Hydraulic coupling device

Abstract

A coupling device (100) useful for fluidly connecting components of a product, such as a vehicle coolant component, is described. The coupling device can be press fit into a male barb interface, thereby providing a robust, durable, liquid-tight seal and allowing for autonomous factory installation. The coupling device includes an inner material (102), an outer material (104), a flared end (106) connected by a cylindrical middle portion (108), and a hollow inner portion (110), where the hardness of the inner material is less than the hardness of the outer material.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] All applications in which a foreign or domestic priority claim is identified in an Application Data Sheet or request filed with this application are incorporated by reference under 37 CFR 1.57 and Rules 4.18 and 20.6. U.S. Provisional Application No. 63 / 177,568, filed April 21, 2021, is incorporated by reference in its entirety.

[0002] The present invention relates to a coupling device, and more particularly, to a hydraulic coupling device for cooling water system applications, including automotive cooling systems. [Background technology]

[0003] Hoses made from traditional plastic and rubber materials are commonly used for sealing interfaces. However, typical low durometer (i.e., hardness) hoses have low axial stiffness and typical high durometer hoses require high installation forces, making them unsuitable for simple assembly. Furthermore, many typical hoses require hose clamps to provide a reliable seal over their lifespan and / or suffer from geometric changes at the sealing interface and insufficient robustness against mechanical damage or debris.

[0004] Therefore, it may be desirable to create a coupling device that is easy to install and that provides a reliable seal in a variety of environments. Summary of the Invention

[0005] 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. Thus, for example, one skilled in the art will recognize that the invention may be embodied or performed to achieve or optimize one advantage or advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein.

[0006] All of these embodiments are intended to be within the scope of the invention disclosed herein. These and other embodiments will become readily apparent to those of ordinary skill in the art from the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, and the invention is not limited to any particular preferred embodiment disclosed.

[0007] In one aspect, a coupling device is disclosed that includes an inner material, an outer material, flared ends connected by a cylindrical middle portion, and a hollow inner portion, where the inner material has a lower hardness than the outer material.

[0008] In some embodiments, the interior material is an interior thermoplastic material. In some embodiments, the interior thermoplastic material comprises rubber. In some embodiments, the exterior material is an exterior thermoplastic material. In some embodiments, the exterior thermoplastic material is selected from the group consisting of polypropylene (PP), polybutylene terephthalate (PBT), nylon, and combinations thereof. In some embodiments, the melting temperature of the interior material is lower than the melting temperature of the exterior material.

[0009] In some embodiments, the coupling device includes an internal lubricant disposed on the inner material. In some embodiments, the coupling device does not include an internal sealant disposed on the inner material. In some embodiments, the inner material and the outer material are disposed directly on top of one another. In some embodiments, the coupling device does not include an additional material disposed between the inner material and the outer material. In some embodiments, the coupling device can withstand an internal pressure of at least about 30 psi. In some embodiments, the coupling device is resistant to degradation from contact with ethylene glycol.

[0010] In some embodiments, each flared end includes a distal end, an intermediate portion, and a proximal portion, and the interior angle of the device increases from the proximal portion to the intermediate portion and from the intermediate portion to the distal end.

[0011] In some embodiments, a battery cooling water system is disclosed that includes a plurality of battery cooling distributors, a plurality of barbs attached to the cooling distributors, a cooling water source, and a plurality of couplings in fluid communication with each of the plurality of barbs and the cooling water source.

[0012] In some embodiments, the plurality of coupling devices are configured to maintain an internal pressure of at least about 30 psi when at least one of the plurality of barbs includes a defect or debris of up to about 250 μm. In some embodiments, the plurality of coupling devices are configured to maintain an internal pressure of at least about 30 psi when at least two adjacent barbs of the plurality of barbs are misaligned. In some embodiments, the system does not include an additional attachment device connecting each of the plurality of coupling devices to the plurality of barbs.

[0013] In some embodiments, a vehicle is described that includes the battery coolant system. In some embodiments, the vehicle further includes an electric motor. [Brief description of the drawings]

[0014] [Figure 1A]FIG. 1 illustrates a perspective view of an embodiment of a coupling device according to some embodiments.

[0015] [Figure 1B] FIG. 1B is a cross-sectional view of one embodiment of the coupling device of FIG. 1A.

[0016] [Figure 2A] 1 illustrates a cross-sectional view of a coupling device according to some embodiments.

[0017] [Figure 2B] 1 illustrates a cross-sectional view of a coupling device according to some embodiments.

[0018] [Figure 2C] 1 illustrates a cross-sectional view of a coupling device according to some embodiments.

[0019] [Figure 2D] FIG. 2D is a diagram of the exemplary device of FIG. 2C, according to some embodiments.

[0020] [Figure 3A] FIG. 1 is a diagram of different barb types.

[0021] [Figure 3B] Photographs of different barb defect types.

[0022] [Figure 3C] This is a photo of Barb's scratch.

[0023] [Figure 4A] FIG. 13 shows a simulated equivalent total strain calculation of a single material connector attached to a barb.

[0024] [Figure 4B] FIG. 13 illustrates a simulated equivalent total strain calculation of two material coupling devices attached to a barb, according to some embodiments.

[0025] [Diagram 5] 1 illustrates a coupling device attached to a barb of a cooling system according to some embodiments.

[0026] [Figure 6] 1 is a photograph of a coupling device installed in a battery cooling system according to some embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] The present disclosure may be understood by reference to the following detailed description: It should be noted that for clarity of illustration, certain elements of the various drawings may not be drawn to scale and may be represented diagrammatically or conceptually and may not otherwise precisely correspond to certain physical configurations of embodiments.

[0028] Embodiments relate to a coupling device useful for fluidly connecting components of a product, such as vehicle coolant components. The coupling device can be press-fit into a male barb interface, thereby providing a robust, durable, liquid-tight seal. The coupling device seal can be resistant to leakage due to barb damage (such as mechanical damage and / or surface imperfections), debris, and / or radial misalignment of adjacent barbs. The coupling device can enable autonomous factory installation.

[0029] The coupling device may be a cylindrical, multi-layered device having a relatively rigid exterior surface and a flexible interior surface. The ends of the cylindrical device may be flared to accommodate a barbed end that engages with each flared end. When the barbed end of the connector attempts to mate with the coupling device, the barbed end is accommodated by the flared end. The interior material may be flexible so that the barbed end of the connector does not perfectly align with the flared end, but can be moved to the proper mounting position without damage. The rigid exterior surface prevents the flexible interior material from moving or stretching excessively in a particular direction upon contact with the barbed ends.

[0030] In one embodiment, the vehicle is an electric vehicle with an electric motor powered by a battery pack, the battery pack being cooled by a cooling water system. In some embodiments, the cooling water system comprises a battery cooling distributor, a cooling water barb attached to the cooling water distributor, a cooling water source, and a coupling device. In some embodiments, the coupling device is attached to the barb and the cooling water source such that the barb and the cooling water source are in fluid communication.

[0031] FIG. 1A shows a perspective view of one embodiment of a coupling device 100 according to some embodiments, and FIG. 1B shows a cross-sectional view of one embodiment of the coupling device of FIG. 1A. The coupling device 100 is formed from an inner material 102 and an outer material 104 and includes a flared end 106 connected by a cylindrical middle portion 108 and a hollow inner portion 110. The flared end 106 includes a distal end 112, a middle portion 114, and a proximal portion 116. As shown in FIG. 1B, the internal angle of the device (relative to normal) increases from the proximal portion 116 to the middle portion 114, and from the middle portion 114 to the distal end 112. FIGS. 2A-2D show further illustrations of coupling devices according to some embodiments.

[0032] The exterior material is selected to provide durability to the coupling device, and the interior material is selected to provide a robust, durable, liquid-tight seal during use. Additionally, the exterior and interior materials may be selected to bond to one another without delamination issues. In some embodiments, the interior material is an interior thermoplastic material. In some embodiments, the interior thermoplastic material comprises rubber. In some embodiments, the rubber is nitrile rubber, butadiene rubber, butyl rubber, chloroprene rubber, ethylene propylene rubber, fluororubber, fluorosilicone rubber, hydrogenated nitrile rubber, isoprene rubber, natural rubber, polyacrylate rubber, silicone rubber, or combinations thereof. In some embodiments, the exterior material is an exterior thermoplastic material. In some embodiments, the exterior thermoplastic material comprises polypropylene (PP), polybutylene terephthalate (PBT), nylon, and combinations thereof.

[0033] In some embodiments, the melting temperature of the inner material is lower than the melting temperature of the outer material. In some embodiments, the melting temperature of the inner material is, is about, is at, or is at about 70°C, 80°C, 90°C, 100°C, 110°C, 120°C, 130°C, 140°C, 150°C, 160°C, 170°C, 175°C, 180°C, 190°C, 200°C, 225°C, or 250°C, or any range of values ​​therebetween. In some embodiments, the melting temperature of the outer material is, is about, is at, or is at least at, or is at about 100°C, 110°C, 120°C, 130°C, 150°C, 175°C, 200°C, 223°C, 225°C, 250°C, 269°C, 275°C, 300°C, 350°C, or 400°C, or any range of values ​​therebetween. In some embodiments, the hardness of the inner material is less than the hardness of the outer material. In some embodiments, the Shore A hardness of the inner material is, is about, is at, or is up to about 5, 10, 20, 30, 40, 50, 60, 70, 75, 80, 85, 90, 100, or 120, or any range of values ​​therebetween. In some embodiments, the Shore D hardness of the inner material is, is about, is at, or is up to about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, or 70, or any range of values ​​therebetween. In some embodiments, the Shore A hardness of the outer material is, is about, is at least about, or is at least about 90, 100, 110, 120, 130, 140, 150, 160, 180, 200, 225, 250, 275, 300, or 350, or any range of values ​​therebetween. In some embodiments, the Shore D hardness of the outer material is, is about, is at least about, or is at least about 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, or 110, or any range of values ​​therebetween.

[0034] In some embodiments, the coupling device includes an internal lubricant disposed on the inner material. In some embodiments, the coupling device does not include an internal sealant disposed on the inner material. In some embodiments, the inner material and the outer material are disposed directly on top of one another. In some embodiments, the coupling device does not include an additional material disposed between the inner material and the outer material.

[0035] The coupling device is configured to provide a liquid tight seal that functions at high pressures, in some embodiments, the coupling device can withstand an internal pressure of, about, at least, or at least about 10 psi, 20 psi, 22 psi, 24 psi, 26 psi, 28 psi, 30 psi, 35 psi, 40 psi, 45 psi, 50 psi, 60 psi, 80 psi, or 100 psi, or any range therebetween.

[0036] The coupling device may be configured to resist degradation. In some embodiments, the coupling device resists degradation due to mechanical damage, aging damage, chemical damage, and combinations thereof. In some embodiments, the device resists degradation due to contact with ethylene glycol. In some embodiments, the device resists degradation due to contact with automotive coolant.

[0037] The coupling device may be configured to attach to the barb, thereby providing a liquid-tight seal. Figure 3A shows diagrams of different barb types, including a double barb, a single barb, and a round single barb. Figures 3B and 3C show photographs of different barb defect types, including a barb with a dent in the sealing surface, a powder coating defect, a bevel dent, and a scratch. In some embodiments, the coupling device can provide a robust seal with a barb having defects and debris, such as the barb shown in Figure 3A and the defects shown in Figures 3B and 3C.

[0038] Figure 4A shows a simulated equivalent total strain calculation for a single material connector attached to a barb, and Figure 4B shows a simulated equivalent total strain calculation for a two material connector attached to a barb. As demonstrated by a comparison of Figures 4A and 4B, the two material connectors exhibit improved total strain when attached to a barb, thereby providing a more effective liquid-tight seal.

[0039] The coupling device may be used to attach to a barb of a cooling system. In some embodiments, the cooling system may be a cooling system of a battery system. In some embodiments, the battery system is a battery system of an automobile. FIG. 5 is a diagram of a coupling device 502 attached to a barb 504 of a cooling system 500. The barb 504 of the cooling system 500 is connected to a cooling distributor 506, and the coupling device 502 is configured to allow the barb 504, the cooling distributor 506, and a cooling water source (not shown) to be in fluid communication when attached to the barb 504. Additionally, the coupling device 502 allows for a robust liquid-tight seal even when the barb is misaligned (508). FIG. 6 is a photograph of the coupling device 602 attached to a barb 604 connected to a cooling distributor 606 of a battery cooling system 600.

[0040] In some embodiments, the plurality of connectors are configured to maintain an internal pressure of at least about 30 psi when at least one of the plurality of barbs includes a defect or debris of, about, up to, or up to about 100 μm, 150 μm, 200 μm, 225 μm, 250 μm, 275 μm, 300 μm, 350 μm, 400 μm, 450 μm, 500 μm, 600 μm, 800 μm, or 100 μm. In some embodiments, the plurality of connectors are configured to maintain an internal pressure of at least about 30 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 offset by, approximately, at least by, or at least approximately 0.5 cm, 1 cm, 2 cm, 3 cm, 4 cm, 5 cm, 6 cm, 8 cm, 10 cm, 12 cm, 14 cm, 15 cm, or 20 cm, or any range of values ​​therebetween. In some embodiments, the system does not include an additional attachment device connecting each of the plurality of coupling devices to the plurality of barbs.

[0041] In some embodiments, the vehicle comprises a battery cooling water system including the coupling device. In some embodiments, the vehicle further comprises an electric motor.

[0042] Although certain specific embodiments have been described, these embodiments are presented merely as examples and are not intended to limit the scope of the present disclosure. Indeed, the novel methods and systems described herein may be embodied in various other forms. In addition, various omissions, substitutions, and modifications of the systems and methods described herein may be made without departing from the spirit of the present disclosure. The appended claims and their equivalents are intended to cover such forms or modifications as fall within the scope and spirit of the present disclosure.

[0043] It should be understood that features, materials, properties, or groups described in connection with a particular aspect, embodiment, or example are applicable to any other aspect, embodiment, or example described in this section or elsewhere in this specification, unless inconsistent therewith. All of the features disclosed in this specification (including the accompanying claims, abstract, and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations in which at least some of such features and / or steps are mutually exclusive. Protection is not limited to the details of any of the foregoing embodiments. Protection extends to any novel, or any novel combination of features disclosed in this specification (including the accompanying claims, abstract, and drawings), or any novel, or any novel combination of steps of any method or process so disclosed.

[0044] Moreover, certain features described in this disclosure in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, although features may be described above as acting in a certain combination, one or more features from a claimed combination can, in some cases, be deleted from the combination, and the combination can be claimed as a subcombination or a variation of the subcombination.

[0045] Furthermore, although operations may be shown in the figures or described herein in a particular order, such operations need not be performed in the particular order shown, or in sequential order, or all operations need not be performed to achieve desirable results. Other operations not shown or described may be incorporated into the exemplary methods and processes. For example, one or more additional operations may be performed before, after, simultaneously with, or between any of the described operations. Furthermore, operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps performed in the illustrated and / or disclosed processes may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be omitted, and other steps may be added. Furthermore, the features and attributes of certain embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, it should be understood that the separation of various system components in the above implementations should not be understood to require such separation in all implementations, and the described components and systems may generally be integrated together in a single product or packaged in multiple products. For example, any of the components of the energy storage system described herein may be provided separately or may be integrated (e.g., packaged together or attached together) to form an energy storage system.

[0046] For purposes of this disclosure, certain aspects, advantages, and novel features have been described herein. Not all such advantages may necessarily be achieved in accordance with any particular embodiment. Thus, for example, one skilled in the art will recognize that the present disclosure may be embodied or performed to achieve one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

[0047] Conditional language such as "can," "could," "might," or "may," unless otherwise specified or understood otherwise within the context in which it is used, is generally intended to convey that certain embodiments include certain features, elements, and / or steps, while other embodiments do not. Thus, such conditional language is generally not intended to imply that features, elements, and / or steps are in any way required by one or more embodiments, or that one or more embodiments necessarily include logic for determining whether those features, elements, and / or steps should be included in or performed in any particular embodiment, with or without user input or prompting.

[0048] Conjunctions such as the phrase "at least one of X, Y, and Z," unless otherwise noted, are understood in the context in which they are generally used to convey that an item, term, etc. can be either X, Y, or Z. Thus, such conjunctive language is generally not intended to imply that a particular embodiment requires the presence of at least one of X, at least one of Y, and at least one of Z.

[0049] As used herein, language of degree, such as "approximately," "about," "generally," and "substantially," describes a value, amount, or characteristic that is close to a stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms "approximately," "about," "generally," and "substantially" can refer to amounts that are less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of the stated amount, depending on the desired function or result.

[0050] The scope of the present disclosure is not intended to be limited by the specific disclosure of preferred embodiments in this section or elsewhere herein, but may be defined by the claims, as presented in this section or elsewhere herein, or as presented in the future. The language of the claims should be interpreted broadly based on the language used in the claims, and not limited to the examples described herein or during the prosecution of this application, and the examples should be interpreted as non-exclusive.

[0051] The headings provided herein, if any, are for convenience only and do not necessarily affect the scope or meaning of the devices and methods disclosed herein.

Claims

1. The internal materials and External material; flared ends connected by a cylindrical intermediate portion, each of said flared ends comprising: A distal end portion. The middle part, a proximal portion; a flared end, the interior angle of the device increasing from the proximal portion to the intermediate portion and from the intermediate portion to the distal end; a hollow interior portion; A coupling device, wherein the inner material has a lower hardness than the outer material.

2. The device of claim 1 , wherein the interior material is an interior thermoplastic material.

3. The apparatus of claim 2 , wherein the inner thermoplastic material comprises rubber.

4. 4. The device of claim 1, wherein the outer material is an outer thermoplastic material.

5. 5. The device of claim 4, wherein the exterior thermoplastic material is selected from the group consisting of polypropylene (PP), polybutylene terephthalate (PBT), nylon, and combinations thereof.

6. 4. The device of claim 1, wherein the inner material has a melting temperature that is lower than the melting temperature of the outer material.

7. The apparatus of claim 1 , wherein the coupling device includes an internal lubricant disposed on the internal material.

8. The apparatus of claim 1 , wherein the coupling device does not include an internal sealant disposed over the internal material.

9. 4. The device of claim 1, wherein the inner and outer materials are disposed directly on top of one another.

10. The device of claim 1 , wherein the connecting device does not include an additional material disposed between the inner material and the outer material.

11. 4. The apparatus of claim 1, wherein the coupling device is capable of withstanding an internal pressure of at least about 30 psi.

12. 4. The apparatus of claim 1, wherein the coupling device is resistant to degradation from contact with ethylene glycol.

13. A plurality of battery cooling distributors; a plurality of barbs attached to the cooling distributor; A cooling water source; 13. A battery cooling water system comprising: a plurality of coupling devices as defined in claim 1 in fluid communication with each of the plurality of barbs and the cooling water source.

14. 14. The system of claim 13, wherein the plurality of coupling devices are configured to maintain an internal pressure of at least 30 psi when at least one of the plurality of barbs contains a defect or debris up to 250 μm.

15. 14. The system of claim 13, wherein the plurality of coupling devices are configured to maintain an internal pressure of at least 30 psi when at least two adjacent barbs of the plurality of barbs are misaligned.

16. 16. The system of claim 13, wherein the system does not include additional attachment devices connecting each of the plurality of coupling devices to the plurality of barbs.

17. A motor vehicle comprising a battery cooling water system according to any one of claims 13 to 15.

18. 20. The vehicle of claim 17, further comprising an electric motor.

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