Abstract:
A piping hose connector adapter can be employed as a stand-alone connector or integrated into a valve or fitting. The adapter can comprise a substantially cylindrical body having inner and outer walls, with a plurality of ledges extending radially outwardly from the outer wall and forming grooves therebetween. O-ring members can be inserted in one or more of the grooves. The adapter can be secured at one end to a fitting, and at the other end to a hose using a pressure applying device that can malform the hose around the outer surface of the adapter so as to compress the o-ring member.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention provides methods, connection devices as well as tooling designs for the permanent connection of flexible and rigid tubing with one or more fittings. In various embodiments, the tubing can be steel, brass, stainless steel or copper corrugated flexible or rigid tubing. 
       BACKGROUND AND SUMMARY OF THE INVENTION 
       [0002]    Piping systems exist to facilitate the flow of fluids (e.g., liquid, steam, gas (such as air) or plasma). For example, homes, schools, medical facilities, commercial buildings and other occupied structures generally require integrated piping systems so that water and/or other fluids can be circulated for a variety of uses. Liquids and/or gases such as cold and hot water, breathable air, glycol, compressed air, inert gases, cleaning chemicals, waste water, plant cooling water and paint and coatings are just some examples of the types of fluids and gases that can be deployed through piping systems. Tubing and piping types can include, for example, copper, stainless steel, CPVC (chlorinated polyvinyl chloride) and PEX (cross-linked polyethylene). For purposes of the present disclosure, the terms “pipe”, “piping”, “tube” or “tubing” will be understood to encompass one or more pipes, tubes, piping elements and/or tubing elements, and may be used interchangeably. 
         [0003]    Piping connections are necessary to join various pieces of pipe and must be versatile in order to adapt to changes of pipe direction required in particular piping system implementations. For example, fittings and valves may be employed at the ends of open pieces of pipe that enable two pieces of pipe to fit together in a particular configuration. Among fitting types there are elbows, “tees”, couplings adapted for various purposes such as pipe size changes, ends, ball valves, stop valves, and partial angle connectors, for example. 
         [0004]    In the past, pipe elements have been traditionally connected by welding and/or soldering them together using a torch. Soldering pipe fittings can be time-consuming, unsafe, and labor intensive. Soldering also requires employing numerous materials, such as copper pipes and fittings, emery cloths or pipe-cleaning brushes, flux, silver solder, a soldering torch and striker, a tubing cutter and safety glasses, for example. The process for soldering pipes can proceed by first preparing the pipe to be soldered, as the copper surface must be clean in order to form a good joint. The end of the pipe can be cleaned on the outside with emery cloth or a specially made wire brush. The inside of the fitting must be cleaned as well. Next, flux (a type of paste) can be applied to remove oxides and draw molten solder into the joint where the surfaces will be joined. The brush can be used to coat the inside of the fitting and the outside of the pipe with the flux. Next, the two pipes are pushed together firmly into place so that they “bottom out”—i.e., meet flush inside the fitting. The tip of the solder can be bent to the size of the pipe in order to avoid over-soldering. With the pipes and fitting in place, the torch is then ignited with the striker or by an auto-strike mechanism to initiate soldering. After heating for a few moments, if the copper surface is hot enough such that it melts when touched by the end of the solder, the solder can then be applied to the joint seam so that it runs around the joint and bonds the pipe and fitting together. 
         [0005]    In addition to welding methods, push-fit technology has been employed with piping systems to reduce the dangers and time involved in soldering joints. Push-fit methods require minimal knowledge of pipe fittings and involve far fewer materials than soldering. For example, one may only need the pipes, quick-connect fittings, a chamfer/de-burring tool and tubing cutter in order to connect pipes using push-fit technology. 
         [0006]    The steps involved in connecting piping systems using push-fit technology can be outlined as follows. First, the pipe is cut to the appropriate length and the end of the pipe is cleaned with the de-burring tool. Then the pipe and fitting are pushed together for connection. The fitting is provided with a fastening ring (also called a collet, grip ring or grab ring) having teeth that grip the pipe as it is inserted. The fastening ring device is employed to provide opposing energy, preventing the device from disconnection while creating a positive seal. Accordingly, no wrenches, clamping, gluing or soldering is involved. Push-fit and/or quick-connect technology for piping systems can be obtained, for example, through Quick Fitting, Inc. of Warwick, R.I., USA, suppliers of the CoPro®, ProBite®, LocJaw®, BlueHawk®, CopperHead® and PushConnect® lines of push fittings and related products. Also, such technology is described, for example, in U.S. Pat. No. 7,862,089, U.S. Pat. No. 7,942,161, U.S. Pat. No. 8,205,915, U.S. Pat. No. 8,210,576, U.S. Pat. No. 8,398,122, U.S. Pat. No. 8,480,134, U.S. Pat. No. 8,844,974 and U.S. Pat. No. 8,844,981, the disclosures of which are incorporated herein by reference in their entireties. 
         [0007]    Among other things, the present invention provides a piping hose connector adapter that can be employed as a stand-alone connector or integrated into a valve or fitting, such as a ball valve as depicted in various drawings. In addition to the compression generated from clamping, the connection can be sealed by the compression of one or more peroxide cured EPDM seals (e.g., “O-rings”). The clamping method in accordance with aspects of the present invention crimps, then clamps the tubing to the hose adapter, which is shown as integrated on a push-fit valve in various drawings. Once the tubing is pushed on the adapter, one or more O-ring seals make contact with the inner diameter of the tubing for a secure seal and fit. 
         [0008]    In various embodiments, the present invention employs existing corrugated or rigid tubing, which has been manufactured to a specific inside diameter, for example. The tubing can comprise, for example, stainless steel or copper corrugated flexible tubing, for example. The present invention requires no adhesives, no lubricants, no soldering and no glues. Additionally, various embodiments of the present invention operate with two retaining cavities. Once the tubing is formed into the cavities, the formed surfaces provide significant resistance to tensile forces, which prevents the failure of the connection under hydraulic hammering or higher pressures. As shown in the drawings, the adapter can be integrated into a push-to-connect ball valve. The valve adapter portion is pushed into the tubing. The assembly is placed in a crimping tool according to embodiments of the present invention to complete the process. 
         [0009]    Once installed, the tubing rests against the adapter stop surface and the o-rings are compressed, providing a stiff connection of the assembly. The O-rings provide the assembler with the ability to hold the assembly in place while applying symmetrical force to the connection. As shown in the drawings, the tooling design is provided to mate the tubing to the adapter, which can be a brass material in various embodiments. The tool makes contact at the axially inward tip of the retaining arch, beginning the inward forming of the tubing. The tool also makes contact at the axially outward edge of the tube over an axially outer lip of the adapter, which can assist in preventing drift of the tube in an axially outward direction as the full crimping process occurs. The retaining arch forming prevents mal-forming of the sealing or crimped areas due to drift. The crimp tool in accordance with the present invention can be designed to be installed in a cylindrical hose crimping machine as indicated in various drawings herein. The tool in accordance with various embodiments of the present invention applies even force to the circumference of the connection area forming a water-tight seal and crimp. In various embodiments, the tooling evenly crimps the assembly on the outer diameter of the tubing. The newly formed channels compress the O-ring seal to exert greater compression of the seals and broaden the sealing surface area. It will be appreciated that the formed connection can be provided as lead-law compliant and full flow. The O-ring seals can be provided as chloramine resistant, exceeding the U.S. standard of temperatures up to 200 F, for example. Also, the crimped connection can resist tensile separation forces over 400 lbf on a ¾″ connection. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a top right perspective view of a valve with adapter in partially exploded form, in accordance with embodiments of the present invention. 
           [0011]      FIG. 2  is a top right perspective view of an adapter in partially exploded form, in accordance with embodiments of the present invention. 
           [0012]      FIG. 3  is a front cross-sectional view of a valve with adapter in accordance with embodiments of the present invention. 
           [0013]      FIG. 4  is a detailed view of encircled portion  4 - 4  of  FIG. 3 . 
           [0014]      FIG. 5  is a left end view of an embodiment of the adapter device in accordance with aspects of the present invention. 
           [0015]      FIG. 6  is a front cross-sectional view of the embodiment of the adapter device taken along line  6 - 6  of  FIG. 5 . 
           [0016]      FIG. 7  is a front elevational view of a valve with adapter aligned with a portion of a corrugated hose in accordance with assembly operations of embodiments of the present invention. 
           [0017]      FIG. 8  is a front cross-sectional view of a valve with adapter, and with a portion of a corrugated hose placed over the adapter portion, in accordance with assembly operations of embodiments of the present invention. 
           [0018]      FIG. 9  is a front elevational view of a valve with adapter and a portion of a corrugated hose, and further with a crimping device shown above and below the adapter portion in accordance with embodiments of assembly operations of the present invention. 
           [0019]      FIG. 10  is a right front perspective view of the elements of  FIG. 9 . 
           [0020]      FIG. 11  is a front cross-sectional view of an assembly in accordance with various embodiments of the present invention, with crimping device engaging the hose element. 
           [0021]      FIG. 12  is a front cross-sectional view of the assembly of  FIG. 11  with crimping device removed. 
           [0022]      FIG. 13  is a view similar to  FIG. 11  in accordance with embodiments of the present invention, with an alternative embodiment of a crimping device shown prior to crimping of the hose element. 
           [0023]      FIG. 14  is a detailed view of encircled portion A-A of  FIG. 13 . 
           [0024]      FIG. 15  is a rear cross-section view similar to  FIG. 13  in accordance with embodiments of the present invention, after crimping of the hose element. 
           [0025]      FIG. 16  is a detailed view of encircled portion B-B of  FIG. 15 . 
           [0026]      FIG. 17  is a rear cross-sectional view similar to  FIG. 15  in accordance with embodiments of the present invention, with crimping device removed. 
           [0027]      FIG. 18  is a right end view of the crimping device in accordance with embodiments of the present invention. 
           [0028]      FIG. 19  is a front elevational view of the device of  FIG. 18 . 
           [0029]      FIG. 20  is a rear cross-sectional view of the device of  FIG. 18  taken along line C-C of  FIG. 18 . 
           [0030]      FIG. 21  is a detailed view of encircled portion D-D of  FIG. 20 . 
           [0031]      FIG. 22  is a front elevational view of an adapter in accordance with embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
       [0032]    As shown in  FIGS. 1 and 2 , the present invention can be provided in various embodiments and with various components, including an adapter  10  which can be mated with a fitting  12  (e.g., the ball valve fitting shown at  12 ). The adapter  10  shown in  FIGS. 1 through 6  is substantially tubular and/or cylindrical with an inner wall  14 , an outer wall  16 , a first axial end  18  with a threaded exterior  20  and a second axial end  19  with ledges  30 ,  34 ,  38 ,  40 . The adapter further includes a rim  22  and a hexagonal or other similarly shaped annular edge  24  to assist, for example, in tightening and loosening the adapter  10  as it is secured to or removed from the fitting  12  in various embodiments. It will be appreciated that, while the adapter member  10  is shown with an axial end  18  having a threaded exterior  20  for a compression-type fitting connection, the adapter member  10  can also be provided with an axial end having a push-to-connect arrangement, such as may be described, for example, in U.S. Pat. No. 7,862,089, U.S. Pat. No. 7,942,161, U.S. Pat. No. 8,205,915, U.S. Pat. No. 8,210,576, U.S. Pat. No. 8,398,122, U.S. Pat. No. 8,480,134, U.S. Pat. No. 8,844,974 and U.S. Pat. No. 8,844,981 identified above. Such a push-to-connect arrangement can involve the fitting  12  having associated receiving structure, such as also described in the aforementioned patents. A wrench or other similar device can be securely placed around the edge  24  in order to grip the adapter for rotation such that the threaded exterior  20  engages with the threaded interior of the fitting  12 , in the compression-type arrangement illustrated in  FIGS. 1 through 3 and 6 , for example. 
         [0033]    As shown in  FIGS. 1 through 16 , the adapter exterior  16  includes a stop surface  25  on the axially outer side of the annular edge  24 , and further includes an axially interior groove  28  between the stop surface  25  and a first radial ledge  30 . Extending axially outwardly from the interior groove  28  are the first radial ledge  30 , a first o-ring groove  32 , a second radial ledge  34 , a second o-ring groove  36 , a third radial ledge  38  and a fourth radial ledge  40 . In various embodiments the grooves  28 ,  32  and  36  are provided such that the first and second o-ring grooves  32 ,  36  have an internal depth that extends radially inwardly and toward the adapter axis  11  farther than the internal depth of the interior groove  28 . In other embodiments, the internal depths of the grooves can be substantially the same. In various embodiments, the radial ledges  30 ,  34 ,  38  and  40  are provided such that the first  30 , second  34  and third  38  radial ledges extend substantially the same radial distance from the axis  11  of the adapter  10 , while the fourth radial ledge  40  extends radially outwardly further from the axis  11 . In this way, the fourth radial ledge  40  provides a circumferential lip  88  that assists in sealing a later-attached hose  50  around the adapter body portion  15 . In various alternative embodiments, the first ledge  30  extends radially outwardly further than second  34  and third  38  ledges to provide an additional circumferential lip (not shown) that further assists in sealing a later-attached hose  50 . In such embodiments, the first ledge  30  can extend radially outwardly approximately the same distance as fourth ledge  40  or radially further outwardly than fourth ledge  40 . In various embodiments, the hose  50  is coined around the adapter body portion  15 , including the fourth radial ledge  40 , after one or more o-ring members  42  have been positioned in respective o-ring grooves  32 ,  36 . The fourth radial ledge  40  can be sloped such that the lip  88  extends radially outwardly from the axis a further distance than the axially outermost edge  90  of the adapter member. In this way, the coining process for positioning the hose  50  around the adapter member is facilitated.  FIGS. 3 and 4  show two o-ring members  42  in position, each within a respective o-ring groove  32 ,  36 . In various embodiments of the present invention, a radially extending lip (not shown) can be provided between the stop surface  25  and the axially interior groove  28 . The lip can assist in positioning when a crimping device  55  in accordance with the present invention is applied to a connected hose element  50  in place around the adapter  10 , for example, as described in more detail hereinafter. 
         [0034]    As shown in  FIGS. 3, 8, 11-13, 15 and 17 , the adapter end  18  adapted can be secured to an interior surface  57  of a fitting  12  either through a threaded/compression connection or a push-to-connect connection as described above. In such ways, the adapter  10  can be appropriately secured to the fitting  12 , receive a hose element  50  and permit proper crimping of the hose element  50  to the adapter outer surface  16 .  FIG. 7  shows a hose element  50  prior to being secured around adapter outer surface  16 . The hose element  50  is generally substantially cylindrical and/or tubular in shape, with an inner  52  and outer  54  surface. When secured around the adapter outer surface  16 , the hose element  50  may be coined or otherwise physically manipulated such that the hose element inner surface  52  slidingly abuts the adapter outer surface  16  until the front edge  56  of the hose element  50  engages or nearly engages the stop surface  25 , as shown in  FIGS. 8 and 13 through 14 . In this position, the assembly of the present invention according to these embodiments is ready for a crimping device  55  to be applied in order to securely seal the components together. 
         [0035]    As shown in  FIGS. 9 through 11, 13 through 16 and 18 through 21 , the crimping device  55  can be provided as substantially cylindrical, tubular or frustoconical in shape, and can include a substantially cylindrical internal surface  65  defining an opening  75  through the body of the device  55 , an external surface  60 , and first and second end surfaces  62  and  64 . In various embodiments, the internal surface  65  is adapted with one or more radial extensions  66 ,  67 ,  68 ,  69  extending towards the interior opening  75  of the crimping device  55 . Such extensions  66 ,  67 ,  68 ,  69  can be spaced apart axially in order to substantially mate with o-rings  42  within the o-ring grooves  32 ,  36  of the adapter  10 . In various embodiments of the present invention, the first end  62  of the crimping device  55  can be provided with a radially extending flange or tool retaining arch  70  for positioning between the stop surface  25  and the axial outer or leading edge  56  of the hose element  50  so as to be appropriately securely aligned prior to pressure being applied and crimping the hose element  50  to the adapter  10 . In various embodiments, as shown in  FIG. 11 , for example, the radially inner surface  65  includes a radially extending ledge element  72  axially outwardly of the axially outermost radial extension  69 . The ledge element  72  can engage the hose element  50  and crimp it so as to form an impression against the axially interior surface  41  (see  FIG. 4 ) of the fourth radial ledge  40  of adapter  10 . In various embodiments, as shown in  FIGS. 4, 6, 8, 14 and 16 , for example, the radially extending ledge element  72  is not provided, but a fourth extension  69  is provided for crimping the tube into a third groove  39 . 
         [0036]    In various embodiments of the present invention, multiple wedge elements  76  of the crimping device  55  extend from the second end  64  to the first end  62  of the crimping device  55  and each wedge element is provided with a respective jaw member  77  extending axially outwardly of the first end  62 , as shown in  FIGS. 9 through 10, 13, 15 and 18 through 21 , for example. The wedge elements  76  can be connected by a common base, such as element  78  in  FIG. 19 , a series of one or more connector ring elements  79 , as indicated in  FIG. 18 , or other securing element. Each wedge element has a pair of radially extending sides  92 . The wedge elements  76  are connected so as to form gaps  95  between their radially extending sides  92 , whereby the compression of the crimping device  55  causes the gaps  95  to narrow and the sides  92  to approach side-by-side engagement with respective neighboring wedge elements  76 . The jaws  77  can be employed by a crimping machine (shown in part at  99 ) to appropriately seat the crimping device  55  during operation. 
         [0037]    According to embodiments of the present invention, an adapter  10  is fixedly secured to a fitting, such as by threaded engagement or push-to-connect engagement, as described above, for example. The threaded engagement embodiment permits tightening and/or loosening by a wrench-type device engaging the hexagonal or appropriately shaped annular edge  24 . Once the adapter  10  and fitting  12  are secured, o-ring elements  42  can be slid over the adapter body  15  and placed in position within o-ring grooves  32 ,  36 . The hose element  50  can then be coined or otherwise manipulated over the axially outer edge  40  and circumferential lip  88  of the adapter  10 , and slid over the adapter  10  until the hose element  50  reaches or approaches a stopping point  25  on the adapter  10 . It will be appreciated that, as the hose is positioned over the adapter member  10 , an axially outer portion  86  of the hose member  50  is crimped about the circumferential lip  88  of the fourth radial ledge  40 , which provides for a first area of resistance to tensile force and restricts the tube from drifting, sliding or being pulled back off of the adapter when the crimping tool compresses the arrangement. 
         [0038]    The crimping device  55  can then be positioned around the hose element  50 , such that the first radial extension  66  is properly positioned near the stop surface  25  and above the leading edge  56  of the hose element  50 . In this way, the radial extensions  67 ,  68  on the radially inner surface  65  of the crimping device  55  are properly aligned above the o-rings  42 . When external pressure is applied to the crimping device  55 , such as by a crimping machine  99 , for example, the malleable hose element  50  is crimped as shown in  FIGS. 11 through 12 and 15 through 17 , for example, such that an axially inner portion  80  of the hose element  50  is bent into the axially interior groove  28  of the adapter  10 . Other portions  82 ,  84 ,  91  of the hose element  50  are crimped and permanently depress the o-rings  42  in the o-ring grooves  32 ,  36 , as shown in  FIGS. 11 through 12 and 15 through 18 , for example. An axially outer portion  86  of the hose element  50  is crimped around the fourth radial ledge  40  of adapter  10  as described above. The crimping machine can then release the crimping device  55 , and the crimping device can then be removed. As a result of the crimping process, the embodiment of the device of the present invention comprising the adapter  10  and hose element  50 , with fitting  12 , is thereby provided with the desired physical characteristics and strength. 
         [0039]      FIG. 22  shows an adapter member  100  in accordance with various embodiments of the present invention, including a rim  102  extending radially outwardly from the body portion  104  of the adapter member  100 . The adapter member  100  includes first  110  and second  112  ends, and each end  110 ,  112  can be provided with multiple radial ledges  114 ,  116 ,  118  and  120  extending radially outwardly of the body portion  104 . In various embodiments, the radial ledges  114 ,  116 ,  118  and  120  are provided such that the first  114 , second  116  and third  118  radial ledges (counted beginning with the axially innermost ledge  114  adjacent the rim  102  on each end  110 ,  112 ) extend substantially the same radial distance from the body portion  104 , while the fourth radial ledge  120  (the axially outermost) extends radially outwardly further from the body portion  104 . In various additional embodiments, the axially innermost  114  and axially outermost  120  ledges extend radially outwardly further from the body portion than internal ledges  116 ,  118 . In this way, the tube or hose element may have greater initial stress in passing over the ledges  114  and  120 , but also have greater surface area contact with such ledges  114 ,  120 . As a result of these factors, the subsequent crimping of the tube or hose element can provide a connection of increased strength. In various embodiments, the radially outward extension of axially innermost ledge  114  can extend further than the radially outward extension of axially outermost ledge  120 . Grooves  122 ,  124 ,  126  and  128  are shown in between respective pairs of radial extensions  102 ,  114 ,  116 ,  118 ,  120 , and one or more o-rings can be placed in one or more of such grooves prior to crimping a hose element about the adapter  100 . By having an adapter  100  with one or more ledges  114 ,  116 ,  118 ,  120  on each end  110 ,  112 , the present invention can accommodate fitting arrangements where multiple hose elements are being mated together with a single adapter. 
         [0040]    It will be appreciated that the present invention provides various connection methods as described herein, as well as suitable valve embodiments, fitting embodiments and hose embodiments as described. 
         [0041]    The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the claims of the application rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.