears like a conventional strand but when you touch it the texture is different, it hardens after the ultrasonic welding), or may be higher level ultrasonic welding so that the strands visibly melt and deform.

In another embodiment, the ultrasonic welding may be performed at intervals, meaning that along the length of the seam there are ultrasonically welded regions and non-ultrasonically welded regions. The spacing space between the ultrasound regions may be between about 0.2cm and 200cm, more preferably between about 1cm and 100cm, more preferably between about 10-50 cm. The width of the ultrasonic zone may be between about 0.2cm and 200cm, more preferably between about 1cm and 100 cm. The tip of the ultrasonic welder may have different shapes, e.g. circular, oval, ribbon, etc., with different dimensions.

The attachment 300 may be located on one side of the innerduct as shown in fig. 1, or may be closer to the middle of the tubes used to divide each tube into two chambers. The three tubes in fig. 1 form three chambers 110, 120, 130. If the attachment 300 is located in the center of the innerduct structure 100 of fig. 1, 6 chambers will be formed (although each chamber will be smaller). The tubes within the innerduct structure may be of different sizes, and the attachment may be at different points in the tubes.

In another embodiment, as shown in FIG. 2, there is an inner catheter structure 100 that acts as a suture tube. The suture tube contains one chamber 110 and is formed from a webbing fabric that is then made into a tube with an attachment 300 along the longitudinal length of the tube.

There are many benefits to producing a tube from a webbing rather than a seamless tube (e.g., using endless weaving or knitting). The first benefit is around the splice. It is much easier to splice flat webbing together to form longer lengths and then turn the tapes into tubes than to splice seamless tubes together. Second, tubes of different sizes can be more easily manufactured, reducing machine downtime. Tubes of different diameters can be produced by simply cutting the webbing into different widths before it is converted into a tube. For many seamless tube making processes, the warp and/or weft yarn arrangement must be rearranged to vary the diameter of the tube produced.

For example, the suture tube may be used as shown in fig. 2, or the suture tube may have another attachment 300 that divides the suture tube into multiple chambers, as shown in fig. 3. The innerduct structure 100 of fig. 3 includes an additional attachment 300 that forms two chambers 110, 120 in the suture tube. In one embodiment, the attachment 300 is in a center tube defined approximately equidistant from two edges of the structure. Preferably, all chambers are formed to be approximately the same size. In another embodiment, the attachment 300 is eccentric, meaning that it is not in the center of the structure. This creates a larger chamber than on the other side. Different sized wires, cables 800, pull straps 900, etc. may preferably be accommodated.

In another embodiment shown in fig. 4, the innerduct structure 10 comprises a plurality of suture tubes that are connected together by the additional attachment member 300. Additional attachments 300 may be placed at any suitable location around the circumference of one or more tubes (e.g., including any of chambers 110, 120, 130, 140), even in the area of the first attachment 300 itself (surrounding the seam of the tubes). The attachments 300 on each tube within the innerduct structure 100 can be at different locations.

In one embodiment, the attachment 300 is located in the center of the middle region, defined as being approximately equidistant from the two edges of the structure. It is preferable to create chambers having all approximately the same dimensions. In another embodiment, the attachment 300 is off-center, meaning that it is not at the center of the structure. This creates a larger cavity in one of the edge regions than in the other edge region. Various sizes of wires, cables, drawstrings, etc. are preferably accommodated.

In fig. 5, the inner conduit structure is shown in a single tear drop configuration in a cannula 200. For a single tear drop, the webbing is folded about its longitudinal axis and the edges are attached together with the attachment 300. This creates a chamber 110 (in which pull straps, cables, micro-cables, etc. are placed). In one embodiment, the edges of the webbing are folded over to increase seam strength and reduce friction.

In another embodiment shown in fig. 6, the inner catheter structure 100 is a multi-lumen, tear-drop-like configuration. The innerduct structure in fig. 6 contains 2 chambers 110, 120, but the innerduct structure may contain any suitable number of chambers, such as 2 or more, 3 or more, 4 or more, 5 or more, or 6 or more chambers. The multi-chambered tear-drop configuration may be formed by folding a plurality of strip-like lengths of fabric to create individual compartments and then attaching the individual compartments together with the attachments 300. The innerduct is made up of a common seam forming the attachment 300 that secures the folds and trim along the length of the fabric (folds underneath) to improve seam strength and reduce friction. In another embodiment, the tear drop shape and chambers may be formed from a single fabric folded multiple times. This embodiment is shown in fig. 6, where one webbing is folded and attached to form two chambers 110, 120.

Referring to fig. 7, another embodiment of an inner conduit structure in a sleeve 200 is shown. The inner conduit structure comprises three regions: a first region, a middle region, and a second region. In the structure 100 of fig. 7, the structure 100 comprises a webbing forming four flexible longitudinal chambers 110, 120, 130, 140 with attachments 300 in the middle region. Each chamber is designed to enclose at least one cable.

Each webbing has a first edge and a second edge. The first edge and the second edge are located in a middle region of the innerduct structure 100. Each fabric strip extends outwardly from the intermediate region to either the first region or the second region and then back to the intermediate region, forming a chamber (110, 120, 130 or 140). The innerduct structure may contain 2 or 3 or more webbing, and at least one of those webbing extends from the first region to the second region. The innerduct structure includes at least one webbing having a fold in both the first area and the second area.

In a preferred embodiment, all of the chambers are formed from a single webbing, as shown in FIG. 7, because it is possible to create the desired number of chambers in the middle region of the structure 100 with a minimum number of webbing edges.

In fig. 7, the structure 100 comprises a webbing forming four longitudinal chambers 110, 120, 130, 140. The first edge of the webbing was in the middle zone, then the webbing was moved outward to either the first zone or the second zone, then to the other of the first zone or the second zone, and the pattern was repeated until 4 chambers were formed and the second edge was in the middle zone.

In this embodiment, the innerduct structure may have any suitable number (two to four or more) of chambers. The number of folds of the webbing in the first and second regions is equal to the number of chambers on the side of the attachment means. For example, if the fabric has one fold in the first region and two folds in the second region, the structure will have one chamber on the first region and two chambers on the second region of the attachment means.

In some embodiments, one or more edges of the webbing are folded. This may be preferred for: preventing the edges of the fabric from becoming caught on other materials during manufacture, installation and/or use of the innerduct structure, and also helps prevent the edges of the webbing from loosening from the attachment 300.

Preferably, the one or more fabrics are attached together and to themselves only at the attachment 300, and not at the first region, the second region, the first edge, or the second edge. This allows the chamber to diffuse and better fill the cannula. In the configuration shown in fig. 7, when installed in a cannula, the cavity of the configuration 100 expands to fill the cannula and has a dragonfly or butterfly-like appearance in cross-section.

In one embodiment, the attachment 300 is located in the center of the middle region, defined as being approximately equidistant from the two edges of the structure. It is preferable to create chambers having all approximately the same dimensions. In another embodiment, the attachment 300 is off-center, meaning that it is not at the center of the structure. This creates a larger chamber in one of these regions than in the other region. Various sizes of wires, cables, drawstrings, etc. are preferably accommodated.

All inner conduit structures are preferably made using woven fabrics. The woven fabric has a plurality of warp yarns extending in a warp direction of the woven fabric. The woven fabric also contains a plurality of weft yarns that extend in a direction that is generally perpendicular relative to the warp direction of the fabric. The weft yarns are interwoven with the warp yarns, wherein the warp yarns extend over and under the weft yarns in a predetermined crossing pattern. In a preferred embodiment, the fabric is a plain weave fabric. The fabric may be any other suitable weave pattern, including twill and satin.

The yarns in the woven fabric may be any suitable yarns. The selection of the type, size and comparison of each yarn in the woven fabric contributes to the final product of the woven fabric. In this application, "yarn" as used herein includes monofilament elongate bodies, multifilament elongate bodies, ribbons (ribbons), tapes (strips), yarns, strips (tapes), fibers, and the like. Woven fabrics may comprise one type of yarn or a plurality of any one or combination of the foregoing. The yarns may be in any suitable form, for example spun yarns, mono-or multifilament yarns, single component, bicomponent or multicomponent yarns, and have any suitable cross-sectional shape, such as round, multi-lobal, square or rectangular (tape) and oval.

The fabric may be formed from a single (single ply) or type of yarn (e.g., the fabric may be formed solely from a mixture comprising cellulosic fibers and synthetic fibersFibers, such as yarns of a blend of polyamide fibers), or the fabric may be formed from multiple (yarns) or different types of yarns (e.g., the fabric may be formed from a first strand of yarn comprising cellulosic fibers and polyamide fibers and a second strand of yarn comprising inherently flame resistant fibers). The yarns may be formed from, but are not limited to, cellulosic fibers (such as cotton, rayon, flax, jute, hemp, cellulose acetate, and combinations, mixtures, or blends thereof), polyester fibers (e.g., polyethylene terephthalate fibers, polypropylene terephthalate (PET) fibers, poly 1, 3-trimethylene terephthalate fibers, polybutylene terephthalate fibers, and mixtures thereof), polyamide fibers (e.g., nylon 6 fibers, nylon 6,6 fibers, nylon 4,6 fibers, and nylon 12 fibers), polyvinyl alcohol fibers, elastomeric polyester-polyurethane copolymers

Flame-retardant meta-aramid (meta-aramid)

And combinations, mixtures or blends thereof. Certain embodiments of the fabrics of the present invention comprise yarns comprising inherently flame resistant fibers. As used herein, the term "inherently flame resistant fibers" refers to synthetic fibers that are flame resistant due to the chemical composition of the material from which they are made, without the need for additional flame retardant treatment. In such embodiments, the inherently flame resistant fibers may be any suitable inherently flame resistant fibers, such as polyoxadiazole fibers, polysulfonamide fibers, polybenzimidazole fibers, polyphenylene sulfide fibers, meta-aramid fibers, para-aramid fibers, polypyridobisimidazole fibers, polybenzothiazole fibers, polybenzoxazole fibers, melamine-formaldehyde polymer fibers, phenol-formaldehyde polymer fibers, oxidized polyacrylonitrile fibers, polyamide-imide fibers, and combinations, mixtures, or blends thereof. In certain embodiments, the inherently flame resistant fibers are preferably selected from the group consisting of polyoxadiazole fibers, polysulfonamide fibers, polybenzimidazole fibers, polyphenylene sulfide fibers, meta-aramid fibers, para-aramid fibers, and combinations thereofA mixture, or a mixture.

In a preferred embodiment, the warp yarns are monofilament yarns. Monofilament yarns are preferred because they have a lower amount of crimp in the woven fabric (as compared to multifilament yarns), and therefore have a lower elongation when the inner catheter is pulled through the sleeve. For example, the warp yarns may be selected from polyesters, polyolefins, such as polypropylene, polyethylene and ethylene-propylene copolymers, and polyamides, such as nylon and aramids, for example

Preferred are yarns having a peak elongation at peak tensile load of 45% or less, preferably 30% or less. Monofilament yarns, including bicomponent yarns and multicomponent yarns, have been found to be particularly useful in innerduct applications. These materials have been found to impart desirable properties to woven fabrics. In one embodiment, all warp yarns are PET monofilament yarns, as PET monofilament yarns have a good balance between performance and cost.

By selecting warp yarns having a relatively low elongation at peak tensile load, the longitudinal elongation of the innerduct structure can be minimized during installation of the innerduct in a conduit, thereby avoiding "bunching" of the innerduct. In addition, by reducing warp crimp during weaving, the extension potential in the warp direction of the fabric incorporated into the innerduct may be minimized. For example, warp crimp can be reduced by increasing the tension on the warp yarns during weaving to achieve a warp crimp of less than 5%, according to ASTM D3883, Standard test methods for yarn crimp and yarn furling in woven fabrics. Reducing warp crimp in a fabric, particularly a plain weave fabric, results in increased crimp in the weft, which has the further advantage of increased seam strength along the longitudinal edges of the fabric portion used to construct the innerduct.

In one embodiment, warp yarns having a denier of 350 to 1200, preferably 400 to 750, may be used. The end count density (end yarn per inch in the warp) is typically in the range of 25 to 75 ends per inch, preferably 35 to 65 ends per inch. In one embodiment of the present invention, a plain weave fabric is provided having 35 to 65 ends per inch of 400 to 750 denier monofilament polyester warp yarns.

The weft yarns may be any suitable yarns including polyesters, polyolefins such as polypropylene, polyethylene and ethylene-propylene copolymers, and polyamides such as nylon and aramids, for example,

and mixtures thereof. Preferred are yarns having a peak elongation at peak tensile load of 45% or less, preferably 30% or less.

The terms "pick", "pick per inch" and "ppi" refer to (a) one weft yarn (filling yarn) passing through the shed formed during weaving and interweaving with the warp yarns; (b) two or more weft yarns which are passed through the shed and interlaced with the warp yarns individually or together during the weaving process. Thus, for the purpose of determining the picks per inch of woven fabric, a weft yarn inserted multiple times is counted as a single pick.

The terms "multiple insertion" and "double insertion" are intended to include: (a) a plurality of weft yarns inserted together into a shed of a weaving machine; (b) a plurality of weft yarns are inserted separately while the shed of the weaving machine remains unchanged; and (c) the plurality of weft yarns are inserted separately, the shed of the loom remaining substantially the same, i.e., the positions of 25% or less of the warp yarns vary with the insertion between the warp yarns. In a preferred embodiment, at least a portion of the picks of the weft thread are multiple insertions.

The fabric may contain one weave pattern along the length of the fabric, or may have different regions of different weave patterns along the longitudinal direction of the fabric. In embodiments where the fabric comprises a plurality of regions, the first woven region may have any suitable weave pattern. Figure 8 shows one possible weave pattern in which the warp and weft yarns in the first weaving zone 501 are plain weave, in which each weft yarn passes over a warp yarn and then under an adjacent warp yarn in a repeating manner across the width of the fabric. Suitable plain weaves include, but are not limited to, ripstop weaves made by incorporating additional yarns or reinforcing yarns in the warp, weft, or both the warp and weft of the fabric at regular intervals during the forming process. A plain weave is preferred because it imparts stability and structure to the fabric. If the first woven region is too small or completely removed, the fabric may be too loose (the warp and weft yarns move easily relative to each other) and thus not suitable for use in innerduct structures.

Other suitable weave patterns may be used as the weave pattern in the first woven region. The terms "woven (or braided)" and "interwoven" are intended to include any configuration incorporating interlocking shaped strips. By way of example only and not limitation, it is contemplated that a weft yarn may pass over two or more adjacent warp yarns 100 before transferring to a position under one or more adjacent warp yarns, thereby forming a so-called twill weave. Suitable twill weaves include warp-faced twill weaves and weft-faced twill weaves, such as 2/1, 3/1, 3/2, 4/1, 1/2, 1/3, or 1/4 twill weaves. The weave may also be, for example, a satin weave, a basket weave, a poplin weave, a jacquard weave, and a crepe weave.

In one embodiment, a special weave is used, as shown in fig. 8. The first weaving zone contains warp yarns all having the same yarn construction (same type of yarn, construction and material). This may be preferred in some embodiments for ease of construction. In one embodiment, the first weaving zone comprises picks of weft yarns (of the same type of yarn, construction and material) that are all of the same yarn construction. This may be preferred in some embodiments for ease of construction.

In another embodiment, first woven zone 501 comprises a repeating pattern of different weft yarns. This may be preferred in order to take advantage of the different properties of different types of yarns. In one embodiment, the weft yarns in the first weaving zone comprise all monofilament yarns. In another embodiment, the weft yarns in the first weaving zone comprise all multifilament yarns. In one embodiment, the picks of weft yarns in the first weaving zone comprise both monofilament and multifilament yarns.

In the weft direction, a variety of different yarns are preferably used to tailor the physical properties of the final fabric and structure. Monofilament yarns are stiffer (retain the same denier and material) than multifilament yarns. The multifilament yarn will be softer. The use of both monofilament and multifilament weft yarns provides a balance between flexibility and stiffness. The incorporation of some multifilament yarns (because they are less stiff) also reduces the opening force in the inner catheter, i.e. the force required to push the cable through the individual cells. Multi-inserted or double-inserted multifilament yarns are preferred because they have a large denier, and therefore the cable "rides" along these ridges in the fabric. Because the surface area of the fabric in contact with the cable is small, friction is reduced and the pulling force required to pull the cable in is generally low.

In one embodiment, the ratio of single pick to multi-filament pick (including both single and multi-insertion) within the overall fabric 10 is in the range of 1: 6 to 4: 1, more preferably between 1: 1 to 1: 4 in the middle. In another embodiment, the ratio of single pick to multi-filament pick (including both single and multi-insertion) within the first weaving zone 501 is in the range of 1: 6 to 4: 1, more preferably between 1: 1 to 1: 4 in the middle. In one embodiment, the ratio of monofilament picks to multifilament picks (including both single and multiple insertions) within the partially float zone (float zone)503 is in the range of 1: 6 to 4: 1, more preferably between 1: 1 to 1: 4 in the middle.

In one embodiment, the pick of weft yarns in the first weaving zone comprises a repeating pattern of at least one monofilament yarn and at least one multifilament yarn. The pattern also contains other yarns, such as monofilament and/or multifilament yarns. In one embodiment, the pick of weft yarns in the first weaving zone comprises a repeating pattern of at least one monofilament yarn and at least one monofilament multifilament yarn.

In one embodiment, the picks of weft yarns in first weaving zone 501 comprise an alternating pattern of at least one monofilament yarn followed by at least one multifilament yarn. In another embodiment, the picks of weft yarns in the first weaving zone comprise an alternating pattern of at least one multi-inserted multifilament yarn followed by at least one monofilament yarn. In another embodiment, the picks of weft yarns in the first weaving zone comprise a repeating pattern comprising at least one monofilament yarn, at least one multi-inserted multifilament yarn and at least one monofilament yarn. In another embodiment, the picks of weft yarns in the first weaving zone comprise a repeating pattern comprising one monofilament yarn, one bi-inserted multifilament yarn and one mono-inserted multifilament yarn. In fig. 8, the pick of the weft yarn in the first weaving zone has a repeating pattern: one monofilament yarn, one biconvex multifilament yarn and one monofilament multifilament yarn (although they may also be arranged in any other suitable order). In one embodiment, the pattern of weft yarns is the same throughout the fabric. This is preferred for ease of manufacture. In another embodiment, the pattern of weft yarns varies from region to region with the fabric.

The first knitted zone may comprise any suitable number of repeats from a single repeat to 10 or more repeats. Preferably, the number of repetitions of the weft pattern is between 2 and 6. This range has been shown to produce a good balance between the regions 501, 503 and good stability in the fabric. In one embodiment, the number of repetitions of the weft picking pattern is the same in all first areas 501 of the fabric.

Referring again to fig. 8, the partially float woven region 503 comprises a repeating picking pattern (weft) comprising at least one monofilament yarn and at least one multifilament yarn. Preferably, the multi-inserted multifilament yarn is a bi-inserted multifilament yarn. The pattern may comprise any other suitable yarns for the pattern in addition to the at least one monofilament yarn and the at least one multifilament yarn. In one embodiment, partially float-knit region 503 comprises an alternating pattern of at least one monofilament yarn followed by at least one multifilament inserted yarn. In another embodiment, the partially float-knit region 503 comprises an alternating pattern of at least one multi-inserted multi-filament yarn followed by at least one monofilament yarn. In another embodiment, partially float-knit region 503 comprises a repeating pattern comprising at least one monofilament yarn, at least one multi-inserted multifilament yarn and at least one monofilament multifilament yarn. In fig. 8, a repeating pattern of one monofilament, one bi-inserted multifilament yarn and one mono-inserted multifilament yarn is shown. It has been found that such a combination and pattern of picks of weft yarn is advantageous for stability, cost and pull tension.

The warp yarns of the fabric are arranged in groups of yarns, wherein each group contains at least 2 yarns, preferably less than 10 yarns. The grouping of these yarns is less important and is not readily distinguishable in the first weaving zone 501 of a woven fabric having a weave pattern that is a simple weave (e.g., a plain or twill weave). These groupings are more easily seen and distinguished in the partially float weaving zone 503 because some of the warp yarns from each warp yarn grouping "float" on some of the picks of weft yarns. The number of warp yarns in each grouping may vary in a regular pattern or randomly. Preferably, all warp yarn groupings contain the same number of warp yarns. Preferably, the set comprises 2 to 5 warp yarns, more preferably 3 yarns.

For warp yarn grouping, only a portion of the warp yarns in at least a portion of the set (meaning less than the total number of warp yarns in the set) float over 3 weft yarns, including over at least one multi-inserted multifilament weft yarn in at least one weft yarn repeat pattern in region 503. This means that for a grouping of 3 warp yarns, 1 or 2 warp yarns float over 3 weft yarns in at least a portion of the weft repeat. When the warp yarns float, more warp yarns are caused to be on the same side of the fabric during these one or more picks. This results in small ridges in the fabric and it is believed that the cable will ride on these ridges and therefore will have less frictional resistance when pulled into the innerduct (and therefore the cable will require less tension). Preferably, in each grouping, at least 1 (and less than the total number of yarns in the group) of yarns floats over 3 weft yarns, including over at least one multifilamentary weft yarn in each weft repeat pattern in region 503. For the non-floating warp yarns in the warp yarn grouping, the non-floating warp yarns form a plain weave in which they pass over and under alternate picks of weft yarn in sequence. This helps to secure the yarns (warp and weft) in the partially float woven region 503.

The partially float knit region 503 may contain any suitable number of repeats from a single repeat to 10 or more repeats. Preferably, the number of repetitions of the weft pattern is between 2 and 6. This range has been shown to produce a good balance between the regions 501, 503 and good stability in the fabric. In one embodiment, the weft picking pattern repeats the same number of times in all of the partially float woven regions 503 of the fabric. In another embodiment, the number of repetitions of the weft picking pattern is different in the partially float weaving zone 503 of at least some of the fabrics.

The balance between the first woven region 501 and the partially float region 503 (and any other optional regions) may control the slack or tightness and flexibility or rigidity of the fabric in the weft direction. In one embodiment, the ratio of picks in the first weaving zone 501 to picks in the partial float zone is between about 1: 4 to 4: 1, more preferably between 1: 2 to 2: 1. The woven fabric may contain additional zones in the repeating pattern of knit zones.

In one embodiment, the woven fabric comprises a uv stabilizer. The stabilizer may be compounded or otherwise formed in the yarn, may be a coating on the yarn, or a coating on the entire fabric. It is somewhat counterintuitive to place the uv stabilizer in the product in the conduit into the ground, but it has been found that the barrel of the inner conduit may be placed outside the element and in the sun for up to a year prior to installation and then installed. Uv stabilizers are used to protect the physical characteristics of the fabric and innerduct until installed and protected from the uv source. Ultraviolet stabilizers include materials that inhibit photoinitiation (e.g., ultraviolet absorbers (UVAs) and excited state quenchers), as well as materials that inhibit subsequent oxidation processes (e.g., free radical scavengers and alkyl hydroperoxide decomposers). Any suitable uv stabilizer may be used, such as carbon black, titanium dioxide, and hydrogen benzophenone.

In order to pass fiber optic cables, coaxial cables, or other cables through an innerduct structure, it is desirable to provide a pull wire for such purpose. Preferably, the pull wire is positioned within a compartment of the innerduct prior to installation of the innerduct within the conduit. For example, the puller wire may be a tightly woven, relatively flat strip of material, or may be a stranded rope or multiple layers of thick wire having a substantially circular cross-section. A pull cord, which is a pull cord or pull tape, is labeled as element 900.

Preferably, the inner catheter and the pull wire have respective elongation percentage values that are substantially equal for a given tensile load. If the elongation of the inner catheter is significantly different from the elongation of the pull wire, one of these structures may lag relative to the other as they are pulled together through the sleeve during installation, resulting in wrinkling of the inner catheter. The puller wire may be formed of a tightly braided polyester material that exhibits a tensile strength of between about 400 pounds and about 3,000 pounds. In one embodiment, the pull wire is a pull tape having a flat cross-sectional shape. In another preferred embodiment, the pull cord is a pull cord having a circular or oval cross-sectional shape. The pull cord is preferred because the innerduct structure (and its associated chamber) is very small and the space occupied by the pull cord within the sleeve is small. Preferably, the innerduct structure (all innerduct structures disclosed in this application) contains at least one drawstring within at least one chamber. In another embodiment, each lumen of the innerduct structure contains a pull cord.

The inner conduit structure comprises the cable after placement in the sleeve (or in other embodiments, before placement in the sleeve). Preferably, at least one of the chambers of the inner conduit structure houses a cable. In one embodiment, the cable is a miniature cable having a diameter smaller than that of a conventional cable. Preferably, the diameter of the micro-cable is less than about 15mm, more preferably less than about 11 mm.

Typically, a bushing is a rigid or semi-rigid pipe or conduit system for protecting and routing cables, wires, and the like. The term "cable" is intended to include fiber optic cables, electrical wires, coaxial cables, and triaxial cables, as well as any other circuitry for transmitting electrical and/or electromagnetic signals. For example, the sleeve may be made of metal, synthetic polymer (such as thermoplastic polymer), clay or concrete. The passage through the cannula may have a circular, elliptical, rectangular or polygonal cross-section. Indeed, the present invention may be used in conjunction with any casing system. Depending on the relative dimensions of the channels in the inner conduit (usually calculated as the inner diameter), one skilled in the art can select from the width of the inner conduit, the number of compartments in each inner conduit and the number of individual inner conduits to maximize the capacity of the cannula.

All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.

The use of the terms "a" and "an" and "the" and similar referents in the context of describing the subject matter of the application (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms "comprising," "having," "including," and "containing" are to be construed as open-ended terms (i.e., meaning "including, but not limited to,") unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided herein, is intended merely to better illuminate the subject matter of the application and does not pose a limitation on the scope of the subject matter unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the subject matter described herein.

Preferred embodiments of the subject matter of the present application are described herein, including the best mode known to the inventors for carrying out the claimed subject matter. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the subject matter described herein to be practiced otherwise than as specifically described herein. Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, this disclosure encompasses any combination of the above-described elements in all possible variations thereof unless otherwise indicated herein or otherwise clearly contradicted by context.

Claims (22)

1. A fabric innerduct structure, comprising at least one chamber configured to enclose and carry at least one cable, wherein the fabric innerduct structure comprises a plurality of yarns and at least one seam, the seam comprising a plurality of stitches and at least a portion of the yarns in the seam being fusion bonded together or ultrasonically welded.

2. The fabric innerduct structure of claim 1, wherein the fabric innerduct structure comprises a woven fabric.

3. The fabric innerduct structure of claim 2, wherein the woven fabric is folded about a centrally located longitudinal axis.

4. The fabric innerduct structure of claim 2, wherein the fabric is a woven fabric comprising:

a plurality of warp yarns arranged in warp yarn groupings, wherein each grouping contains from 2 to 10 warp yarns; and

a plurality of picks of weft yarn;

wherein in each first weaving zone the pick of weft yarns comprises a repeating first weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein in each partially float weaving zone the pick of weft yarns in said partially float weaving zone comprises a repeating second weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein only a portion of the warp yarns in at least a portion of the warp yarn groupings float over 3 weft yarns, including at least one over-inserted multifilament weft yarn in at least a portion of the weft pattern repeat, and wherein outside of the floats, non-floating warp yarns pass over and under alternating picks of weft yarns in sequence.

5. The fabric innerduct structure of claim 1, wherein the fabric innerduct structure has a width of less than 60 mm.

6. The fabric innerduct structure of claim 1, wherein the fabric innerduct structure has a width of less than 40 mm.

7. The fabric innerduct structure of claim 1, further comprising a draw cord or tape located within the fabric innerduct structure.

8. The fabric innerduct structure of claim 1, wherein the fabric innerduct structure comprises at least two chambers, each chamber designed to enclose at least one cable.

9. The fabric innerduct structure of claim 1, wherein the fabric innerduct structure comprises at least one annular fabric tube and at least one seam.

10. The fabric innerduct structure of claim 9, wherein the fabric innerduct structure comprises at least two endless fabric tubes and at least one seam joining the at least two endless fabric tubes together.

11. The fabric innerduct structure of claim 1, wherein the yarns in the seam have a repeating pattern of areas of ultrasonically welded stitches and non-ultrasonically welded stitches.

12. A casing system, characterized in that the casing system comprises:

a sleeve;

at least one fabric innerduct structure comprising at least one chamber configured to enclose and carry at least one cable, the fabric innerduct structure comprising a plurality of yarns and at least one seam comprising a plurality of stitches and at least a portion of the yarns in the seam being fusion bonded together or ultrasonically welded; the at least one fabric innerduct structure is located within the sleeve.

13. A cannula system according to claim 12, wherein the in-fabric catheter structure comprises a woven fabric.

14. The cannula system of claim 13, wherein the woven fabric is folded about a centrally located longitudinal axis.

15. The cannula system of claim 13, wherein the fabric is a woven fabric comprising:

a plurality of warp yarns arranged in warp yarn groupings, wherein each grouping contains from 2 to 10 warp yarns; and

a plurality of picks of weft yarn;

wherein in each first weaving zone the pick of weft yarns comprises a repeating first weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein in each partially float weaving zone the pick of weft yarns in said partially float weaving zone comprises a repeating second weft pattern of at least one monofilament yarn, at least one multifilament inserted yarn and optionally at least one multifilament inserted yarn,

wherein only a portion of the warp yarns in at least a portion of the warp yarn groupings float over 3 weft yarns, including at least one over-inserted multifilament weft yarn in at least a portion of the weft pattern repeat, and wherein outside of the floats, non-floating warp yarns pass over and under alternating picks of weft yarns in sequence.

16. The cannula system of claim 12, wherein the cannula has an inner diameter of less than 60 mm.

17. A cannula system according to claim 12, wherein the width of the conduit structure within the fabric is less than 60 mm.

18. A cannula system according to claim 12, wherein the width of the cannula is less than 40 mm.

19. A cannula system according to claim 12, wherein the width of the conduit structure within the fabric is less than 40 mm.

20. The cannula system of claim 12, further comprising a pull cord or tape located in the fabric innerduct structure.

21. A sleeving system according to claim 12, wherein said in-fabric conduit structure comprises at least two chambers, each chamber being designed for enclosing at least one cable.

22. The sleeving system of claim 12 wherein the yarns in the seam have a repeating pattern of areas of ultrasonically welded stitches and non-ultrasonically welded stitches.

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