Coupler and method of making molded coupler

A coupler device for fluid transport that includes a body with an outer sidewall. The body defines a slot disposed proximate one end, and extends in a direction transverse to and through the outer sidewall. A latch assembly is connected with the body. The latch assembly includes at least one outer member being disposed on the outer surface of the body, and is externally exposed of the body. The inner member is connected with an inner member being disposed through the slot. A soft overmold portion is formed over the outer sidewall of the body. The overmold portion includes a shroud portion that extends outward from the outer sidewall, and partially covers the outer member of the latch assembly.

FIELD OF INVENTION

This invention is related to a fluid connector and method of making a molded connector. More particularly, the present invention is related to a fluid connector with a soft overmold.

BACKGROUND OF THE INVENTION

Fluid couplers used in fluid transport applications are common and widely used. Typically, such connectors require proper dimensioning so that seal and/or assembled surfaces can be maintained to provide a no leak, no spill connector. These connectors also employ quick connect/disconnect features having manually operated latches for connecting other pieces of fluid dispensing equipment. Further, valve control parts and assemblies may be employed for controlling fluid flow. Such latch parts and assemblies are often disposed external the main flow bore or channel of the coupling body for user operation and accessibility.

U.S. Pat. Nos. 5,494,074 and 5,938,244 employ latch assemblies including multiple parts that reside out of the bore and on the outer surface of the coupling body. In order to protect these latch assembly parts, vertical sidewalls are formed as part of the main coupling body. To reduce costs, these couplers are formed as integrally molded parts, including such vertical sidewalls and other irregular, non-symmetric structures.

However, in forming these irregular structures on a coupling body, problems can occur in the dimensions of the inner bore and flow channel. In the molding process while transiting from thick to thin surfaces to provide for non-symmetric shapes, the flow channel dimensions, for instance, may become distorted. This distortion can occur due to the unpredictability of the resulting molded part, and can produce coupling body dimensions with inconsistent results. The unpredictability occurs when a molded part designed with inconsistent wall sections (combination of thick and thin wall sections) is injection molded and then allowed to cool post-mold. The plastic material shrinks as it cools and causes dimensional deformation, and may occasionally produce internal voids. Furthermore, different plastic materials may not have the same shrink characteristics.

While shrinkage is anticipated and accounted for in the build of a molding tool, the solution may not be as uniform or linear as engineering simulations and models suggest. Molding tools generally are built using an overall shrink compensation factor. An experienced tool builder can then make additional dimension modifications to the desired scale of the molding tool, and compensate for problems that the models do not predict. Further, post-mold shrinkage is not consistent from cycle to cycle, and sometimes the part-to-part differences can be dramatic. Such problems can be further aggravated by asymmetric parts or parts having thick wall sections or sharp corners.

For coupling bodies that require tight, specific dimensions and that undergo this distortion, the sealing and/or assembled surfaces inside the bore may be compromised. Typically, this distortion can make it necessary to go back and fine-tune the coupling body part back to specification requirements.

While the above devices are suitable for their purposes, there is a need for an improved coupler device including a soft overmold portion that provides the non-symmetrical structure needed to protect and cover any parts outwardly extending from the coupling body. Further, a coupling device is needed where the coupling body avoids dimension distortion and where sealing surfaces and other assembled surfaces are preserved. A connector is desired that provides a design suitable for quick connect/disconnect couplers, while being produced with lower cost and higher efficiency.

SUMMARY OF THE INVENTION

In accordance with the present invention, the above and other problems were solved by providing a coupler device with a soft-overmold portion formed over a main body. The overmold portion forms a partial cover over a latch assembly that protrudes outside the outer sidewall of the main body, where the latch assembly is used for quick connection/disconnection of the coupling device to another piece of fluid transport equipment.

In one embodiment, a coupler device includes a body with an outer surface being an outer circumferential sidewall. The outer sidewall has a first end and a second end with an opening extending through the first and second ends. The body defines a slot disposed proximate one of the first end or second end. The slot extends in a direction transverse to the opening and through the outer sidewall. A latch assembly includes at least one outer member being disposed outside the body, and is connected with an inner member being disposed through the slot. The outer member protrudes from the outer surface and reciprocates with respect to the outer sidewall. The inner member reciprocates within the slot, and is in fluid communication with the opening, whereby the body is releasably connectable with a piece of fluid transport equipment through the inner member. An overmold portion is formed over the outer sidewall of the body. The overmold portion includes a shroud portion partially covering the outer member of the latch assembly.

Preferably, the body is constructed of a molded material. More preferably, the molded material is a plastic material, where the body is a material more rigid than the overmold portion.

Preferably, the overmold portion is a soft overmold material that is more soft and flexible than the body.

Preferably, the opening defined in the body is substantially radially symmetrical.

Preferably, the shroud portion is a wall formed around the outer member of the latch assembly. More preferably, the wall protrudes a distance away from the outer surface at least the same as a distance that the outer member protrudes.

Preferably, the body is connectable to a fluid line at the end opposite the end where the slot is disposed.

In one embodiment, a coupler device further includes a valve assembly insertable into one of the first and second ends of the body opposite the slot, and being in fluid communication with the opening. The valve assembly contains a poppet member, a sleeve and a biasing member. The poppet member is coaxially mounted within the opening of the body. The sleeve is disposed between the poppet member and an inner wall of the body. The sleeve is slidably engaged with the poppet member and the inner wall, where the biasing member is disposed coaxially between the sleeve and the poppet member. The biasing member biases the sleeve in sealing engagement with the poppet member, such that the valve assembly is in the normally closed position.

In another embodiment, a coupler device is further includes an insert assembly connected to the body in a quick connect/disconnect configuration. The insert assembly is connectable at the end where the slot and latch assembly is disposed. The insert includes a body with a first end and a second end, where an opening is defined between said first and second ends. The insert includes a valve assembly that is operatively engageable with the valve assembly of the body. The valve assembly includes a poppet member slidingly engaged within the opening. A biasing member disposed between one of the first or second ends and the poppet member for biasing the poppet member into a normally closed position and in sealing engagement with the opening.

In one embodiment, a method of making a molded coupler includes forming a molded body having an outer surface being an outer sidewall. The outer sidewall contains a first end and a second end with an opening extending through the first and second ends. The body defines a slot disposed proximate one of the first end or second end. The slot extends in a direction transverse to the opening and through the outer sidewall. An overmold portion is formed over the outer sidewall of the body, and a shroud is formed while forming the overmold portion. The shroud portion protrudes outward a distance transverse to the outer surface. A latch assembly is provided and disposed within the slot. The latch assembly includes at least one outer member being disposed outside the molded body, and connected with an inner member being disposed through the slot. The outer member protrudes from the outer surface of the body. The shroud portion protrudes a distance, such that the shroud portion partially covers the outer member.

These and other various advantages and features of novelty, which characterize the invention, are pointed out in the following detailed description. For better understanding of the invention, its advantages, and the objects obtained by its use, reference should also be made to the drawings which form a further part hereof, and to accompanying descriptive matter, in which there are illustrated and described specific examples of an apparatus in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

In the following description of the illustrated embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration of the embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized as structural changes may be made without departing from the spirit and scope of the present invention.

FIGS. 1A through 1Eillustrate one preferred embodiment of a coupler body20with a soft overmold30. The coupler body20includes an outer surface being an outer sidewall21with a first end22and a second end24. Preferably, the outer sidewall21is a radially shaped outer sidewall forming a substantially cylindrical shaped coupler body. An opening29extends through the first and second ends22,24, and substantially resembles a longitudinal bore extending through the coupler body20. The body defines a slot26proximate the first end22. Preferably, the slot26extends in a direction transverse to the opening29and through the outer sidewall21. As best illustrated inFIG. 1C, the slot26extends through opposite portions of the outer sidewall21.

A connection means23is disposed at the second end24, such that the coupler body20is connectable to a piece of fluid transport equipment. Preferably, the connection means23is defined by a groove formed between the outer sidewall21and the opening29. As illustrated, the groove is a socket fitting where a suitable mating coupling member can be inserted. A piece of fluid transport equipment may be any suitable coupling member or connector mateable with the connection means23, for connecting the coupler body20to a well-known fluid transport system or fluid line. It will be appreciated that the connection means is not limited to the specific configuration illustrated, as other socket fitting configurations and/or interference fittings may be employed.

For purposes of describing one preferred structure for the present invention, the slot26and connection means23have been defined at first and second ends22,24, respectively. It also will be appreciated that a coupler body20may include the slot26proximate the second end24and the connection means23at the first end22.

In one most preferred embodiment, the slot26is formed to mechanically retain and engage a latch assembly40, which is further described below, for releasably connecting the coupler body20to a piece of fluid transport equipment. By way of example only, the piece of fluid transport equipment may be another connector, such as a mating insert valve, mating coupler valve or a fluid line. A recessed face26amay be disposed on the outer surface about said slot26. The recessed face26aextends in a direction along the outer sidewall21toward said first and second ends22,24. The recessed face26aprovides a space for members of the latch assembly40to comfortably be disposed. Preferably, the recessed face26ais a substantially planar face. A retention shoulder26bis disposed adjacent the slot26. Preferably, the retention shoulder26bis oppositely disposed from the recessed face26a. The retention shoulder26bretains the latch assembly40within the slot26(best shown inFIG. 3C). As illustrated in the top and bottom views ofFIGS. 1D and 1E, the recessed face26acan define a top portion of the coupler body20, and the retention shoulder26bcan define an opposite bottom portion of the same. It will be appreciated that such top and bottom designations are for illustrative purposes only, as the top portion may be defined with the retention shoulder26band the bottom portion may be defined with the recessed face26a.

As above, the slot26, recessed face26aand retention shoulder26bare formed to mechanically engage and retain a latch assembly. It is well known that such latch assemblies, as hereinafter described, are used in quick connect/disconnect couplings. Such latch assemblies are disposed within the slot26, and include manually operated parts residing outside of the coupler body20and extending away from the outer sidewall21. It will be appreciated that mechanisms other than a latch assembly may be constructed and arranged, so as to be disposed and retained in the slot26. By way of example only, such mechanisms may be valve actuators that also include manually operated parts residing externally of the outer sidewall21of the coupler body20.

The coupler body20may further include first and second shoulder portions25,27formed within the opening29. Preferably, the first shoulder portion25is disposed proximate the first end22, and more preferably adjacent the slot26on the backside of the slot toward the second end24. As shown and described, the first shoulder portion25is formed as a tapered annular surface about the inside of the opening29, where the diameter is greater toward the slot26. The first shoulder portion25limits the amount of insertion for a connecting insert.

The second shoulder portion27preferably is disposed downstream from the first shoulder portion25and toward the second end24. The second shoulder portion27is formed as an annular surface such that the diameter is greater toward the second end24. The second shoulder portion27provides a suitable stop surface for a valve assembly or other fluid transport control structures that are incorporated within the opening29.

FIGS. 2A through 2Eillustrate individual views of the coupler body20without the overmold30.

As shown and described, the overmold30is formed substantially about the outer sidewall21of the coupler body20. Preferably, the overmold30is formed directly over the outer sidewall21as an additional molded layer. The overmold30is a material relatively softer than the more rigid coupler body20. The overmold30includes a shroud portion33that extends transversely outward from the outer sidewall21, and is disposed as a wall about the recessed face26aand adjacent the slot26. The shroud portion33is open faced from the top and exposes the slot26and recessed face26a. Preferably, the shroud portion33extends a distance perpendicularly from the outer sidewall21and forms a well-shaped structure about the recessed face26a. The shroud portion33provides a partial cover for external structures disposed outside of the coupler body20. More preferably, the shroud portion33partially covers and protects external structures, such as manually operated parts of the latch assembly40that reside outside the coupler body20. The shroud portion33is formed of the same material as the overmold30, and preferably is made from the same tool in the same molding process. Preferably, the shroud portion is resilient while maintaining its well shape.

In a further preferred embodiment, the coupler body20may be formed with an indexing rim28. The indexing rim28is formed proximate the first end22, and disposed adjacent the recessed face26a. The indexing rim28extends outwardly from the outer sidewall21. Preferably, the shroud portion33is formed over the indexing rim28, which provides strength and support of the shroud portion33.

Preferably, the coupler body20is a molded part made of a plastic material. The coupler body is a rigid, hard plastic material. More preferably, the coupler body is a molded material being polypropylene. It will be appreciated that other plastic materials and resins may be employed as appropriate for providing the properties of a rigid, plastic molded coupler body.

The overmold30is a molded material that is softer than the rigidly molded coupler body20. Preferably, the overmold30is a low tolerance material, and can provide soft touch and ergonomic feeling, while protecting the coupler body20. More preferably, the overmold30is formed of a thermoplastic rubber material suitable for providing such properties. Further, the overmold30may be formed as a color overmold for identification purposes.

The coupler body20and overmold30are formed using well-known injection molding techniques. Further, well-known two-shot molding techniques may be used by first forming the coupler body20and subsequently forming the overmold30over the coupler body20. Preferably, the coupler body20and overmold30are formed for non-spill couplers using flow sizes at about ¼ and ⅜ inches for the opening29. It will be appreciated that the flow sizes may vary as needed.

By forming a coupler body20with the overmold30as described above, the coupler body can be molded with tight, specific dimensions, while the overmold30can form the shroud portion33. The shroud portion33can cover and protect any exposed irregular shaped parts that are disposed and/or mounted externally of the outer sidewall21. The coupler body20can be formed to avoid distortion or any added windaging inside the bore, which could occur if the coupler body and shrouding were formed as a single non-symmetrically molded part.

By forming the overmold30as a separate layer outside the coupling body20, the outer shape of a coupler can be modified as needed to protect external structures disposed outside the coupler body20, such as those in the latch assembly40discussed below. In this manner, the need to fine-tune the coupling body20back to specific dimensions can be avoided. Further, seal surfaces that can require specific dimensions, such as the radial dimension of the inner bore, may be protected as distortion is prevented. Preferably, the coupling body20is a substantially uniform and symmetrical part, where any sealing and/or other assembled surfaces that require tight tolerances are preserved. In this configuration, the coupling body20may be molded using standard round core pins, while enabling the cycling of the part to be made faster. The coupling body20and the overmold30can be made with thicker wall surfaces, while avoiding dimensional distortion. A finished coupling body20with the overmold30, defining both under molded and over molded portions and having asymmetric geometry and irregular wall sections, can be efficiently manufactured while avoiding the shrinkage problems that would result from creating a similar geometry using only a single material. As a result, a more convenient coupler can be produced faster and at low cost using inexpensive materials and standard equipment.

FIGS. 3A-3Cillustrate the coupler device10, including the coupling body20, overmold30and latch assembly40, that is releasably connected with a valve assembly50. In one example only, the latch assembly40includes at least one outer member connected with an inner member. The outer member is disposed outside the outer surface of the coupling body20, and preferably resides within the shroud portion33and on the recessed face26a. Preferably, the outer members include a actuating member41and a biasing member45protruding outwardly from the outer surface of the coupling body20and partially covered by the shroud portion33. Preferably, the actuating member41is a thumb portion. The biasing member45is disposed between the actuating member41and the recessed face26a. Preferably, the biasing member45is a coiled spring resting on and engaged with the recessed face26aand under the thumb portion. It will be appreciated other biasing members may be employed.

The inner member is moveably disposed within the slot26. Preferably, the inner member is a plate43having an aperture corresponding with the opening29of the coupling body20, so as to allow insertion and connection of a mating connector therein. The actuating member41provides a surface for a user to manually operate the latch assembly40for quickly connecting and disconnecting the coupling body20with a piece of fluid transport equipment. When activated, the actuating member41reciprocates with respect to the outer surface of the coupling body20through action of the biasing member45, so as to move toward and away from the outer sidewall21. Further, the plate43reciprocates within the slot26, and includes a tapered edge43awith a transverse edge43b. The edges43a,43bprovide a ramp surface and retention shoulder within the opening29, where a piece of fluid transport equipment, such as a mating insert, can be connected to the coupling body20. By depressing the actuating member41, the edges can be moved out of the opening29to provide clearance for removal of an insert.

A retention member47holds the latch assembly40within the slot26and on the recessed face. The retention member47is oppositely disposed from the outer members41,45. The retention member provides a shoulder surface engageable with the retention shoulder26b. The shroud portion33also provides a wall structure so as to position the actuating member41and biasing member45in engagement with the recessed face26a. Preferably, the shroud portion33is adjacent the outer members41,45extending a distance in a direction transverse to the outer surface of the coupling body20. More preferably, the shroud portion33surrounds the outer members41,45, and protrudes at least the same distance from the outer surface of the coupling body as the actuating member41. In this configuration, the shroud portion33can provide suitable protection and cover of the outer members41,45.

In one preferred example, the valve assembly50is insertable in the second end24of the coupling body20and opposite the slot26. The valve assembly50is in fluid communication for enabling and disabling flow through the coupling body20. Preferably, the valve assembly50is actuatable from a normally closed position to an open position. The valve assembly50includes a poppet member51, a sleeve member53and a biasing member55.

The poppet member51is coaxially mounted within the opening29of the coupler body. The poppet member51includes a main body51cwith an elongated portion51aextending toward the first end22. The elongated portion51ahas a smaller diameter than the portion of the main body51cproximate the second end24. The poppet member includes at least one opening in a portion of the main body mounted proximate the second end24, so as to allow fluid flow therethrough. Proximate the second end24, the poppet member51includes a retention barb51eannularly disposed thereon. The retention barb51eprovides an interference fit with the inner wall of the coupling body20. The retention barb51eretains the poppet member51within the coupling body20, and includes an annular flange51fthat fits against the second end24of the coupling body20.

The sleeve member53is coaxially disposed between the poppet member51and the inner wall of the coupling body. The sleeve53is slidingly engaged with the poppet member51and coupling body20. An annular flange53adisposed on an end proximate the second end24provides a stop structure to engage with the second shoulder27of the coupling body20. This relationship limits movement of the sleeve toward the first end22. A resilient o-ring52bis disposed in a groove53bprovides a fluid tight seal with the coupling body20. The sleeve53includes an opening where the poppet member51is insertable in a fluid tight seal, such that the valve assembly50is in a closed position. An o-ring52adisposed in a groove51bof the elongated member51asealingly engages the sleeve53, when the poppet member51is inserted in the sleeve53.

A biasing member55biases the valve assembly50in a normally closed position, and is disposed coaxially between the sleeve53and poppet member51. The biasing member biases the o-ring52ato remain in a fluid tight seal with the sleeve53. Preferably, the biasing member55resides between surfaces53dand51dof the sleeve53and poppet member51, respectively. More preferably, the biasing member55is a coiled spring. The sleeve53may be slidingly moved toward the second end24when actuated to release the sealing engagement with the poppet member51, so as to allow fluid flow through the coupling body20. The valve assembly50may be actuated into an open position when, for instance, an insert assembly60is inserted into the coupling body20. Such insert assemblies are further discussed below.

The coupling body20may be connected with an adapter57for connecting the coupling device10to a fluid transport system, such as a well known fluid line (not shown). The adapter57is connectable with the connection means23having a fitting57ainsertable in the socket structure of the connection means23. As discussed above, the connection means23is not limited to the specific socket fitting structure illustrated, as other well known connection structures may be employed. Likewise, the fitting57amay be modified as necessary to connect with the connection means23. The connection means23and fitting57amay cooperate in a fluid tight seal so as to prevent leakage or spill from the coupling device10and adapter57. A barbed outer tubing57cstructure allows the adapter to be connected with a fluid line in an interference fitting arrangement. It will be appreciated that the adapter may employ other structures suitable for connecting the coupling device10to a piece of fluid transport equipment or fluid dispensing system. The adapter57also may include a shoulder57bengageable with the annular flange51fof the poppet member and provides additional support for retaining the poppet member51.

FIGS. 4A through 4Cillustrate one example of an insert assembly60insertable into the coupling body20. The insert assembly60includes a main body63having a first end62and a second end64with an opening therethrough. The first end62is insertable into the opening29of the coupling body20at the first end22, and includes an o-ring62aformed in a groove. The first end62sealingly engages the inner wall when inserted into the coupling body20. The insert assembly60includes a poppet member61coaxially disposed within the main body63. The poppet member61is slidingly engageable with the main body63. A biasing member65is disposed coaxial within the main body63, and resides between the poppet member61and the second end64of the main body63. The biasing member65biases the poppet member61into sealing engagement with an inner surface of the main body63, where an o-ring62bcontacts an inner wall of the main body63. In this configuration, the insert assembly60is in a normally closed position.

When connected with the coupling body20, the poppet member61is moveable and pushed back toward the second end64as the poppet member61engages the poppet member51of the valve assembly50. Likewise, the first end62engages the sleeve53and pushes the sleeve53back toward the second end24, while the o-ring62asealingly engages the inner wall of the coupling body20to form a fluid tight seal. The insert assembly60is connectedly retained in the coupling body20when a tapered surface67rides along and past the edge43afor the edge43bto move into the groove68. As the inner member43reciprocates within the slot26, the edges43a, b can be depressed downward for the tapered surface67to pass through. Once the tapered surface67clears the inner member43, the inner member43is biased back to its original position to lock the insert assembly60. By depressing the actuating member41, the insert assembly60can be disconnected and removed. This configuration is typical of quick connect/disconnect couplers and many variations may be employed using such principles.

An adapter70is connectable at the second end64, and mates with a connecting means64athrough a fitting73at the end72. A shoulder70bprovides a surface for the biasing member65to rest against. Similar to the adapter57, a barbed structure may be employed at an end74opposite end72. The barbed end74enables the insert assembly60to be connected with a piece of transport equipment or fluid transport system, such as a fluid source or fluid line (not shown).

The insert assembly60may also include an overmold66formed over at least a portion of the main body63. Preferably, the overmold66is the same material as the overmold33, and may be of the same color. In this configuration, the insert assembly60can be color-keyed with a similarly colored coupling body. Such a design may be useful for coupler and inserts requiring predetermined and specific connection.

FIG. 5illustrates another embodiment of a coupling device100showing the coupling body20with the overmold30and shroud33connected with the latch assembly40. A fitting, such as the adapter57may be connected at one end so that the coupling device100is connectable with another piece of fluid transport equipment, for instance a well known fluid line (not shown).FIG. 5illustrates the coupling device without the valve assembly shown inFIG. 3C. Similar parts and features are shown that have been detailed above and are not further discussed.

FIG. 6illustrates one preferred embodiment of a coupling relationship showing the coupling device10ofFIGS. 3A-3Cconnected with the mating insert assembly60ofFIGS. 4A-4C. The coupling device10and the insert assembly60are connected in an open position, as discussed above. Similar parts and features are shown that have been detailed above and are not further discussed.

Preferably, the latch assembly, valve assembly and insert assembly are made of molded parts, and more preferably, are made of a molded plastic material, such as the coupling body. The o-ring seals discussed preferably are made of a resilient material, such as a rubber material or the like. It will be appreciated the biasing members may be made of machined metal or a molded plastic material.

As discussed above, the present invention provides advantages for a coupling device. By forming a coupler body with the overmold as described above, the coupler body can be molded with tight, specific dimensions, while the overmold can form the shroud portion. The shroud portion covers and protects any irregular shapes residing outside the outer surface of the coupler body. The coupler body can be formed to avoid distortion or any added windaging inside the bore. By forming the overmold as a separate layer outside the coupling body, the outer shape of a coupler can be modified to protect external structures disposed outside the coupler body, such as those in a latch assembly. In this manner, the need to fine-tune the coupling body back to specific dimensions can be avoided. Further, seal surfaces that can require specific dimensions, may be protected as distortion of the coupling body is prevented. The coupling body is formed as a substantially uniform and symmetrical part, where any seal surfaces and/or other assembly interfaces that require tight tolerances are preserved. In this configuration, the coupling body may be molded using standard core pins, while enabling the cycling of the part to be made faster. The present invention provides a more convenient coupler that can be produced faster and at low cost using inexpensive materials and standard equipment.

Having described the embodiments of the present invention, modifications and equivalents may occur to one skilled in the art. It is intended that such modifications and equivalents shall be included with the scope of the invention.