Non-metallic fluid connector

Abstract

The present invention discloses a non-metallic fluid connector incorporating a current transmission element. The connector is formed by two C-shaped halves of non-metallic, non-conductive material, each half including an integral hinge and latch, or including a hinge and latch made of the same material as the C-shaped halves. A non-metallic, substantially rigid sealing sleeve can be incorporated into the connector to seal the connector while maintaining the strength of the connector.

Description

Technical Field

[0001] The present invention generally relates to coupling assemblies, and more particularly to non-metallic fluid coupling assemblies using a seal sleeve. Background Art

[0002] Coupling assemblies are used in fluid systems within a number of industries such as aerospace. Types of fluid systems include, but are not limited to, fuel systems or waste water systems within an aircraft. Since these systems include a number of tube assemblies that allow fluid transfer, coupling assemblies must be used to connect them together, which must form a secure seal, have minimal flexibility within each joint, and allow electrical current to flow from one tube to the next. Leakage can occur without a proper seal, and in some cases such as fuel or flammable liquids, leakage can lead to catastrophic failure. Electrical current flow requires dissipation of static electricity to prevent formation of sparks inside or near the fluid system.

[0003] Joints within these systems are formed using two fluid tubes that are mechanically attached to a ferrule adapter, a clamshell like coupling, a seal sleeve or body, and two seals such as O-rings. The O-rings are first placed in circumferential grooves on the ferrule adapter. The seal sleeve or body is then slid over the two O-rings. The interface between the O-rings and the seal sleeve provides a radial fluid seal. To prevent the ferrule adapter from pulling apart axially, the clamshell like coupling is placed around the ferrule adapter. The interface between the groove on the ferrule adapter that houses the O-ring and the lip of the retainer half on the coupling provides an axial seal. Due to the hinge and latch mechanism mounted on the coupling, the coupling is able to remain in the closed position.

[0004] Coupling assemblies were made of metal materials in the past. These metal components are heavy, are susceptible to corrosion over time, and may cause problems with the lightning protection capabilities of an aircraft.

[0005] The present invention relates to a seal sleeve and a coupling for an entire coupling assembly. Summary of the Invention

[0006] The present invention is configured to have components made of non-metallic materials, such as plastics, composite materials, polymers, fiberglass, or combinations of these materials. For example, the retainer half can be made of PEEK and have the same interface dimensions as existing metal connectors. The seal sleeve or seal body can also be made of non-metallic materials such as fiberglass and have the same interface dimensions as the metal seal sleeve. Using the same interface dimensions allows for interchangeability between components within a metal connector assembly and the non-metallic components of the present invention. For example, the metal connector in an existing metal connector assembly can be replaced by a non-metallic connector of the present invention, or the metal seal sleeve in an existing metal connector assembly can be replaced by a non-metallic (e.g., fiberglass) seal sleeve as described herein. Depending on the metal or metal alloy of the component to be replaced, replacing existing metal components with components of the present invention can result in a weight savings of up to seventy percent (70%).

[0007] The non-metallic connector retainer half has a semi-cylindrical shape, and when the connector is closed, the connector assembly forms a nearly perfect cylindrical shape. These retainer halves have two lips on opposite sides that are designed to engage with the ferrule adapter lips when the connector is closed. The inner diameter of the connector is slightly larger than the outer diameter of the seal sleeve or seal body such that when the connector is in the closed position, the seal sleeve or seal body can be assembled within the connector both axially and radially.

[0008] A single pin inserted into the hinge can be used to assemble the non-metallic connector retainer halves together. Unlike metal connectors that have many smaller components assembled into the hinge and latch mechanism, both the hinge and latch of the present invention are incorporated into the retainer half to reduce the number of parts and minimize assembly time. When not integrally formed, the hinge and latch of the non-metallic connector are preferably made of the same material as the retainer half. The combination of an integral latch mechanism and hinge mechanism allows the connector to open and close like a "clam shell".

[0009] The sealing sleeve or sealing body can be made of a non-metallic material such as fiberglass, and this component provides a seal between two adjacent tubes, each tube having a ferrule adapter and an O-ring. The sealing sleeve is made of a relatively hard material and / or the final part produced is hard and hardly flexible. Each ferrule adapter has a circumferential groove formed by an inner lip and an outer lip, and this groove allows the O-ring to be located therein. The inner diameter of the sealing sleeve is slightly larger than the outer diameters of the inner lip and the outer lip of the ferrule adapter, so that the sealing sleeve can be installed on the combination of the O-ring and the ferrule adapter to form a fluid-tight seal. The sealing sleeve provides strength in the radial (hoop) direction according to the internal pressure from the fluid system. The combination of the O-ring or seal and the ferrule adapter and the assembly of the sealing sleeve provide flexibility within each joint.

[0010] When the connector closes around the assembled ferrule adapter, sealing sleeve and O-ring, the lips of the ferrule halves engage the outer lip of the ferrule adapter and prevent the two separate ferrule adapters and tubes from separating axially.

[0011] A bonding mechanism that contacts both tubes is used to form one or more electrical contacts across the connector and allows current to flow from one tube to the other. The bonding mechanism is preferably made of a conductive material including but not limited to metal. The bonding mechanism is axially located on the surface of the ferrule halves of the connector to provide contact from one tube to the other. The bonding means is attached to the ferrule halves in such a way that the features of the ferrule halves hold the bonding tab in place and prevent the bonding tab from falling off. Overmolding and / or sonic welding are examples of manufacturing processes that will allow the ferrule halves to hold the bonding tab in place.

[0012] The advantages of the present invention are that non-metallic connectors and sealing sleeves can be used in existing metal connector assembly designs. Prior art connector designs have attempted to replace the ferrule adapter with a flexible sealing sleeve that is connected or attached to the fluid tube using an adhesive or sealant. However, since these designs do not utilize the ferrule adapter and require a change in the sealing sleeve, the interfaces of such prior art connectors are less adaptable and have more problems than those of the present invention. The present invention allows for interchangeability of components with existing metal assemblies, including replacing a metal connector or sealing sleeve with the non-metallic parts of the present invention.

[0013] For a typical metal connector assembly, due to the number of components involved, the latch mechanism and the hinge mechanism can be made of different materials. The present invention combines the latch mechanism and the hinge mechanism into the retainer half, and the hinge mechanism can be made of the same material as the retainer half. The hinge mechanism and the latch mechanism are incorporated into the retainer half by injection molding or a similar manufacturing process. This improvement results in fewer parts and less assembly time. Additionally, the present invention relies on the natural flexibility of a non-metallic material to latch / unlatch the connector in the absence of a metal spring, and since the material is preferably not a flexible material, the sealing sleeve does not flex or hardly flexes. What provides the flexibility or movement in the seal of the present invention is the O-ring or seal and the fit between the sealing sleeve and the ferrule adapter.

[0014] These and other features of the present invention will be best understood with reference to the accompanying drawings and the detailed description of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a perspective view in an oblique view of a first embodiment of a connector of the present invention;

[0016] Figure 2 is Figure 1 a perspective exploded view of the connector of

[0017] Figure 3 is Figure 1 a longitudinal sectional view of the embodiment of

[0018] Figure 4 is Figure 1 an axial sectional view of the embodiment of DETAILED DESCRIPTION OF THE INVENTION

[0019] Figure 1 and Figure 2FIG. 0 shows a first embodiment of the present invention, which includes a fluid conduit coupler 10 that mates a first tube 12 with a second tube 14. Each tube assembly 12, 14 is formed with a ferrule adapter 16 that surrounds the tube end and is used to mate the tubes together as is well known in the art. The coupler 10 is formed by a C-shaped first half 20 and a C-shaped second half 22, which are held together at a first circumferential location by a hinge 24 and releasably closed at a second circumferential location by a latch 26. Four equally spaced engagement means 28 are positioned around the coupler and hold each engagement in place by projecting the bosses 30 of the ferrule halves 20, 22 outwardly onto the outer surface of the ferrule halves. The latch mechanism 26 includes a base 32 that may be integrally formed with the C-shaped second half 22, and two downward-facing barbed projections 34 extend circumferentially from the base 32 toward the half 20. As shown, the half 20 includes a shoulder 36 that receives the barbed projection 34 to latch the second half 22 to the first half 20. In addition, the first half 20 may have a single upward-facing barbed projection 38 that extends circumferentially between the barbed projections 34 in such a way that it can pass through a hole 40 in the base 32 and be captured on a ledge 42. The barbed projections 34, 38 are fixed to the opposite half of the corresponding mating as the diameter of the corresponding half increases, thereby forcing the barbed projections to engage the mating surface with greater force. The halves 20, 22 can be easily released by pressing down on the barbed projection 38 and lifting up on the barbed projection 34 to release contact with the ledge 42 and the shoulder 36, respectively. It should be understood that other connection types are also available and are part of the present invention.

[0020] The components of the hinge 24 and the components of the latch 26 can be integrally formed with the halves 20, 22 of the coupler 10 using a non-metallic material that is molded together during manufacture. That is, the half 20 can be integrally formed as a single unit with a hinge bearing 44, a shoulder 36, and an upward-facing barbed projection 38. Similarly, the half 22 can be integrally formed as a single unit with a hinge bearing 46, a base 32, and a downward-facing barbed projection 34. Only a pin 48 is required to complete the assembly of the coupler 10.

[0021] Figure 3Figure 1 shows a first cross-sectional view of the connector 10, where the first fluid tube 12 and the second fluid tube 14 are joined at their respective ferrule adapters 16. The ferrule adapters 16 are formed with circumferential O-ring grooves 50, 52. Each O-ring groove receives a flexible O-ring (omitted for clarity), which abuts the ferrule adapter 16 and is compressed by the seal sleeve to prevent leakage past the radial seal. Since the hinge 24 and the latch 26 are non-metallic and integral with the connector halves 20, 22, there is no electrical circuit path across the connector that could generate a spark or an electrical short. The connector 10 is assembled over the outer lip of the ferrule adapter 16 and the outer lip of the seal sleeve 54 to capture and seal the mating tubes, thereby providing an axial seal. Due to the assembly of the seal sleeve, the O-ring, and the connector, as well as the O-ring seal, this configuration allows a certain degree of flexure. A seal is formed at the seal sleeve 54 adjacent to the O-ring seal located on the ferrule adapter 16 to prevent radial leakage. In this way, the joint is sealed in both the radial and axial directions, while allowing a certain degree of flexure of the joint.

[0022] Figure 4 Figure 2 shows a side view of the connector 10, which shows the latch 26 in an integral state and the hinge 24 in an integral state. Each half 20, 22 can be made of a non-metallic material, such as a material like plastic, composite material, polymer, fiberglass, or a combination of these materials. For example, the halves 20, 22 can be made of PEEK, and their interface dimensions are the same as those of existing metal connectors. The seal sleeve 54 and the halves 20, 22 can also be made of a non-metallic material such as fiberglass, and their interface dimensions are the same as those of existing metal seal sleeves. The same interface dimensions allow the use of alternative non-metallic connectors to be interchangeable between components within an existing metal connector assembly. For example, as taught by the present invention, the metal connector in an existing metal connector assembly can be replaced with the non-metallic connector of the present invention, or the metal seal sleeve in an existing metal connector assembly can be replaced with a fiberglass seal sleeve.

[0023] In Figure 4 it can be seen that the non-metallic connector halves 20, 22 have a semi-cylindrical or C-shaped form, and when the connector 10 is closed, the connector assembly has an approximately perfect cylindrical shape. The inner diameter of the connector 10 can be slightly larger than the outer diameter of the seal sleeve 54, such that when the connector 10 is in the closed position as shown, the seal sleeve 54 can be assembled within the connector both axially and radially.

[0024] A single pin 48 inserted into hinge 24 at mating structures 44, 46 can be used to assemble the non-metallic coupler retainer halves 20, 22 together. Different from metal couplers that have many smaller components assembled into the hinge and latch mechanism, the hinge 24 and latch 26 of the present invention are both integrally incorporated into the retainer halves and formed as a single unit to reduce the number of parts and minimize the assembly time. In another embodiment, the hinge 24 and latch 26 of the non-metallic coupler 10 are not integral but are made of the same material as the retainer halves 20, 22. The latch 26 and hinge 24 cooperate to open and close the coupler 10 like a "clam shell". Since in the preferred embodiment, the hinge and latch are incorporated into the retainer halves, the retainer halves can be the same as or different from those specified in this application.

[0025] The seal sleeve 54 can be made of a non-metallic material such as fiberglass, and this component provides a seal between two adjacent tubes 12, 14 that both have ferrule adapters 16 and O-rings. The seal sleeve 54 is made of a relatively rigid material and / or the final fabricated member is rigid and hardly flexible. In some other embodiments, the O-ring can be replaced with other seals. The inner diameter of the seal sleeve 54 is slightly larger than the outer diameter of the ferrule adapter lip. The outer and inner lips of the ferrule adapter flange form a groove near the seal sleeve 54, and the O-ring is located in this groove. Thus, the seal sleeve can be installed on the combination of the O-ring and the ferrule adapter 16 to form a fluid-tight seal. The seal sleeve 54 provides strength in the radial (hoop) direction according to the internal pressure from the fluid system. The combination of the O-ring or seals and the ferrule adapter 16 and the assembly with the seal sleeve 54 allows for flexibility within each joint.

[0026] When the coupler 10 is closed around the assembled ferrule adapters 16, seal sleeve 54, and O-rings of the respective tubes 12, 14, the "C" shape profile and flange prevent the two separate ferrule adapters and tubes from separating axially. The force exerted by the retainer halves 20, 22 on the outer lip of the ferrule adapter provides axial strength along the pipeline. The coupler also provides additional sealing in the radial (hoop) direction.

[0027] The coupling mechanism 28 makes contact with and is connected to the swaged ferrules 16 of the tubes 12, 14 and allows current to flow from one tube to the other. The coupling mechanism 28 is made of a conductive material including but not limited to metal. The coupling mechanism 28 is axially positioned on the surfaces of the connector ferrule halves 20, 22 to provide contact from one tube to the other. Although four coupling mechanisms are shown, more or fewer coupling mechanisms may be added or reduced without departing from the scope of the present invention. The coupling mechanisms are attached to their respective ferrule halves in a manner that allows the non-metallic material of the connector 10 to be molded over the coupling means 28 to hold the coupling means in place while allowing electrical contact. The ferrule halves include extruded projections 30 that may have various shapes, sizes, and numbers, and the projections 30 are molded or remolded over the coupling means to hold the coupling means in place.

[0028] Although certain embodiments have been illustrated and described in this disclosure and the drawings, the present invention is not intended to be limited to any particular illustrated or described embodiment. Rather, those of ordinary skill in the art will readily appreciate and understand that many variations and substitutions can be made in the described embodiments, and the scope of the present invention is intended to include all such variations and substitutions. Thus, unless expressly stated otherwise, the scope of the present invention is not limited hereby, and the scope of the present invention is appropriately measured by the appended claims and the plain and ordinary meaning accorded thereto in light of these specifications and the appended Figure 1 drawings.

Claims

1. A fluid connector for connecting a first fluid tube and a second fluid tube, the first fluid tube and the second fluid tube each having a ferrule adapter at their respective mating ends, the connector comprising: a first semi-cylindrical element and a second semi-cylindrical element, the first semi-cylindrical element and the second semi-cylindrical element mating to form a cylindrical connector, the first semi-cylindrical element and the second semi-cylindrical element being formed of a non-metallic material; a first hinge element and a second hinge element, the first hinge element being integrally formed on the respective first semi-cylindrical element, the second hinge element being integrally formed on the respective second semi-cylindrical element, for pivoting the first semi-cylindrical element and the second semi-cylindrical element to open and close the connector; a pin passing through the first hinge element and the second hinge element; a non-metallic sealing sleeve positioned adjacent the ferrule adapter of each fluid tube to seal the connector; a plurality of equi-circumferentially spaced conductive bonding mechanisms formed on the connector and adapted to make electrical contact with the first fluid tube and the second fluid tube when the connector is in a closed position, thereby conducting electricity from the first fluid tube to the second fluid tube, the conductive bonding mechanisms extending from a first lateral edge of one of the first semi-cylindrical element and the second semi-cylindrical element across its outer surface and onto the opposite lateral edge; and a pair of barbed protrusions integrally formed on the first semi-cylindrical element and configured to bend radially inwards onto a shoulder of the second semi-cylindrical element, and a barbed protrusion integrally formed on the second semi-cylindrical element and configured to bend radially outwards onto a latch integrally formed on the first semi-cylindrical element between the pair of barbed protrusions.

2. The connector according to claim 1, wherein, the first semi-cylindrical element and the second semi-cylindrical element are made of a composite material.

3. The connector according to claim 1, wherein, the first semi-cylindrical element and the second semi-cylindrical element are made of a polymer.

4. The connector according to claim 1, wherein, the first semi-cylindrical element and the second semi-cylindrical element are made of plastic.

5. The connector according to claim 1, wherein, the sealing sleeve is made of fiberglass.

6. The connector according to claim 1, wherein, the outer diameter of the sealing sleeve is less than the inner diameter of the semi-cylindrical element such that the sealing sleeve can be positioned within the connector in both axial and radial dimensions.

7. The connector according to claim 1, wherein, the bonding mechanism is attached to a respective C-shaped cylindrical element by molding the material for forming the C-shaped cylindrical element onto the bonding mechanism.

8. The connector according to claim 1, wherein, the connector includes no more than one pin.

9. The connector according to claim 1, wherein, The first hinge element is formed integrally with the first semi-cylindrical element, and the second hinge element is formed integrally with the second semi-cylindrical element to form a first integrally formed portion and a second integrally formed portion.

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