Patent Description:
Hoses manufactured from traditional plastic and rubber materials are typically used for sealing interfaces. However, typical low-durometer (i.e. hardness) hoses have poor axial stiffness and typical high-durometer hoses require high installation forces, making them ill-suited for straightforward assembly. Furthermore, many typical hoses require hose clamps in order to create reliable seals over their lifetimes and/or suffer from poor robustness to geometric variation and mechanical damage or debris at the sealing interfaces.

<CIT> discloses a push-on hose construction for a self-gripping connection with a barbed nipple or other push in fitting end. The hose has an innermost core tube which exhibits a reduced coefficient of friction for easier insertion of the fitting end. Further prior art is described in <CIT>.

As such, it may be desirable to produce a coupling device that may easily be installed and create reliable seals in varying environments.

For purposes of summarizing the disclosure and the advantages achieved over the prior art, certain objects and advantages of the disclosure are described herein. Not all such objects or advantages may be achieved in any particular embodiment.

In one aspect, a coupling device is disclosed. The coupling device includes an internal material, an external material, flared ends connected by a cylindrical intermediary portion, and a hollow interior portion, wherein a hardness of the internal material is less than a hardness of the external material.

In some embodiments, the internal material is an internal thermoplastic material. In some embodiments, the internal thermoplastic material comprises rubber. In some embodiments, the external material is an external thermoplastic material. In some embodiments, the external thermoplastic material is selected from the group consisting of polypropylene (PP), polybutylene terephthalate (PBT), nylon, and combinations thereof. In some embodiments, a melt temperature of the internal material is less than a melt temperature of the external material.

In some embodiments, the coupling device comprises an internal lubricant disposed over the internal material. In some embodiments, the coupling device does not comprise an internal sealant disposed over the internal material. In some embodiments, the internal and external materials are disposed directly over one another. In some embodiments, the coupling device does not comprise an additional material disposed between the internal and external materials. In some embodiments, the coupling device is able to withstand an internal pressure of at least about <NUM> kPa (<NUM> psi). In some embodiments, the coupling device is resistant to degradation from contact with ethylene glycol.

Each flared end includes a distal end, a medial portion, and a proximal portion, wherein an internal angle of the device increases from the proximal portion to the medial portion, and from the medial portion to the distal end.

In some embodiments, a battery coolant system is disclosed. The battery coolant system includes a plurality of battery cooling distributers, a plurality of barbs attached to the cooling distributers, a coolant source, and a plurality of above-described coupling devices in fluid communication with each of the plurality of barbs and the coolant source.

In some embodiments, the plurality of coupling devices are configured to maintain an internal pressure of at least about <NUM> kPa (<NUM> psi) when at least one of the plurality of barbs comprises a defect or debris of at most about <NUM>. In some embodiments, the plurality of coupling devices are configured to maintain an internal pressure of at least about <NUM> kPa (<NUM> psi) when at least two adjacent barbs of the plurality of barbs are misaligned. In some embodiments, the system does not comprise an additional attachment device connecting each of the plurality of coupling devices to the plurality of barbs.

In some embodiments, an automotive vehicle comprising the battery coolant system is described. In some embodiments, the automotive vehicle further comprising an electric motor.

The present disclosure may be understood by reference to the following detailed description. It is noted that, for purposes of illustrative clarity, certain elements in various drawings may not be drawn to scale, may be represented schematically or conceptually, or otherwise may not correspond exactly to certain physical configurations of embodiments.

Embodiments, relate to a coupling device useful for fluidly connecting components of products, such as vehicle coolant components. The coupling device may be press-fit onto male barb interfaces and thereby create a robust and durable liquid-tight seal. The seal of the coupling device may be resistant to leakage due barb damage (such as mechanical damage and/or surface imperfections), debris and/or radial misalignment of adjacent barbs. The coupling device may allow for autonomous factory installation.

The coupling device may be a cylindrical multilayer device with a relatively rigid outer surface and a pliable inner surface. The ends of the cylindrical device are flared to receive a barbed end that engages with each flared end. As the barbed end of a connector attempts to mate with the coupling device, the barbed end is received by the flared end. Because the inner material may be pliable, the barbed end of the connector may not align perfectly with the flared end, but still move into a proper mounting position without being damaged. The rigid outer surface prevents the pliable inner surface material from moving or stretching too far in any particular direction upon contact with the barbed end.

In one embodiment, the vehicle is an electric vehicle powered by a battery pack and comprising an electric motor, and wherein the battery pack is cooled by a coolant system. In some embodiments, a coolant system comprises battery cooling distributers, coolant barbs attached to the cooling distributers, a coolant source, and coupling devices. In some embodiments, the coupling devices attach to the barbs and coolant source such that the barbs and coolant source are in fluid communication.

<FIG> shows a perspective view of one embodiment of a coupling device <NUM> according to some embodiments, and <FIG> is a cross-sectional view of one embodiment of the coupling device from <FIG>. The coupling device <NUM> is formed from an internal material <NUM> and an external material <NUM>, and includes flared ends <NUM> connected by a cylindrical intermediary portion <NUM> and a hollow interior portion <NUM>. The flared end <NUM> includes a distal end <NUM>, a medial portion <NUM> and a proximal portion <NUM>. As shown in <FIG>, the internal angle of the device (relative to normal) increases from the proximal portion <NUM> to the medial portion <NUM>, and from the medial portion <NUM> to the distal end <NUM>. <FIG> show additional illustrations of a coupling device according to some embodiments.

The external material is selected to provide durability to the coupling device, and the internal material is selected to provide a robust and durable liquid tight seal when in use. Furthermore, external and internal materials may be selected such that they bond to each other without delamination issues. In some embodiments the internal material is an internal thermoplastic material. In some embodiments, the internal thermoplastic material includes rubber. In some embodiments, the rubber is a nitrile rubber, a butadiene rubber, a butyl rubber, a chloroprene rubber, a ethylene propylene rubber, a fluorocarbon rubber, a fluorosilicone rubber, a hydrogenated nitrile rubber, an isoprene rubber, a natural rubber, a polyacrylate rubber, a silicone rubber, or combinations thereof. In some embodiments, the external material is an external thermoplastic material. In some embodiments, the external thermoplastic material includes polypropylene (PP), polybutylene terephthalate (PBT), nylon, and combinations thereof.

In some embodiments, a melt temperature of the internal material is less than a melt temperature of the external material. In some embodiments, the melt temperature of the internal material is, is about, is at most, or is at most about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween. In some embodiments, the melt temperature of the external material is, is about, is at least, or is at least about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween. A hardness of the internal material is less than a hardness of the external material. In some embodiments, the Shore A hardness of the internal material is, is about, is at most, or is at most about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween. In some embodiments, the Shore D hardness of the internal material is, is about, is at most, or is at most about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween. In some embodiments, the Shore A hardness of the external material is, is about, is at least, or is at least about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween. In some embodiments, the Shore D hardness of the external material is, is about, is at least, or is at least about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween.

In some embodiments, the coupling device comprises an internal lubricant disposed over the internal material. In some embodiments, the coupling device does not comprise an internal sealant disposed over the internal material. In some embodiments, the internal and external materials are disposed directly over one another. In some embodiments, the coupling device does not comprise an additional material disposed between the internal and external materials.

The coupling device is configured such that it creates a liquid-tight seal that performs at elevated pressures. In some embodiments, the coupling device is able to withstand an internal pressure of, of about, of at least, or at least about, <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi), <NUM> kPa (<NUM> psi) or <NUM> kPa (<NUM> psi), or any range of values therebetween.

The coupling device may be configured to resist degradation. In some embodiments, the coupling device is resistant to degradation due to mechanical damage, aging damage, chemical damage, and combinations thereof. In some embodiments, the device is resistant to degradation from contact with ethylene glycol. In some embodiments, the device is resistant to degradation from contact with automotive coolant.

The coupling device may be configured to attach to a barb, and thereby create a liquid-tight seal. <FIG> shows illustrations of different barb types, including a double barb, single barb and a rounded single barb. <FIG> shows photographs of different barb defect types, including a barb with a dent on the sealing surface, a powder coat defect, a dent on the ramp, and scratches. In some embodiments, the coupling device can create a robust seal on barbs with defect and debris, such as the barbs shown in <FIG> and the defects shown in <FIG>.

<FIG> shows simulated equivalent total strain calculations of a single-material coupling device attached to a barb, and <FIG> shows simulated equivalent total strain calculations of a two-material coupling device attached to a barb. As demonstrated in the comparisons between <FIG> the two-material coupling device shows improved total strain when attached to a barb, thereby creating a more effective liquid-tight seal.

The coupling device may be used to attach to barbs of a cooling system. In some embodiments, the cooling system may be cooling system of a battery system. In some embodiments, the battery system is a battery system of an automotive vehicle. <FIG> is an illustration of coupling devices <NUM> attached to barbs <NUM> of a cooling system <NUM>. The barbs <NUM> of the cooling system <NUM> connect to cooling distributers <NUM>, wherein the coupling devices <NUM> when attached to the barbs <NUM> are configured to allow the barbs <NUM>, the cooling distributers <NUM> and a coolant source (not depicted) to be in fluid communication. Furthermore, coupling devices <NUM> allow for robust liquid-tight seals even when the barbs are misaligned <NUM>. <FIG> is a photograph of coupling devices <NUM> attached barbs <NUM> connected to cooling distributers <NUM> of a battery cooling system <NUM>.

In some embodiments, the plurality of coupling devices are configured to maintain an internal pressure of at least about <NUM> kPa (<NUM> psi) when at least one of the plurality of barbs comprises a defect or debris of, of about, of at most, or of at most about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween. In some embodiments, the plurality of coupling devices are configured to maintain an internal pressure of at least about <NUM> kPa (<NUM> psi) when at least two adjacent barbs of the plurality of barbs are misaligned. In some embodiments, two adjacent barbs of the plurality of barbs are misaligned by, by about, by at least, or by at least about, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, or any range of values therebetween. In some embodiments, the system does not comprise an additional attachment device connecting each of the plurality of coupling devices to the plurality of barbs.

In some embodiments, an automotive vehicle includes the battery coolant system comprising the coupling device. In some embodiments, the automotive vehicle further includes an electric motor.

For example, the terms "approximately," "about," "generally," and "substantially" may refer to an amount that is within less than <NUM>% of, within less than <NUM>% of, within less than <NUM>% of, within less than <NUM>% of, and within less than <NUM>% of the stated amount, depending on the desired function or desired result.

The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.

Claim 1:
A coupling device (<NUM>, <NUM>, <NUM>) comprising:
an internal material (<NUM>);
an external material (<NUM>);
flared ends (<NUM>) connected by a cylindrical intermediary portion (<NUM>), wherein each flared end (<NUM>) comprises:
a distal end (<NUM>);
a medial portion (<NUM>); and
a proximal portion (<NUM>);
wherein an internal angle of the device increases from the proximal portion (<NUM>) to the medial portion (<NUM>), and from the medial portion (<NUM>) to the distal end (<NUM>); and
a hollow interior portion (<NUM>);
wherein a hardness of the internal material (<NUM>) is less than a hardness of the external material (<NUM>).