Patent Description:
The present disclosure relates to flexible hose assemblies for fluid containment and transfer under a variety of pressures and temperatures between two points, and to methods of making such hose assemblies. More particularly, the disclosure relates to multi-layer or "hybrid" flexible hose assemblies having a first layer providing a first property (e.g., cleanability) and a second layer providing a second property (e.g., gas impermeability).

Documents <CIT>, <CIT>, <CIT> and <CIT> relate to hose assemblies of the prior art. Summary of the Disclosure.

According to an aspect of the invention a hose assembly is provided as set out in claim <NUM>.

According to another aspect of the invention a method of making a hose assembly is provided as set out in claim <NUM>.

According to another aspect of the invention a method of using a hose assembly is provided as set out in claim <NUM>.

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 application 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). In addition to flexibility, different hose properties may be a consideration for use in a particular fluid system, including, for example, system temperature, system pressure, chemical compatibility, resistance to contamination, and gas permeability. In some applications, a multi-layer or "hybrid" flexible hose may be provided with an inner core tube providing a desired first property, and an outer tube providing a desired second property. While the inner and outer tubes may be laminated or otherwise attached to each other, in some embodiments, the inner and outer tubes may be separate from each other, and even radially spaced apart from each other, for example, to facilitate assembly or function of the hose.

<FIG> illustrates an exemplary prior art hose assembly <NUM> including a plastic inner core tube <NUM> and a corrugated metal outer tube <NUM>, described in greater detail in European Patent Publication No. <CIT> (the "'<NUM> Patent"). An end portion <NUM> of the inner core tube <NUM> is installed over a nose portion <NUM> of a coupling member <NUM> and a collar <NUM> is installed over the inner core tube end portion to radially clamp the core tube end portion <NUM> between against the coupling member <NUM> to form a connector <NUM> secured to the inner core tube end portion. A flange portion <NUM> of the coupling member is welded (e.g., an orbital weld) at Wi to an outboard flange portion <NUM> of the collar <NUM>, and an end portion <NUM> of the metal outer tube <NUM> is welded (e.g., an orbital weld) at to an inboard flange portion <NUM> of the collar <NUM>. Another exemplary dual layer hybrid hose arrangement is described in co-owned <CIT> (the "'<NUM> Patent").

In a dual layer hybrid hose arrangement (e.g., the hose of the '<NUM> Patent), the plastic inner core tube may be selected for superior fluid compatibility, and the corrugated metal outer tube may be selected for gas impermeability (e.g., less than about <NUM>×<NUM>-<NUM> scc/sec or between about <NUM>×<NUM>-<NUM> scc/sec and about <NUM>×<NUM>-<NUM> scc/sec), to compensate for the relatively higher gas permeability (e.g., greater than about <NUM>×<NUM>-<NUM> scc/sec, or between about <NUM>×<NUM>-<NUM> scc/sec and about <NUM>×<NUM>-<NUM> scc/sec) of the inner core tube. For example, the inner core tube may include at least one of polytetrafluoroethylene (PTFE) or perfluoroalkoxy alkane (PFA), and the metal outer tube may include stainless steel (e.g., <NUM> SS).

In a hybrid hose assembly having a more permeable inner core tube and a less permeable outer tube, certain challenges may result from permeation of system fluid through the wall of the inner core tube into an outer annular cavity between the inner core tube and the outer tube. For example, in applications where pressurized gas has permeated into the outer annular cavity, rapid depressurization of the interior hose passage may result in inward compression or collapse of the inner core tube by the pressurized gas in outer annular cavity. As another example, in applications where the hose is used with a first pressurized gas that has permeated into the outer annular cavity, and is subsequently used with a second fluid, the first pressurized gas may permeate through the wall of the inner core tube into the inner hose passage, contaminating the second fluid.

According to an aspect of the present disclosure, an outer tube of a dual layer hybrid hose may be provided with (e.g., integrally formed with or connected to a component having) one or more vent ports to permit controlled venting or evacuation of any fluid in the radial space or outer annular cavity between the inner core tube and the outer tube of the hose, for example, due to permeation of pressurized gas within the interior hose passage through the gas permeable inner core tube into the outer cavity of the hose. This venting or evacuation of the pressurized gas from the outer cavity may prevent inward compression or collapse of the inner core tube when the interior hose passage is rapidly depressurized, and may prevent contamination of a gas fluid within the interior hose passage by a pressurized second gas fluid remaining in the outer cavity of the hose (e.g., from a prior hose application) and permeating inward through the wall of the inner core tube.

In one such arrangement, as shown in <FIG>, a dual layer hybrid hose <NUM>, having a plastic inner core tube <NUM> and a corrugated metal outer tube <NUM>, includes a welded coupling connection <NUM> provided with a venting port <NUM>. Similar to the embodiment shown in <FIG> and described above and in the above '<NUM> Patent, the welded coupling connection <NUM> includes a collar <NUM> welded to the metal outer tube <NUM>, and a coupling member <NUM> secured to the collar (e.g., welded) for clamping retention of the first end <NUM> of the inner core tube <NUM> between an outboard clamping portion <NUM> of the collar <NUM> and a nose portion <NUM> of the coupling member <NUM>, which is inserted into the inner core tube first end <NUM>. The end of the nose portion <NUM> may be narrowed or tapered to facilitate insertion and flaring of the core tube end <NUM>. In the illustrated example, a flange portion <NUM> of the coupling member <NUM> is secured (e.g., orbital weld at w1) to an outboard flange portion <NUM> of the collar <NUM>.

In the illustrated embodiment, an outboard end 137a of the outboard clamping portion <NUM> of the collar <NUM> has a first inner diameter d1 sized to accommodate the flared first end <NUM> of the inner core tube <NUM>, and an inboard end 137b of the outboard clamping portion includes a radially inward protrusion <NUM> having a second inner diameter d2 smaller than the first inner diameter d1 and sized to impede withdrawal of the flared first end of the inner core tube from the collar. The venting port <NUM> is disposed on an inboard venting portion <NUM> of the collar that has a third inner diameter d3 larger than the second inner diameter d2 and sized to permit fluid flow between the venting port <NUM> and an outer annular cavity C between the inner core tube <NUM> and the metal outer tube <NUM>, for example, by maintaining at least a minimal gap between the collar venting portion <NUM> and the inner core tube <NUM>. The venting port <NUM> may include a tube stub <NUM> or other connector (e.g., integrally formed with or welded to the collar <NUM>) to facilitate connection of the venting port to a purge line <NUM>, for example to apply a vacuum (e.g., any pressure lower than the outer cavity pressure) to the outer cavity C through the venting port <NUM>, or to supply a purge gas to the outer cavity through the venting port. As shown, an inboard end 147b of the venting portion <NUM> includes a weld end <NUM> (e.g., flange) sized to facilitate welding (at w2) to the end portion <NUM> of the metal outer tube <NUM> (e.g., to an outer corrugation of the corrugated metal tube).

In an exemplary method of producing a vented hybrid hose assembly <NUM>, the weld end <NUM> of the collar <NUM> is welded to the end portion <NUM> of the metal outer tube <NUM> (e.g., orbital welding). The inner core tube <NUM> is installed through the metal outer tube <NUM>, such that a first end of the inner core tube is aligned with an outboard portion 137a of the collar <NUM> (e.g., at a location 137c corresponding to the outboard end of the installed nose portion <NUM>), with an outer cavity C disposed between the inner core tube and the metal outer tube and in fluid communication with the venting port. The nose portion <NUM> of the coupling member <NUM> is inserted into the first end <NUM> of the inner core tube <NUM>, bringing the flange portion <NUM> of the coupling member <NUM> into abutment with the outboard flange portion <NUM> of the collar <NUM>, such that the core tube first end is flared into clamping retention between the nose portion <NUM> and the outboard clamping portion <NUM> of the collar <NUM>. The flange portion <NUM> of the coupling member <NUM> is then welded to the outboard flange portion <NUM> of the collar <NUM>.

While the clamping and venting portions <NUM>, <NUM> of the collar <NUM> may be integrally formed in a single monolithic collar component, as shown in <FIG>, in other embodiments, a collar may be formed by a clamping member secured to (e.g., welded to) a venting adapter, for example, to facilitate manufacturing or formation of the clamping and venting portions of the collar.

In the illustrated embodiment of <FIG>, a dual layer hybrid hose <NUM>, having a plastic inner core tube <NUM> and a corrugated metal outer tube <NUM>, includes a welded coupling connection <NUM> having a collar <NUM> formed from a clamping member <NUM> defining an outboard clamping portion <NUM>, radially inward protrusion <NUM>, and outboard flange portion <NUM> of the collar <NUM>, and a venting adapter <NUM> defining an inboard venting portion <NUM>, venting port <NUM>, and weld end flange <NUM> welded (e.g., an orbital weld at w2) to the end portion <NUM> of the metal outer tube <NUM> (e.g., to an outer corrugation of the corrugated metal tube). In the illustrated example, the venting adapter <NUM> includes an outboard end portion (e.g., flange) <NUM> welded (e.g., an orbital weld at w3) to an inboard end portion (e.g., flange) <NUM> of the clamping member <NUM>.

Similar to the embodiments of <FIG> and <FIG>, a coupling member <NUM> is secured (e.g., welded) to the collar (for clamping retention of the first end <NUM> of the inner core tube <NUM> between the outboard clamping portion <NUM> of the collar <NUM> and a nose portion <NUM> of the coupling member <NUM>, which is inserted into the inner core tube first end <NUM>. The end of the nose portion <NUM> may be narrowed or tapered to facilitate insertion and flaring of the core tube end <NUM>. In the illustrated example, a flange portion <NUM> of the coupling member <NUM> is secured (e.g., orbital weld at w1) to the outboard flange portion <NUM> of the collar <NUM>.

In the illustrated embodiment, an outboard end 237a of the outboard clamping portion <NUM> of the clamping member <NUM> has a first inner diameter d1 sized to accommodate the flared first end <NUM> of the inner core tube <NUM>, and an inboard end 237b of the outboard clamping portion includes a radially inward protrusion <NUM> having a second inner diameter d2 smaller than the first inner diameter d1 and sized to impede withdrawal of the flared first end of the inner core tube from the collar. The inboard venting portion <NUM> of the venting adapter <NUM> has a third inner diameter d3 larger than the second inner diameter d2 and sized to permit fluid flow between the venting port <NUM> and an outer annular cavity C between the inner core tube <NUM> and the metal outer tube <NUM>, for example, by maintaining at least a minimal gap between the venting portion <NUM> and the inner core tube <NUM>. The venting port <NUM> may include a tube stub <NUM> (e.g., integrally formed with or welded to the venting adapter <NUM>) or other connector to facilitate connection of the venting port to a purge line <NUM>, for example to apply a vacuum (e.g., any pressure lower than the outer cavity pressure) to the outer cavity C through the venting port <NUM>, or to supply a purge gas to the outer cavity through the venting port.

In an exemplary method of producing a vented hybrid hose assembly <NUM>, the outboard end portion <NUM> of the venting adapter <NUM> is welded to the inboard end portion <NUM> of the clamping member <NUM> to form the welded collar assembly <NUM>. The weld end <NUM> of the venting adapter <NUM> is welded to the end portion <NUM> of the metal outer tube <NUM>, and the inner core tube <NUM> is installed through the metal outer tube <NUM>, such that a first end <NUM> of the inner core tube is aligned with the outboard portion 237a of the clamping member <NUM> (e.g., at a location 237c corresponding to the outboard end of the installed nose portion <NUM>), with an outer cavity C disposed between the inner core tube and the metal outer tube and in fluid communication with the venting port. The nose portion <NUM> of the coupling member <NUM> is inserted into the first end <NUM> of the inner core tube <NUM>, bringing the flange portion <NUM> of the coupling member <NUM> into abutment with the outboard flange portion <NUM> of the clamping member <NUM>, such that the core tube first end <NUM> is flared into clamping retention between the nose portion <NUM> and the outboard clamping portion <NUM> of the clamping member <NUM>. The flange portion <NUM> of the coupling member <NUM> is then welded to the outboard flange portion <NUM> of the clamping member <NUM>.

In use, to evacuate pressurized gas fluid from the outer cavity C of the hose assembly <NUM>, <NUM> (e.g., in advance of depressurization of the interior hose passage P, or prior to using the hose with a different gas fluid), the venting port <NUM>, <NUM> may be connected to a purge line <NUM>, <NUM> (e.g., hose or tube), for example, to permit release of the pressurized gas (e.g., to atmospheric or vacuum pressure) or to provide continuous evacuation of pressurized gas fluid from the outer cavity C. In another arrangement, a purge gas may be applied to the venting port <NUM>, <NUM>, with the purge gas passing through the length of outer cavity for evacuation the fluid through a venting port at an opposite end of the hose <NUM>, <NUM> (e.g., through a venting port in a collar portion of a weld connector on the opposite end of the metal outer tube). The venting port <NUM>, <NUM> may be plugged when not needed (e.g., in low pressure gas service), and may include any suitable end connector, including, for example, a tube butt weld joint (as shown) or a tube fitting connection. While the illustrated embodiment shows a single venting port <NUM>, in other embodiments, more than one venting port may be provided.

Claim 1:
A hose assembly (<NUM>, <NUM>) comprising:
an inner core tube (<NUM>, <NUM>);
a first coupling member (<NUM>, <NUM>) having an inboard nose portion (<NUM>, <NUM>) extending into a flared first end (<NUM>, <NUM>) of the inner core tube;
a metal outer tube (<NUM>, <NUM>) surrounding the inner core tube and terminating at a first end (<NUM>, <NUM>) axially inward of the first end of the inner core tube, with an outer cavity (C) disposed between the inner core tube and the metal outer tube; and
a first collar (<NUM>, <NUM>) having:
an outboard clamping portion (<NUM>, <NUM>) surrounding the nose portion for clamping retention of the first end of the inner core tube therebetween; and
an inboard venting portion (<NUM>, <NUM>) welded to the first end of the metal outer tube, the inboard venting portion including a venting port (<NUM>, <NUM>) in fluid communication with the outer cavity;
wherein:
an outboard end (137a, 237a) of the outboard clamping portion has a first inner diameter (d1) sized to accommodate the flared first end of the inner core tube;
an inboard end (137b, 237b) of the outboard clamping portion includes a radially inward protrusion (<NUM>, <NUM>) having a second inner diameter (d2) smaller than the first inner diameter and sized to impede withdrawal of the flared first end of the inner core tube from the first collar; and
the inboard venting portion has a third inner diameter (d3) larger than the second inner diameter and sized to permit fluid flow between the outer cavity and the venting port.