Patent Description:
The present disclosure relates to flexible hose assemblies and to methods of making flexible hose assemblies. More particularly, the disclosure relates to flexible metal hoses having a weld connection between a tube (e.g., annular or helical corrugated tube) and an end connection configured to minimize or eliminate entrapment areas between the tube end and the welded end connection. Such hose assemblies are e.g. disclosed in <CIT>. The flexible metal hose has a corrugated tube and a protective hose made of a metallic mesh.

In accordance with an exemplary embodiment of the present disclosure, a hose assembly includes a metal hose, an end connection having a distal end defining a fluid connector and a proximal end defining a tube stub received in a distal end portion of the hose, and a weld collar surrounding the distal end portion of the hose and the tube stub of the end connection, with the weld collar, the hose distal end portion, and the tube stub being welded together at a welding zone proximal to a distal edge of the metal hose.

In accordance with another exemplary embodiment of the present disclosure, a method of making a hose assembly is contemplated. In an exemplary method, a distal end portion of a metal hose is inserted into a proximal end of a weld collar. A proximal end tube stub of an end connection is inserted into the distal end portion of the metal hose, such that the distal end portion of the metal hose is radially disposed between the weld collar and the tube stub. The weld collar, the hose distal end portion, and the tube stub are together at a welding zone proximal to a distal edge of the metal hose.

In accordance with another exemplary embodiment of the present disclosure, a method of making a weld collar for a hose end is contemplated. In an exemplary method, a tube section is provided. Using a crimping tool, the tube section is crimped to form a radially inward extending distal end portion defining an internal stepped portion, a tapered proximal end portion, and an intermediate portion extending axially and radially between the proximal end portion and the distal end portion.

While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions--such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on--may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Parameters identified as "approximate" or "about" a specified value are intended to include both the specified value and values within <NUM>% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present disclosure may, but need not, be to scale, and therefore may be understood as teaching various ratios and proportions evident in the drawings. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.

Many applications have requirements for flexible hose to provide a fluid connection between two points in a fluid system, with the flexibility of the hose allowing for various fluid line routing requirements, thermal expansion, misalignment, and intermittent or continuous flexing (e.g., due to system vibrations). A flexible metal hose configured to provide, for example, desired system temperature ratings, system pressure ratings, chemical compatibility, and gas impermeability, commonly includes an inner metal tube corrugated to promote flexibility and an outer sheath, cover or other such reinforcement layer (e.g., a metal braided sheath) providing protection for the metal tube while permitting bending movement.

To facilitate installation into a fluid system, hose assemblies are commonly provided with any of a variety of end connectors, including, for example, tube fittings, tube ends (e.g., for welding or installation in a tube fitting), or quick disconnect couplings, and therefore require a leak-tight connection between the inner and outer flexible hose tube components and the end connection. For metal hose assemblies, such end connectors are commonly welded to the hose ends. In some such applications, welds performed on metal tube corrugations and sheath braiding of a metal hose may generate contaminants (e.g., loose burrs) and/or entrapment areas, which may be undesirable in some fluid systems.

According to an exemplary aspect of the present disclosure, a metal hose and welded end connection may be configured to provide a welded zone free from entrapment areas by capturing a distal tube end of the hose between a crimped outer weld collar and a proximal tube end of the end connection, and welding the weld collar, hose tube end, and end connection tube end together. Such an arrangement may allow for automatic (e.g., orbital) welding of the hose ends, thereby reducing weld times and weld skill requirements, and providing for improved yields of leak tight assemblies.

In an exemplary embodiment, as shown in the cross-sectional views of <FIG>, a metal hose assembly <NUM> includes a metal end connection <NUM>, a hose <NUM>, and a metal weld collar <NUM>. The hose assembly components may be provided in any suitable material, including, for example, stainless steel, Hastelloy®, and other alloys that can be autogenously welded. Further, while the drawings only show one end of the hose assembly <NUM>, it is to be understood that an opposite end of the hose assembly may, but need not, include a similar end connection and corresponding attachment arrangement.

The exemplary end connection <NUM> includes a distal end connector, shown schematically at <NUM>, for connecting with a fluid system (e.g., a tube fitting, tube stub, quick disconnect coupling), and a proximal end tube stub <NUM> insertable into the hose <NUM> and weldable with the weld collar <NUM> and hose, as described in greater detail below.

The exemplary hose <NUM> includes a corrugated metal tube <NUM> and surrounding sheath <NUM> (e.g., a braided metal sheath). The corrugated tube <NUM> includes a plurality of corrugations <NUM>, with crest portions engaging and supporting the sheath <NUM>, and root portions defining an inner diameter of the hose <NUM>. In other embodiments, other hose constructions may be used, including, for example, a corrugated metal tube with a different reinforcing sheath, a corrugated metal tube without a reinforcing sheath, a tube having cylindrical end cuffs (e.g., integrally formed, welded, etc.), or a hose having a coiled wire ("spring guard") or flat coil ("armor guard") sleeve on the outer diameter and/or inner diameter of the metal hose.

The exemplary weld collar <NUM> includes a narrowed distal end portion <NUM> and an expanded proximal end portion <NUM>. As initially installed (<FIG>), a distal edge <NUM> of the hose <NUM> is received in the proximal end portion <NUM> of the weld collar <NUM> and into abutment with a stepped portion <NUM> of the weld collar, thereby preventing extrusion of the corrugated tube <NUM> past the distal end portion <NUM> of the weld collar. As shown, the weld collar <NUM> may (but need not) be provided with an outward tapered proximal end portion <NUM> (e.g., an inner diameter taper of approximately <NUM>°), for example, to facilitate funneling of the hose end <NUM> (often including cut/frayed braiding) into the weld collar <NUM>. An intermediate portion <NUM> of the weld collar may include an inner diameter sized for slip fit engagement with the sheath <NUM> of the inserted hose end <NUM>.

The weld collar may be formed using a variety of manufacturing processes, including, for example, machining, additive manufacturing, deep draw from sheet, or crimp formed from tube. In an exemplary embodiment, as shown in <FIG>, the weld collar <NUM> may be formed by crimping a section of thin-walled tube (shown in phantom at <NUM>'), using a crimping tool <NUM>. The exemplary collar forming crimping tool <NUM> includes a distal inner wall <NUM> providing a stop for the thin-walled tube end, a shoulder portion <NUM> for forming the stepped portion <NUM> of the weld collar <NUM>, an intermediate portion <NUM> for forming the intermediate portion <NUM> of the weld collar, and a tapered proximal end portion <NUM> for forming the outward tapered proximal end portion <NUM> of the weld collar. While many different size tube sections may be used, in an exemplary embodiment, a <NUM>/<NUM>" nominal diameter, <NUM>" wall thickness stainless steel tube section about <NUM>" long is used to form a weld collar for a <NUM>/<NUM>" diameter hose end.

As shown in <FIG>, the end connection tube stub <NUM> may be inserted into the hose <NUM> to a depth selected to align a proximal end or nose portion <NUM> of the tube stub with a designated welding zone <NUM> on the intermediate portion <NUM> of the weld collar <NUM>, proximal to the stepped portion <NUM> of the weld collar, to ensure a complete, uniform weld proximal to the distal edge <NUM> of the hose <NUM>. As discussed in greater detail below, a tight fit between the weld collar <NUM>, hose <NUM>, and tube stub nose portion <NUM> in the welding zone <NUM> provide for a full penetration weld that consumes this endmost nose portion of the tube stub <NUM>, such that there is no portion of the tube stub extending proximal to the weld that could form areas of entrapment within the hose end. As shown, the proximal end <NUM> of the tube stub <NUM> may include an inner diameter chamfer <NUM>, for example, to aid in flow of weld purge gas, and/or to facilitate generation of a full penetration weld at the tube stub end.

Many arrangements may be used to properly align the end connection tube stub <NUM> within the weld collar <NUM>. In the illustrated embodiment, as shown in <FIG>, an alignment tool <NUM> includes a distal base wall <NUM>, defining a first datum plane x1, for engaging a distal end face <NUM> of the end connection <NUM>, and an axially extending proximal wall <NUM>, defining a second datum plane x2, for engaging a distal end face <NUM> of the weld collar <NUM>, to properly align the welding zone <NUM> of the weld collar with the tube stub proximal end <NUM>.

In this aligned arrangement, a hose connection crimping tool <NUM> (which may be positioned by the proximal wall <NUM> of the alignment tool <NUM>) may be used to form a crimped or compressed attachment of the weld collar <NUM>, hose <NUM>, and end connection <NUM> prior to welding. In an exemplary embodiment, as shown in <FIG>, the hose connection crimping tool <NUM> includes a distal end <NUM> that compresses the distal end <NUM> of the weld collar <NUM> into an interference fit with the end connection tube stub <NUM> to maintain the axial positions of the weld collar and end connection prior to welding. An intermediate portion <NUM> of the exemplary hose connection crimping tool <NUM> includes a raised rib or projection <NUM> positioned and configured to form an annular recess or groove <NUM> in the welding zone <NUM> of the weld collar <NUM>, to provide a weld joint centerline locating feature in the welding zone, and to create a reverse taper that will lock and hold the corrugated tube <NUM> and braided sheath <NUM> in place prior to welding. Between the welding zone <NUM> and the proximal end <NUM> of the weld collar <NUM>, a hose securing portion <NUM> of the hose connection crimping tool <NUM> may be configured to apply a nominal interference fit between the weld collar <NUM> and the hose <NUM>, while maintaining a slip fit at the proximal end <NUM> of the weld collar, for example, to provide a tight fit near the weld location and eliminate flexing and movement of the hose near the weld area. Between the welding zone <NUM> and the distal end <NUM> of the weld collar <NUM>, a hose compressing portion <NUM> of the hose connection crimping tool <NUM> may be configured to substantially flatten the compressed portion of the corrugated tube <NUM> into a cuff-like geometry <NUM>. In some applications, this tight engagement with the core tube may allow for welding a wider variety of core tubes, including, for example, helical and multi-ply helical core tubes, and/or may promote withdrawal of weld heat away from the braid wire resulting in maintaining cold worked strength in the wire. In some embodiments, a notch <NUM> (shown in phantom in <FIG>) may be formed (e.g., cut or machined) in the welding zone <NUM> of the weld collar <NUM> prior to installation, reducing the wall thickness in the weld collar welding zone to facilitate groove formation and hose compression during crimping, and/or to facilitate weld penetration and control the edge of the weld puddle for improved weld aesthetics.

While many different types of weld arrangements may be used, the end connection <NUM>, hose <NUM>, and weld collar <NUM> may be configured to accommodate an autogenous weld, by which the weld may be formed by the end connection, corrugated tube, and weld collar materials without the addition of a filler material. In such an arrangement, the thinned-down welding zone of the weld collar may (but need not) include an enlarged rib (not shown) providing sacrificial weld material to facilitate formation of the autogenous weld. This enlarged rib may further facilitate weld positioning or component alignment. In other embodiments, the welded assembly may use a filler material. Further, the welding operation may involve movement of the weld electrode around the weld collar (i.e., an orbital weld), or rotation of the workpiece components proximate a stationary electrode. In other arrangements, the electrode/torch may oscillate, or a magnetic arc control may be used to stitch the weld puddle, thereby aiding in the wetting of all weld components to the weld puddle for inclusion into the weld.

As a result of an autogenous welding operation, portions of the tube stub <NUM>, hose <NUM>, and weld collar <NUM> (at welding zone <NUM>) are consumed in a weld puddle during a welding operation (using electrode E) to form a uniform, full penetration weld bead W, as shown in <FIG>. Because the hose distal edge extends around and axially distal to welded portion of the tube stub <NUM>, the hose edge is disposed outside of the hose flowpath (i.e., is not wetted), and therefore does not form entrapment areas or loose burrs or other contaminants within the flowpath. This facilitates cleaning, and maintaining a clean condition, of the internal flowpath of the hose, and allows for the elimination of a deburring step for the cut hose, as the cut area containing potential burrs is outside of the weld zone and isolated from the hose flowpath. Further, the extension of the braided sheath <NUM> past the welding zone (over and past the tube stub proximal end <NUM>) ensures that all braid wires are included in and penetrated by the weld, as compared to welding of a terminated end of a braided sheath, in which one or more of the terminated braid wires may pull or melt back and not be included in the weld. In the present invention, the braid is penetrated by the weld.

The weld arrangement described above may produce an enclosed space <NUM> between the welding zone <NUM> and the stepped portion <NUM> of the weld collar <NUM>. In another exemplary feature of the hose assembly, an outer surface of the tube stub <NUM> extending across this enclosed space, and compressed against the weld collar distal end <NUM>, may include one or more grooves, notches, or knurled surfaces <NUM> that form flow paths extending axially from the enclosed space to the distal end face <NUM> of the weld collar <NUM>, allowing for venting of weld gases during welding, for example, to prevent a weld blowout. Other venting arrangements may additionally or alternatively be used, including, for example, a vent hole machined or otherwise formed in the distal end wall of the weld collar.

Claim 1:
A hose assembly (<NUM>) comprising:
a metal hose (<NUM>);
an end connection (<NUM>) having a distal end defining a fluid connector and a proximal end defining a tube stub (<NUM>) received in a distal end portion of the hose; and
a weld collar (<NUM>) surrounding the distal end portion of the hose and the tube stub of the end connection, with the weld collar, the hose distal end portion, and the tube stub being welded together at a welding zone (<NUM>) proximal to a distal edge (<NUM>) of the metal hose;
wherein a proximal edge of the tube stub is disposed at the welding zone, such that the tube stub does not extend proximal to the welding zone.