Patent Publication Number: US-11028946-B2

Title: Fluid permeable hose carcass

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     The following application is a continuation application filed under 35 U.S.C. § 120 and claims priority from co-pending U.S. patent application Ser. No. 14/867,477, filed Sep. 28, 2015 and published on Apr. 7, 2016 as United States Patent Publication No. 2016/0097472, which claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 62/059,531 filed Oct. 3, 2014 entitled FLUID PERMEABLE HOSE CARCASS. The above-identified applications all from which priority is claimed are incorporated herein by reference in their entireties for all purposes. 
    
    
     TECHNICAL FIELD 
     The present disclosure relates to a fluid permeable hose carcass, and more particularly, a flexible fluid permeable hose carcass that provides skeletal strength to a hose assembly while allowing for the passage of fluid to prevent failure during substantially instantaneous depressurization of the hose assembly. 
     BACKGROUND 
     Conventional hose assemblies provide pliable transport lines serving to provide deep-water conduits to deep-sea oil tankers. The conventional hose assemblies are several thousand meters long and can internally comprise several individual internal hoses such as electrical lines or fiber optics for controls or communications or for the passage of fluids. 
     Because of the deep-sea application, the hose assemblies are exposed to extremely high-pressure conditions that require an internal metallic carcass to prevent collapsing. Many of such assemblies are required to be constructed under Specification 17 for Unbonded Flexible Pipe set forth by the American Petroleum Institute (“API”). An example of such a hose assembly is a product sold by MFX do Brasil of Salvador. Brazil under pan number 1¼″ HCR10KPSI. The specification of the MFX do Brasil part number 1¼″ HCR10KPSI hose assembly and API Specification 17 for Unbonded Flexible Pipe are both incorporated herein by reference. 
     Further discussion relating to the construction and application of conventional hose assemblies is discussed in U.S. Patent Publication No. 2011/0162750 to Marchand entitled FLEXIBLE PIPE FOR CONVEYING HYDROCARBONS HAVING A HIGH CORROSION RESISTANCE. AND METHOD OF MAKING SAME that was published on Jul. 7, 2011. The above-identified U.S. patent publication is incorporated herein by reference in its entirety. 
     SUMMARY 
     One example embodiment of the present disclosure includes a flexible hose assembly that includes a flexible fluid permeable annular carcass arrangement having an inner and an outer diameter formed about a central axis. The carcass arrangement provides skeletal strength to the hose assembly against radial forces. The carcass arrangement has a plurality of convolutions formed by a metal strip and fastened at convoluted joints between the convolutions. The convoluted joints have an inner Up and an outer lip at opposite ends of the convolutions. The carcass further includes a plurality of channels formed along an entire length of first and second sides of the strip, the channels creating at least one fluid passage in each of the convoluted joint forming the carcass for the passage of fluids between the inner and outer diameters. 
     Another example embodiment of the present disclosure includes a flexible hose assembly comprising a flexible fluid permeable annular carcass arrangement having an inner and an outer diameter formed about a central axis. The carcass arrangement provides skeletal strength to the hose assembly against radial forces. The carcass arrangement comprises a plurality of convolutions formed by a metal strip and fastened at convoluted joints between the convolutions. The convoluted joints have an inner lip and an outer lip at opposite ends of the convolutions. The carcass further comprises a plurality of notches spaced along the opposite ends of the strip, the notches creating at least one fluid passage in each of the convoluted joints forming the carcass for the passage of fluids between the inner and outer diameters. 
     While yet another example embodiment of the present disclosure includes a method of manufacturing a hose assembly comprising the steps of: passing a single metal strip through a die; winding the Strip on a mandrel to create a plurality of convolutions; fastening adjacent convolutions together at an interlocked joint to form a continuous carcass; surrounding the continuous carcass with a sealing sheath; surrounding the sealing sheath with at least one braided layer; and surrounding the at least one braided layer with an external sheath. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing and other features and advantages of the present disclosure will become apparent to one skilled in the art to which the present invention relates upon consideration of the following description of the invention with reference to the accompanying drawings, wherein like reference numerals refer to like parts unless described otherwise throughout the drawings and in which: 
         FIG. 1  is a flexible tubular hose assembly constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 2  is a partial perspective view of a carcass arrangement constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 3  is a partial section view of  FIG. 2 ; 
         FIG. 4  is a magnified view of a portion of the carcass arrangement of  FIG. 3 ; 
         FIG. 5  is a partial perspective view of a carcass arrangement constructed in accordance with another example embodiment of the present disclosure; 
         FIG. 6  is a partial section view of  FIG. 5 ; and 
         FIG. 7  is a magnified view of a portion of the carcass arrangement of  FIG. 6 . 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure. 
     The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. 
     DETAILED DESCRIPTION 
     Referring now to the figures generally wherein like numbered features shown therein refer to like elements throughout unless otherwise noted. The present disclosure relates to a fluid permeable hose carcass, and more particularly, a flexible fluid permeable hose carcass that provides skeletal strength to a hose assembly while allowing for the passage of fluid to prevent failure during substantially instantaneous depressurization of the hose assembly. 
       FIG. 1  is a flexible tubular hose assembly  10  constructed in accordance with one example embodiment of the present disclosure. The flexible tubular hose assembly  10  is intended in one example embodiment for offshore oil production, and more particularly for the transporting of fluids, such as oil. In an alternative example embodiment, the hose assembly  10  acts as a conduit for electrical cables and/or the transport of fluids. 
     The hose assembly  10  comprises from the inside radially outward, an internal fluid permeable hose carcass arrangement  20 , a polymeric or nylon sealing sheath  30 , one or more braided layers  40  and  50 , and a polymeric external sheath  60 . The polymeric sealing sheath  30  has the role of confining the fluid flowing inside the hose assembly  10 . 
     In conventional hose assemblies substantially instantaneous depressurization (evacuation to equilibrium in less than one second) caused by an explosion, rupture, or release of a plug or end cap causing the evacuation of the carcass and/or surrounding sealing sheath to a lower pressure has resulted in localized collapsing of the carcass. The carcass in conventional hose assemblies primary role was only to endure radial forces from deep-sea fluid pressure that would otherwise collapse the hose. This new form of failure from instantaneous depressurization has created a need for a new carcass design. 
     The flexible tubular hose assembly  10  is constructed to meet the standards required under API Specification 17 for unbounded flexible pipe. Moreover, the fluid permeable hose carcass  20  is advantageously designed for the passage of fluent material or fluids to prevent failure during substantially instantaneous depressurization of the hose assembly  10 . 
       FIG. 2  is a partial perspective view of a flexible fluid permeable hose carcass arrangement  20  constructed in accordance with one example embodiment of the present disclosure. The carcass arrangement  20  is a formed metal strip, or ribbon,  22  that is helically wound with the edges of adjacent convolutions interlocked in such a way that the hose is flexible yet permeable for the passage of fluent material or fluids between an internal cavity or inner diameter  24  to a region  26  outside the carcass and within the sealing sheath  30 . 
     Typically, a majority of fluid or fluent material passes axially (along axis x) of the carcass  20  shared with the central axis of the hose  10  to create a flow of fluent material axially through the hose  10 . While the hose  10  may be used to transport any suitable fluent material, it is specially adapted to convey particulate material from place to place. 
     In the illustrated example embodiment, the carcass arrangement  20  is made from stainless steel. However, other metals of similar strength and properties are intended to be within the spirit and scope of the present disclosure. 
     The carcass arrangement  20  is formed by passing the flat thin metal strip  22  through forming dies and helically winding the strip on a mandrel with adjacent convolutions being fastened together at an interlocked joint  32  to form a continuous carcass of adjoining convolutions. Further details concerning the specific apparatus directed toward the methods of assembly of the flexible metal hose are disclosed in U.S. Pat. No. 3,682,203 to Foti et al., which is incorporated herein by reference in its entirety. The carcass arrangement  20  like the hose  10  may be of any suitable diameter or length. It should be apparent to those skilled in the art that a variety of carcass  20  and hose  10  sizes may be manufactured. 
     The strip  22  is passed through a die and wound on the mandrel to form a generally “S-shaped” ribbon (as seen in  FIG. 3 ) having radially inner and outer body portions  34 ,  36 , respectively that are axially spaced apart and joined by a radially extending transition wall  38 , and further including reversely curved radially inner and outer lips  41 ,  42 , respectively that extend from respective body portions to form opposite strip edges. As the strip  22  passes onto the mandrel, the radially inner lip  41  interfits with the radially outer lip  42  of the adjoining convolution, as shown by  FIGS. 3 and 4 . The strip  22  continues to be wound on the mandrel in this fashion to produce a continuous carcass arrangement  20  made from interlocked helical adjoining convolutions or joint  32  of a single metal strip. 
     Adjoining convolutions are so constructed and arranged that the carcass arrangement  20  and hose  10  may be flexed and subjected to twisting forces without unwinding the convolutions. In the illustrated example embodiment of  FIGS. 2-4 , forming dies emboss a plurality of channels  44  for the passage of fluid or fluent material from between inner and outer regions  24 ,  26 , respectively. The channels  44  are grooves that extend on both a first  46  and second  48  sides of the entire length of the strip  22 . 
     The channels  44  positioning on both sides of the strip  22  advantageously allow for the permeability of the carcass arrangement  20  between inner and outer regions  24 ,  26 . Moreover, the plurality of channels  44  create multiple fluid or fluent material passages  70  in the interlocked joint  32 . Thus, the channels  44  allow for the flexible fluid permeable hose carcass  20  to facilitate the passage of fluid to prevent failure during substantially instantaneous depressurization of the hose assembly  10 . 
     In the illustrated example embodiment, the channels  44  are approximately one-ten thousandth (0.0001″) of one inch deep or deep enough to allow easy passage of the fluid on both sides  46 ,  48  of the metal strip  22  and transverse to the ends  28  of the strip  22 . In another example embodiment, the channels  44  are perpendicular to the ends  28  of the strip and substantially parallel with the central axis x of the carcass arrangement  20  and hose assembly  10 , the channels extending about the entire length and on both sides  28  of the strip. Thus advantageously, fluid passages are formed by the channels  44  as well as between the sealing sheath  30  and outer portion  26  of the carcass  20 . 
     In multiple tests of the carcass arrangement  20  of  FIGS. 2-4 , the internal fluid pressure was elevated in excess of seventeen thousand (17,000) psi before exposed to a substantially instantaneous depressurization (less than one-second) of the carcass  20  and hose assembly  10 . In each test, no damage occurred to the carcass arrangement  20  or hose assembly  10 . After undergoing the above test, the tested carcass arrangement  20  underwent standardized carcass testing, such as an external force crush test and exceeded six-thousand (6,000) psi before experiencing any localized damage. 
       FIG. 5  is a partial perspective view of a flexible fluid permeable hose carcass arrangement  120  constructed in accordance with another example embodiment of the present disclosure. The carcass arrangement  120  is a formed metal strip, or ribbon,  122  that is helically wound with the edges of adjacent convolutions interlocked in such a way that the hose is flexible yet permeable for the passage of fluent material or fluids between an internal cavity or inner diameter  124  to a region  126  outside the carcass and within the sealing sheath  30 . 
     Typically, a majority of fluid or fluent material passes axially (along axis x) of the carcass  120  shared with the central axis of the hose  10  to create a flow of fluent material axially through the hose. While the hose  10  may be used to transport any suitable fluent material, it is specially adapted to convey particulate material from place to place. 
     In the illustrated example embodiment, the carcass arrangement  120  is made from stainless steel. However, other metals of similar strength and properties are intended to be within the spirit and scope of the present disclosure. 
     The carcass arrangement  120  is formed by passing the flat thin metal strip  122  through forming dies and helically winding the strip on a mandrel with adjacent convolutions being fastened together at an interlocked joint  132  to form a continuous carcass of adjoining convolutions. Further details concerning the specific apparatus directed toward the methods of assembly of the flexible metal hose are disclosed in U.S. Pat. No. 3,682,203 to Foti et al., which is incorporated herein by reference in its entirety. The carcass arrangement  120  like the hose  10  may be of any suitable diameter or length. It should be apparent to those skilled in the art that a variety of carcass  120  and hose  10  sizes may be manufactured. 
     The strip  122  is passed through a die and wound on the mandrel to form a generally “S-shaped” ribbon (as seen in  FIG. 7 ) having radially inner and outer body portions  134 ,  36 , respectively that are axially spaced apart and joined by a radially extending transition wall  138 , and further including reversely curved radially inner and outer lips  141 ,  142 , respectively that extend from respective body portions to form opposite strip edges. As the strip  122  passes onto the mandrel, the radially inner lip  141  interfits with the radially outer lip  142  of the adjoining convolution, as shown by  FIGS. 6 and 7 . The strip  122  continues to be wound on the mandrel in this fashion to produce a continuous carcass arrangement  120  made from interlocked helical adjoining convolutions or joint  132  of a single metal strip. 
     Adjoining convolutions are so constructed and arranged that the carcass arrangement  120  and hose  10  may be flexed and subjected to twisting forces without unwinding the convolutions. In the illustrated example embodiment of  FIGS. 5-7 , punching dies form a plurality of spaced arcuate notches  144  for the passage of fluid or fluent material from between inner and outer regions  124 ,  126 , respectively. The notches  144  are arcuate passages that are spaced and through both first  146  and second  148  ends of the entire length of the ends of the strip  122 . 
     The arcuate notches  144  positioning on both ends  146  and  148  of the strip  122  advantageously allow for the permeability of the carcass arrangement  120  between inner and outer regions  124 ,  126 . Moreover, the plurality of notches  144  create multiple fluid or fluent material passages  170  in the interlocking convolution  132 . Thus, the arcuate notches  144  allow for the flexible fluid permeable hose carcass  120  to facilitate the passage of fluid to prevent failure during substantially instantaneous depressurization of the hose assembly  10 . 
     While arcuate notches  144  are shown, it should be appreciated that other aperture fluid-passage geometries are contemplated to be within the spirit and scope of the present disclosure. For example, elliptical or rectangular passages are suitable geometrical forms of notches  144 . 
     In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the disclosure as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings. 
     The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The disclosure is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued. 
     Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a nonexclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment the terms are defined to be within for example 10%, in another possible embodiment within 5%, in another possible embodiment within 1%, and in another possible embodiment within 0.5%. The term “coupled” as used herein is defined as connected or in contact either temporarily or permanently, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed. 
     To the extent that the materials for any of the foregoing embodiments or components thereof are not specified, it is to be appreciated that suitable materials would be known by one of ordinary skill in the art for the intended purposes. 
     The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.