Abstract:
A self-sealing flexible metal hose includes a band adapted for winding on conventional winding equipment. The band includes receiver and insert assemblies adapted for interlocking with adjacent windings or turns of the band. A sealing flange provides continuous contacts and is urged into sealing engagement with the band by exhaust gas pressure within the hose bore. Alternative embodiments include different configurations of the flanges and legs which form the contacts, and accommodate packing material for greater sealing performance.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION  
       [0001]    Continuation-in-Part of U.S. patent application, Ser. No. 09/792,331, filed Feb. 24, 2001. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    I. Field of the Invention  
           [0003]    The present invention relates generally to flexible metal hose and in particular to a self-sealing hose design adaptable for exhaust gas applications.  
           [0004]    II. Description of the Prior Art  
           [0005]    Flexible metal hose is commonly used for conveying liquids and gases, particularly in applications where the hose may need to be reconfigured or may need to accommodate relative movement between its respective ends. For example, vehicle exhaust pipe applications commonly use flexible metal hose for conveying exhaust gas. The advantages of flexible metal hose in such applications include its ability to resist vibration and the ability to locate the hose between separate vehicle components, such as an engine and an exhaust system.  
           [0006]    The present invention accommodates vibration. Installation is simplified by providing flexibility. Efficient conveyance of exhaust gas is accomplished by configuring the bands with flanges providing a smooth inner bore with multiple contact points for sealing. In particular, the internal pressures tend to increase the sealing effect by pushing the sealing elements against other band elements.  
           [0007]    Heretofore there has not been available a flexible metal hose with the advantages and features of the present invention. Prior art flexible hose designs, including the example described herein, lack the sealing features in the combination of the present invention.  
         SUMMARY OF THE INVENTION  
         [0008]    In the practice of the present invention, a self-sealing flexible metal hose is provided which includes a spiral-wound band. The band includes receiver and insert assemblies each comprising double-folded inner and outer legs. The receiver assembly of one winding or turn of the band receives the insert assembly of an adjacent winding or turn whereby the hose is interlocked. The band also includes a flange extending in a downstream direction and engaging the band at multiple contact points for greater sealing capability. Alternative embodiments of the present invention include different configurations of the legs and the flanges, and can include packing material.  
         Objects and Advantages of the Inventions  
         [0009]    The principal objects and advantages of the present invention include providing flexible metal hose; providing such a hose which is leak-resistant; providing such a hose which is selfsealing; providing such a hose which is well-adapted for exhaust hose application; providing such a hose which resists vibrational loads; providing such a hose which can be manufactured on conventional metal hose winding equipment; and providing such a hose which is efficient in operation, economical to manufacture, capable of a long operating life and which is particularly well adapted for the purposes and applications thereof.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]    [0010]FIG. 1 is a cross-sectional view of a prior art flexible metal hose.  
         [0011]    [0011]FIG. 2 is a cross-sectional view of a self-sealing flexible metal hose embodying the present invention.  
         [0012]    [0012]FIG. 3 is a cross-sectional view of a flexible metal hose comprising a first modified embodiment of the present invention.  
         [0013]    [0013]FIG. 4 is a cross-sectional view of a flexible metal hose comprising a second modified embodiment of the present invention.  
         [0014]    [0014]FIG. 5 is a cross-sectional view of a flexible metal hose comprising a third modified embodiment of the present invention.  
         [0015]    [0015]FIG. 6 is cross-sectional view of a flexible metal hose comprising a fourth modified embodiment of the present invention.  
         [0016]    [0016]FIG. 7 is a cross-sectional view of a flexible metal hose comprising fifth modified embodiment of the present invention.  
         [0017]    [0017]FIG. 8 is an enlarged, cross-sectional view of a single winding of a formed band which is spiral, wound to form the fifth modified embodiment flexible metal hose.  
         [0018]    [0018]FIG. 9 is a cross-sectional view of a flexible metal hose comprising a sixth modified embodiment of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]    I. Introduction and Environment  
         [0020]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.  
         [0021]    II. Preferred Embodiment Self-Sealing Flexible Metal Hose  
         [0022]    Referring to the drawings in more detail, the reference numeral  2  generally designates a self-sealing flexible metal hose embodying the present invention. The flexible hose  2  compromises a band  4  which is spiral-wound for interlocking in a manner which permits the resulting hose  2  to flex or bend without compromising the fluid-tight characteristics thereof As shown in FIG. 2, the band profile includes a leading edge  6  and a trailing edge  8  located generally upstream and downstream respectively with respect to a gas flow direction through the hose  2 .  
         [0023]    A double-fold receiver assembly  10  is formed adjacent to the leading edge  6  and includes a receiver outer leg  12  connected to a receiver inner leg  14  located in generally parallel, spaced relation therefrom whereby a receiver  16  is defined therebetween. The leading edge  6 , which can be curved, connects the receiver assembly legs  12 ,  14 . The receiver assembly  10  also includes a receiver offset  16  connected to the outer leg  12  in spaced relation from the receiver inner leg  14  whereby a clearance  18  is formed and adapted for receiving a double-fold insert assembly  22 . The insert assembly  22  is connected to the offset  16  by a transition  20 . The insert assembly  22  includes an insert outer leg  24  which is folded double and located adjacent to an insert inner leg  26 . As shown in FIG. 1, the legs  24 ,  26  of the insert assembly  2  are folded relatively tightly with respect to each other, whereas the receiver legs  12 ,  14  are spaced apart to define a receiver  16  therebetween. The insert legs  24 ,  26  are spaced outwardly from the transition  20  by upstream and downstream insert offsets  28 ,  30  respectively. A sealing flange  32  extends downstream from the downstream offset  30  and includes an upstream section  34  and a downstream section  36 , the later terminating at the trailing edge  8 . A sealing flange offset  38  is located between the sealing flange sections  34 ,  36  and places the downstream section  36  slightly inwardly from the upstream section  34 .  
         [0024]    As shown, the hose  2  is assembled with the insert assembly  22  received in the receiver  16  whereby the insert legs  24 ,  26  are captured between the receiver legs  12 ,  14  and the insert assembly offsets  28 ,  30  are captured within the clearance  18 . The insert assembly  22  is adapted to slidably move within the clearance  18  to facilitate the hose  2  flexing. Sealing contacts  42 ,  44  are provided at an upstream location  42 .  
         [0025]    II. First Modified Embodiment Self-Sealing Flexible Metal Hose  102   
         [0026]    [0026]FIG. 3 shows a hose  102  comprising a first modified embodiment of the present invention and including a modified receiver assembly  110  with an inner leg  114  formed with an outwardly-concave/inwardly-convex channel  116  adapted to receive string-like packing material  118 . The packing material  118  facilitates forming a seal between the inner legs  114 ,  126 . The packing material  118  can be spiral wound along with the band  4  as the hose  102  is formed on conventional winding equipment.  
         [0027]    IV. Second Modified Embodiment Self-Sealing Flexible Metal Hose  202   
         [0028]    [0028]FIG. 4 shows a flexible hose  202  comprising a second modified embodiment of the present invention. The flexible hose  202  includes a band  204  with a profile which is similar to that of the flexible hose  2  described above, except that the entire sealing flange  234  is substantially co-planer, as are upstream and downstream base sections  246 ,  248 .  
         [0029]    V. Third Modified Embodiment Self-Sealing Flexible Metal Hose  302   
         [0030]    [0030]FIG. 5 shows a flexible metal hose configuration comprising a third modified embodiment of the present invention general designated by the reference numeral  302 . The flexible hose  302  is generally similar to the flexible hose  202  described above, with the addition of the reconfigured receiver inner leg  314  for receiving packing material  318 .  
         [0031]    VI Fourth Modified Embodiment Self-Sealing Flexible Metal Hose  402   
         [0032]    [0032]FIG. 6 shows a flexible metal hose section  402 . As shown, the hose  402  includes an outer band  404  with an S-shaped cross-sectional profile configuration whereby inwardly and outwardly open channels  406 ,  408  are formed. The inwardly open channel  406  receives packing material  410  and the upstream leg  412  of another section of the outer band  404 . An inner band  406  has an L-shaped cross-sectional profile with a base leg  410  and a return leg  412  projecting outwardly therefrom. The return leg  412  engages a respective outer band upstream leg  412  within a respective inwardly-open channel  406 . The inner band  406  provides a smoother bore  420  and also increases the sealing aspect of the hose  402  by providing upstream and downstream contact points  422 ,  424  respectively.  
         [0033]    VII. Fifth Modified Embodiment Self-Sealing Flexible Metal Hose  502 .  
         [0034]    New FIGS. 7 and 8 show a self-sealing flexible metal hose  502  comprising a fifth modified embodiment of the present invention. The flexible metal hose  502  comprises a band  504  which is spiral-wound for interlocking on suitable spiral hose winding equipment. The profile of the band  504  includes leading and trailing edges  506 ,  508  located generally upstream and downstream, respectively with respect to a gas flow direction through the hose  502 . An upstream receiver assembly  510  is located adjacent to the leading edge  506  and is enclosed by a double thickness of the band material. A downstream receiver assembly  512  is located intermediate the upstream receiver assembly  510  and the trailing edge  508  and is also formed by a double thickness of the band material. A transition  520  connects the upstream and downstream receiver assemblies  510 ,  512 . A sealing flange  522  extends downstream from the downstream receiver assembly  512 . The sealing flange  522  is slightly offset with respect to the transition  520 .  
         [0035]    The band  504  is spiral-wound and interlocked as shown in FIG. 7. Contact points between adjacent windings of the band  504  are located at the interlocking connection of the upstream and downstream receiver assemblies  510 ,  512  of the adjacent band windings and are generally designated  524   a, b, c.  The sealing flanges  522  are sufficiently long to provide an overlap  526  defining a contact point.  
         [0036]    VIII. Sixth Modified Embodiment Self-Sealing Flexible Metal Hose  602 .  
         [0037]    [0037]FIG. 6 shows a flexible metal hose section  602  comprising a sixth modified embodiment of the present invention. The sixth modified embodiment flexible metal hose section  602  includes a band  604  with a generally flush transition  620  and sealing flange  622 . The sealing flange of each band  604  winding thus forms two spiral contacts  624   a, b.  The first or upstream contact  624   a  is between a transition  620  and a sealing flange  622 . The second or downstream contact  624 b is between the sealing flanges  622  of the adjacent windings.