Non-woven self-wrapping acoustic sleeve and method of construction thereof

1. A method of constructing a self-wrapping sleeve used to route and protect elongate members and to prevent noise generation from the elongate members, the method comprising the steps of:

providing a sheet of non-woven engineered material having a predetermined initial thickness;

needlefelting the sheet to a predetermined depth;

forming the needlefelted sheet into a tubular shape with opposite sides of the sheet being overlapped with one another; and

heat-setting the sheet to remain biased in said tubular shape with the opposite sides remaining in detached and readily separable relation with one another under an externally applied force, wherein the opposite sides automatically return substantially to their biased overlapping relation upon releasing the externally applied force.

2. The method of claim 1 further including reducing the initial thickness of said sheet to a finished thickness that is less than said initial thickness.

3. The method of claim 2 further including reducing the initial thickness at least partially during said needlefelting step.

4. The method of claim of claim 2 further including reducing the initial thickness at least partially between a pair of plates spaced from one another a distance less than said initial thickness.

5. The method of claim 4 further including drawing said sheet between said plates.

6. The method of claim 5 further including using a pair of rollers to perform the drawing.

7. The method of claim 1 further including wrapping said sheet about a mandrel of a predetermined diameter in said forming step.

8. The method of claim 1 further including needlefelting said sheet completely through said initial thickness.

9. The method of claim 1 further including cutting said sheet to a finished length of said sleeve.

10. The method of claim 9 further including performing said cutting after said forming step.

11. The method of claim 9 further including performing said cutting before said forming step.

12. A method of constructing a self-wrapping sleeve used to route and protect elongate members and to prevent noise generation from the elongate members, the method comprising the steps of:

providing a sheet of non-woven engineered material having a predetermined initial thickness;

compacting said sheet to a reduced thickness;

forming the compacted sheet into a tubular shape with opposite sides of the sheet being overlapped with one another; and

heat-setting the sheet in said tubular shape with the opposite sides remaining detached and readily separable away from one another under an externally applied force, wherein the opposite sides automatically return substantially to their biased overlapping relation upon releasing the externally applied force.

13. The method of claim 12 further including needlefelting said sheet and entangling individual fibers within said sheet.

14. The method of claim 13 further including performing the needlefelting during the compacting step.

15. The method of claim 14 further including compacting the initial thickness between a pair of plates spaced from one another a distance less than said initial thickness and performing the needlefelting between said pair of plates.