Abstract:
A hose coupler generally includes a hose adapter including opposing ends, an interior surface forming a fluid passage between the opposed ends, and an exterior surface including a series of barbs for engaging an interior surface of a hose that is configured to be fluidly connected to the hose adapter. A ferrule is connected to the hose adapter and is positioned to at least partially surround the exterior surface of the hose adapter. The ferrule has an interior surface facing the exterior surface of the hose adapter. The interior surface defines at least one cutting rib having a sharp corner or edge for piercing an outer layer of the hose and a plurality of compression ribs each defining a rounded surface for compressing the hose against the barbs.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 62/116,743, filed Feb. 16, 2015, the entirety of which is incorporated by reference herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to couplings for flexible hoses. 
       BACKGROUND OF THE INVENTION 
       [0003]    This invention relates generally to a coupling member that is to be installed on the end of a hose As is described in U.S. Pat. No. 4,111,469 to Kavick, which is incorporated by reference herein in its entirety, the coupling member is securely installed on the end of the hose such that it will not become detached in service. The coupling member includes a hose adapter having a nipple or stem portion that is adapted to be inserted into the bore of the hose. A substantially concentric ferrule surrounds the hose adapter such that an annular space is formed between the ferrule and the hose adapter. The annular space is sized to receive the hose. After the end of the hose is loosely positioned in the annular space, the coupling member is placed in a swaging apparatus which reduces the diameter of the ferrule, thereby compressing the hose wall between the ferrule and the nipple of the hose adapter. The coupling member may be threaded or provided with other means for connection to another device. 
       SUMMARY OF THE INVENTION 
       [0004]    A hose coupler generally includes a hose adapter including opposing ends, an interior surface forming a fluid passage between the opposed ends, and an exterior surface including a series of barbs for engaging an interior surface of a hose that is configured to be fluidly connected to the hose adapter. A ferrule is connected to the hose adapter and is positioned to at least partially surround the exterior surface of the hose adapter. The ferrule has an interior surface facing the exterior surface of the hose adapter. The interior surface of the ferrule defines at least one cutting rib having a sharp corner or edge for piercing an outer layer of the hose and a plurality of compression ribs each defining a rounded surface for compressing the hose against the barbs. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         [0005]      FIG. 1  depicts a schematic view of a hose connection in accordance with an exemplary embodiment of the present invention. 
           [0006]      FIG. 2A  depicts a bottom plan view of a coupler of the hose connection of  FIG. 1 . 
           [0007]      FIG. 2B  depicts a partial cross-sectional view of the coupler of  FIG. 2A  taken along the lines  2 B- 2 B, wherein various surface of the coupler are cut-away to reveal interior features of the coupler. 
           [0008]      FIG. 3  depicts an isometric view of the ferrule of the coupler of  FIG. 2A , which is shown partially cutaway. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0009]    As used herein, the term ‘fluid’ encompasses gasses, liquids and/or partial solids. 
         [0010]      FIG. 1  depicts a schematic view of an exemplary hose connection including a coupler. As shown in  FIG. 1 , a fluid source  1  is connected to a hose  2 . The hose  2  has a threaded female connector  3  on one end thereof. The female threaded connector  3  is threadedly connected to a threaded male connector  4  (shown in broken lines) of a hose coupler  5 . The hose coupler  5  includes a ferrule  6 , which is crimped to another hose  7 . In operation, fluid travels from the fluid source  1 , through the hose  2 , through the hose coupler  5  and into the hose  7 . It should be understood that the exemplary hose connection shown in the schematic view is provided for reference purposes only, and the hose coupler  5  (also referred to herein as a ‘coupler’) that is described herein is not limited to forming part of the exemplary hose connection. 
         [0011]    The features of the individual components of the coupler  5  will be described hereinafter with reference to  FIGS. 2A and 2B .  FIG. 2A  is a bottom plan view of the coupler  5 , according to a first example of the invention; and  FIG. 2B  is a partial cross-sectional view of the coupler  5  of  FIG. 2A  taken along the lines  2 B- 2 B. Various surfaces are hidden in  FIG. 2B  to reveal interior features of the coupler  5 . 
         [0012]    Unless noted otherwise, the individual components and features of the coupler  5  are substantially cylindrical and are revolved about a longitudinal axis  21 . Also, as used herein, the term “proximal” refers to either a location or a direction towards the mating surface  23  of the coupler  5 , and the term “distal” refers to either a location or a direction away from the mating surface  23  of the coupler  5 . 
         [0013]    The coupler  5  generally comprises a hose adapter  20  and a ferrule  6  that is mounted in an annular recess  22  formed on an exterior surface of the hose adapter  20 . The individual components of the coupler  5  may be composed of zinc plated wrought steel, zinc plated cast ductile iron, or stainless steel, for example, or any other material that is known to those of ordinary skill in the art. 
         [0014]    The hose adapter  20  includes a substantially cylindrical body having a hollow interior region  27  through which fluid may pass. The revolved interior surface of the hose adapter  20  is smooth to limit the build-up of media thereupon. The inner diameter of the hose adapter  20  is larger at its proximal end than at its distal end. 
         [0015]    The proximal end of the revolved exterior surface of the hose adapter  20  includes a connector  4  comprising male mechanical threads for releasably connecting to a female threaded connector, such as the female threaded connector  3  in  FIG. 1 . Those of ordinary skill in the art will recognize that the connection means at the proximal end of the hose adapter  20  may vary from that which is shown and described. For example, although not shown, the connector  4  may be a clip, clamp, barb, fastener, or mating surface. 
         [0016]    The connector  4  terminates at a flange  9  that is formed on the exterior surface of the hose adapter  20  at a location distal of the connector  4 . The exterior surface of the flange  9  may include one or more flat surfaces  11  for accommodating a standard tool, such as a wrench. 
         [0017]    The tool is used to mount the coupler  5  to a mating connector, such as the female threaded connector  3  in  FIG. 1 . For example, the outer surface of the flange  9  may be hexagonal. 
         [0018]    The recess  22  is formed on the exterior surface of the hose adapter  20  at a location distal of the flange  9 . The proximal end of the ferrule  6  is positioned in the recess  22 , as shown in  FIG. 2B . 
         [0019]    The distal end of the revolved exterior surface of the hose adapter  20  includes a hose fitting  26 . The hose fitting  26  is located at a position that is distal of the recess  22 . The hose fitting  26  comprises a series of barbs that are spaced apart along the length of the distal end of the hose adapter  20 . The barbs are configured to engage the interior surface of a hose, such as the hose  7  shown in  FIG. 1 . According to one example of the coupler  5 , the hose fitting  26  is a  3  inch male NPT-style connector. Each barb includes a substantially planar surface that is orthogonal to the longitudinal axis  21 , and an angled surface that extends from the exterior surface of the hose adapter  20  in a proximal direction (e.g., toward connector  4 ). The angled surface and the planar surface form an acute angle ‘A.’ The angle ‘A’ of the barbs substantially limits or prevents the hose  7  from moving in the distal direction and withdrawing from the coupler  5 . Those of ordinary skill in the art will recognize that other hose fittings exist, and may be incorporated into the hose adapter  20  without departing from either the scope or the spirit of the invention. 
         [0020]    The ferrule  6  has a substantially cylindrical body having a substantially constant wall thickness. The proximal end of the ferrule  6  includes a reduced-diameter frustoconical portion  29 . The frustoconical portion  29  terminates at a flange  30 . The flange  30  is positioned in the recess  22  of the hose adapter  20  such that the ferrule  6  is fixedly mounted to the hose adapter  20 . The area of engagement between the recess  22  and the flange  30  may be referred to herein as the attachment point between the ferrule  6  and the hose adapter  20 . The ferrule  6  may be connected to the hose adapter  20  by a crimping or swaging operation. 
         [0021]      FIG. 3  depicts a perspective view of the ferrule  6 , which is shown partially cutaway. The revolved exterior surface of the ferrule  6  is substantially flat. In contrast, the revolved interior surface of the ferrule  6  includes a series of compression ribs  40  and cutting ribs  42  and  44 . 
         [0022]    The compression ribs  40  are spaced apart along the length of the ferrule  6 . The spacing of the ribs  40  may be uneven, as shown, or even. Each compression rib  40  includes a rounded convex surface having a radius. The radius of each compression rib  40  may be equal, as shown, or the radii may differ. There are no sharp edges or surfaces formed on the compression ribs  40 . 
         [0023]    The spacing between adjacent ribs  40  generally decreases from the proximal to distal ends of the ferrule  6 . The annular surface  48  between adjacent compression ribs  40  at the proximal end of the ferrule  6  is substantially flat, whereas, a concave valley  46  having a radii matching that of the compression ribs  40  is formed between adjacent compression ribs  40  at the distal end of the ferrule  6 . The number of compression ribs  40  may vary. According to this example, the geometry of the ribs  40  differs from that of the barbs of the hose fitting  26 . 
         [0024]    The cutting rib  42  is positioned in a central region of the ferrule  6  at a location between adjacent compression ribs  40 . The cutting rib  42  comprises a flat annular surface  50  extending from the interior of the ferrule  6  and facing the longitudinal axis  21 . The flat annular surface  50  extends parallel to the longitudinal axis  21  of the coupler  5 . A sharp corner  52  is formed on both sides of the flat annular surface  50 . The cutting rib  42  has a greater length than the compression ribs  40 , i.e., the rib  42  extends closer to the longitudinal axis  21  than the ribs  40 . Stated differently, the rib  42  extends further from the interior surface of the ferrule  6  than the compression ribs  40 . The cutting rib  42  may be omitted from the ferrule  6 , if so desired. 
         [0025]    The cutting rib  44  is positioned at the proximal end of the ferrule  6  at a location that is proximal of the compression ribs  40  and the cutting rib  42 . Like the cutting rib  42 , the cutting rib  44  comprises a flat annular surface extending from the interior of the ferrule  6  and facing the longitudinal axis  21 , and a sharp corner is formed on both sides of the flat annular surface. The flat annular surface extends parallel to the longitudinal axis  21  of the coupler  5 . The cutting rib  44  has a greater length, i.e., extends further from the interior surface of the ferrule  6  toward the axis  21 , than the cutting rib  42  and the compression ribs  40 . According to this example, the geometry of the ribs  44  and  42  differs from that of the barbs of the hose fitting  26 . 
         [0026]    The purpose of each rib  40 ,  42  and  44  is described with reference to the process of swaging the ferrule which is discussed hereinafter. 
         [0027]    In an assembled and pre-swaged configuration of the coupler  5 , an annular space  32  is formed between the interior surface of the ferrule  6  and the exterior surface of the distal end of the hose adapter  20 . The distal end  36  of the hose adapter  20  extends beyond the distal end  38  of the ferrule  6  for at least the purpose of initially locating the bore of the hose  7  on the hose adapter  20  prior to advancing the hose  7  into the annular space  32 . Although not shown, the end of the hose  7  may bear on the interior surface  34  at the proximal end of the ferrule  6 . 
         [0028]    To mount the hose  7  to the coupler  5 , the hose  7  is first slid over the hose adapter  20  and delivered into the annular space  32  until the free end of the hose  7  either contacts or approaches the interior surface  34  of the ferrule  6 . The ferrule  6  is then placed in a swaging tool which reduces the diameter of the ferrule  6 , thereby compressing the wall of the hose  7  between the ferrule  6  and the hose fitting  26  of the hose adapter  20 . The ferrule  6  is shown pre-swaged in the figures. 
         [0029]    Upon swaging the ferrule  6 , the cutting ribs  42  and  44  compress the hose  7  against the barbs of the hose fitting  26 . The cutting ribs  42  and  44  pierce the outer surface of the hose  7  and physically contact and create electrical continuity with an interior shielding layer of the hose  7  (assuming that hose  7  has a shielding layer). Alternatively, the cutting rib  42  may not pierce the outer surface of the hose  7  depending on the diameters of the cutting rib  42  and the hose  7 . The shielding layer may comprise a steel braid. A hose having a shielding layer is described in U.S. Pat. No. 3,684,602 to Ball, which is incorporated by reference herein in its entirety. The barbs of the hose fitting  26  either may or may not pierce the interior surface of the hose  7 . 
         [0030]    The ribs  42  and  44  and the barbs of the hose fitting  26  help to retain the hose  7  in its assembled position within the coupler  5  and also prevent delamination of the hose layers under high temperature and/or pressure conditions. It should be understood that the rib  44  pierces the hose  7  at a depth greater than that of the rib  42 . 
         [0031]    The compression ribs  40  are dimensioned to compress the hose  7  against the barbs of the hose fitting  26  without piercing the outer surface of the hose  7 . The hose  7  can expand within the valleys  46  and spaces formed between the various compression ribs  40 . The ribs  40  and valleys  46  also help to retain the hose  7  in its assembled position within the coupler  5 . 
         [0032]    The length of the hose  7  that is contained within the annular space  32  is subjected to a non-uniform pressure. More particularly, the engineered combination of high compression areas created by the radiused ribs  40  and the cutting ribs  42  and  44  along with the low compression areas created by the valleys  46  and  48  permit controlled expansion of the hose  7  during periods of high temperature and/or pressure conditions without compromising the integrity of the vulcanization between the various layers (e.g., rubber and steel braid layers) of the hose  7 . 
         [0033]    Although the invention is illustrated and described herein with reference to specific examples, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention. For example, the diameter and length of the various components of the coupler  5  may vary to conform to different hose sizes. As another example, the compression ribs and/or the cutting ribs may extend continuously around the entire inner circumference of the ferrule  6 , or they may be non-continuous and extend around one or more portions of the inner circumference of the ferrule  6 . Similarly, one or more barbs of the hose fitting  26  may extend continuously around the entire outer circumference of the hose fitting  26 , or they may be non-continuous and extend around one or more portions of the outer circumference of the hose fitting  26 .