Improved end connector having a smooth stem overlap region and a smooth ferrule overlap region

Abstract

An end connector and hose assembly. The end connector, in one embodiment, includes a stem having a smooth stem overlap region formed in a stem outer diameter (ODS), as well as (N) seal grooves for sealing elements formed in the stem outer diameter (ODS). In one aspect, the seal grooves have a seal groove width (LS6), wherein a ratio of (LS6 x N) / ODS5 is at least 0.05.

Description

IMPROVED END CONNECTOR HAVING A SMOOTH STEM OVERLAP REGION AND A SMOOTH FERRULE OVERLAP REGIONCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Application Serial No. 63 / 691,423, filed on September 6, 2024, entitled “IMPROVED END CONNECTOR HAVING A SMOOTH STEM OVERLAP REGION AND A SMOOTH FERRULE OVERLAP REGION,” commonly assigned with this application and incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] This application is directed, in general, to an end connector for a hose, a hose assembly, and a method for manufacturing a hose assembly.BACKGROUND

[0003] Hose assemblies (e.g., high pressure hoses capable of withstanding pressures up to 69 MPa and above) are employed in many industries, but find particularly important use in the mining, construction, energy, marine and petrochemical industries. These industrial applications typically require the use of the hose assembly to transfer fluids from one component to another, while enduring the operational conditions associated with these industries. The hose assemblies often comprise one or more end connectors coupled to a hose, the end connectors allowing the hose assembly to be quickly coupled and decoupled to and from the operational equipment that the hose assembly is intended to be used with. While the hose material itself can be manufactured to withstand the operational wear, high pressures and / or temperatures, the point of failure of the hose assembly often occurs where the end connectors attached to the hose. Even when a hose is crimped tightly onto the hose, failure can still occur, which can result in operational failure of the hose assembly.

[0004] One application for the use of these hose assemblies is in the drilling industry. A hose assembly including a flexible rubber hose runs between the pump piping system on the rig and the kelly that is coupled to the rotating drill string. In such applications, the hose assembly is subjected to high pressures and / or high frequency of pressure cycles. The high pressure is required to transfer drilling fluid into the wellbore and overcome static return head pressures. Ultimately, the deeper the wellbore, the higher the pressure. The hose assembly is also subject to further stresses in thatit hangs down within the derrick supported at either end by the end connector. Moreover, the fact that the kelly is moved up and down literally thousands of times during the drilling operation presents additional hurdles. This can result in the hose assembly being subjected to stress at the end connector (in addition to being subject to stress throughout its length). If the hose assembly breaks, circulation may be lost resulting in a well blowout situation. Thus, a highly reliable coupling between the hose and the end connectors is required for protection of personnel and equipment.BRIEF DESCRIPTION

[0005] Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0006] FIGs. 1A through 1C illustrate various different cross-sectional views of a stem, for example as might form part of an end connector for a hose, designed, manufactured and / or operated according to one or more embodiments of the disclosure;

[0007] FIGs. 2A and 2B illustrate various different cross-sectional views of a ferrule, for example as might form pail of an end connector for a hose, designed, manufactured and / or operated according to one or more embodiments of the disclosure;

[0008] FIG. 3 illustrates a cross-sectional view of an end connector, for example as might be used with a hose, designed, manufactured and / or operated according to one or more embodiments of the disclosure;

[0009] FIGs. 4A and 4B illustrate various different cross-sectional views of the end connector of FIG. 3 having a hose (e.g., reinforced hose) positioned within its cavity;

[0010] FIG. 5 illustrates a cross-sectional view of the end connector and hose of FIGs. 4A and 4B after a ferrule forming process (e.g., first and second ferrule forming process) and an optional expansion process have been conducted, thereby forming a completed hose assembly; and

[0011] FIG. 6 illustrates a cross-sectional view of a hose assembly designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure.DETAILED DESCRIPTION

[0012] In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale orin somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.

[0013] Various values and / or ranges are explicitly disclosed in certain embodiments herein. However, values / ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited. Similarly, values / ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited. In the same way, values / ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. Similarly, an individual value disclosed herein may be combined with another individual value or range disclosed herein to form another range and / or ratio.

[0014] The embodiments of this disclosure are directed to an improved end connector of a hose assembly (e.g., high-pressure reinforced hose assembly). The improved end connector, in one or more embodiments, may be employed for a hose assembly subjected to high frequency pressure cycles. The improved end connector, in one or more embodiments, provides for a low compression deformation of the hose while attaching the improved end connector to the hose. The disclosed low compression deformation is configured to reduce the occurrence of failure that can occur at the point where the reinforced hose is attached to the end connector. As used herein, “attached” or “attaching” means a process of slipping the end connector over the hose, and thereafterplastically deforming the end connector to bind the end connector with the hose. Tn at least one embodiment, the process of attaching includes known swaging, crimping and expanding processes, among others.

[0015] The embodiments of this disclosure provide a unique end connector that includes a unique stem and a unique ferrule that couple together to form the end connector. The stem, in at least one embodiment, includes a stem outboard end and stem inboard end separated by a stem length (Lso), a stem outer diameter (ODs), a stem inner diameter (IDs), the stem inner diameter (IDs) defining a fluid passageway between the stem outboard end and the stem inboard end. The stem, in at least this one embodiment, additionally includes a stem reinforcement anchor region formed in the stem outer diameter (ODs) between the stem outboard end and the stem inboard end, the stem reinforcement anchor region having a first stem length (Lsi). The stem, according to this embodiment, further includes a smooth stem overlap region formed in the stem outer diameter (ODs) between the stem reinforcement anchor region and the stem inboard end, the smooth stem overlap region having a second stem length (Ls2) entirely free of protrusions. The phrase “entirely free of protrusions,” as used herein, means that the region is free of any raised or recessed feature (e.g., including teeth, barbs, bumps, flutes, lands, spines, etc., and excluding grooves for sealing elements) that have a purpose or intent of preventing a hose located within the end connector of axially moving therein. Along this smooth second stem length region, the stem OD surface is parallel with the longitudinal axis of the hose / fitting + / - 0.01 degree. However, the surface is also considered free of protrusions even though there might be small or microscopic manufacturing imperfections in the surface (e.g., surface roughness) that can result from a manufacturing process. In at least one embodiment, other than the grooves for sealing elements, the smooth stem overlap region has a surface roughness no greater than 1 mm, if not no greater than 50 pm, if not no greater than 10 pm, if not no greater than 3.2 pm. The stem, in accordance with this one embodiment, further includes one or more grooves for sealing elements formed in the stem outer diameter (ODs) of the smooth stem overlap region, again these one or more grooves allowed while the smooth stem overlap region remains free of protrusions.

[0016] The ferrule, in at least one embodiment, is coupled to the stem at a coupling point, and includes a ferrule outboard end and ferrule inboard end separated by a ferrule length (LFO), and a ferrule outer diameter (ODF) and a ferrule inner diameter (IDF). The ferrule, in at least this one embodiment, further includes a ferrule reinforcement anchor region formed in the ferrule innerdiameter (IDF) between the ferrule outboard end and the ferrule inboard end, the ferrule reinforcement anchor region having a first ferrule length (LFI). The ferrule, in accordance with this embodiment, further includes a smooth ferrule overlap region formed in the ferrule inner diameter (IDF) between the ferrule reinforcement anchor region and the ferrule inboard end, the smooth ferrule overlap region having a second ferrule length (LFI) entirely free of protrusions. In one or more embodiments, the smooth ferrule overlap region at least partially radially aligns with the smooth stem overlap region. In at least this one embodiment, the stem outer diameter (ODs) and ferrule inner diameter (IDF) form a cavity that extends from the coupling point to the ferrule inboard end, the cavity configured to receive an end of a hose therein.

[0017] The present disclosure, having spent many hundreds of hours of research, development, and experimentation, is the first to conclude that various dimensions of the stem and / or ferrule must be precisely matched, for example based upon a size of the hose that one intends to make up the hose assembly, to accomplish the desires set forth herein (e.g., a hose assembly that can handle the ever increasing number of high frequency pressure cycles). It is these newly determined dimensions, and various ratios thereof, that provide an end connector and / or hose assembly that is capable of withstanding the high frequency pressure cycles disclosed above. While a variety of newly determined dimensions are disclosed herein to provide the end connector and / or hose assembly that is capable of withstanding the high frequency pressure cycles disclosed above, in certain embodiments it is the ratio of two or more determined dimensions and or multiple different ratios of two or more determined dimensions that provides significant results.

[0018] Turning to FIGs. 1A through 1C, illustrated are various different cross-sectional views of a stem 100, for example as might form part of an end connector for a hose, designed, manufactured and / or operated according to one or more embodiments of the disclosure. The stem 100, in the illustrated embodiment, includes a stem outboard end 110 and stem inboard 115, for example separated by a stem length (Lso). The stem 100, in the illustrated embodiment, additionally includes a stem outer diameter (ODs) and a stem inner diameter (IDs), the stem inner diameter (IDs) defining a fluid passageway 118 between the stem outboard end 110 and the stem inboard end 115.

[0019] In one or more embodiments, the stem 100 may be broken into a number of different regions. For example, in one or more embodiments, the stem 100 includes a stem reinforcement anchor region 120 and a smooth stem overlap region 150. In certain embodiments, the stem 100may additionally include a stem outer overlap region 180, and a stem exposed region 190. In at least one embodiment, the stem reinforcement anchor region 120 is formed in the stem outer diameter (ODs) between the stem outboard end 110 and the stem inboard end 115. In the disclosed embodiment, the stem reinforcement anchor region 120 includes a first stem length (Lsi), a first stem outer diameter (ODsi), a first stem inner diameter (IDsi), and a first stem thickness (Tsi).

[0020] In the illustrated embodiment, the stem reinforcement anchor region 120 is not free of protrusions, but in contrast includes one or more stem engaging features 125 (e.g., teeth, barbs, bumps, flutes, lands, spines, etc.) that are configured to prevent a hose located within the end connector from axially moving therein. The number, size, period, etc. of the stem engaging features 125 may vary greatly and remain within the scope of the disclosure. For example, the number, size, period, etc. of the stem engaging features 125 may vary greatly, for example based upon what type of hose is coupling with the stem 100, including cable, wire, or other reinforcement type hoses.

[0021] In at least one embodiment, the stem engaging features 125 include a stem tooth width (Wst) and a stem tooth depth (Dst). The present disclosure has determined, for example through extensive testing, that a ratio of the stem tooth width (Wst) to diameter of the reinforcement wire used in the hose (dr) (e.g., Wst I dr), is quite important to the design of the stem 100. In at least one embodiment, Wst / drranges from 0.1 to 1.2. In yet another embodiment, Wst I drranges from 0.15 to 1.0, and in even yet another embodiment Wst / drranges from 0.25 to 0.75. The present disclosure in yet another embodiment has determined, for example through extensive testing, that a ratio of the stem tooth depth (Dst) to diameter of the reinforcement wire used in the hose (dr) (e.g., Dst / dr), is quite important to the design of the stem 100. In at least one embodiment, Dst I drranges from 0.05 to 1.3. In yet another embodiment, Dst / drranges from 0.1 to 1.2, and in even yet another embodiment Dst / drranges from 0.25 to 0.9.

[0022] The smooth stem overlap region 150, in the illustrated embodiment, is formed in the stem outer diameter (ODs) between the stem reinforcement anchor region 120 and the stem inboard end 115. In at least one embodiment, the smooth stem overlap region 150 has a second stem length (LS2) entirely free of protrusions. In yet another embodiment, the smooth stem overlap region 150 may be broken into a first stem overlap region 155a located between the stem reinforcement anchor region 120 and the stem inboard end 115, and a second stem overlap region 155b located between the first stem overlap region 155a and the stem inboard end 115.

[0023] The first stem overlap region 155a, in one or more embodiments, includes first and second end lengths (Ls3a, Ls3b), a seal region length (Ls4), a seal region outer diameter (ODs4), a seal region inner diameter (IDs4), and a seal region thickness (Ts4). In at least one embodiment, the first stem overlap region 155a additionally includes a liner dam 157, as well as one or more seal grooves 160 having one or more seals 165 therein, such one or more elastomeric “O” rings. The number (N), size, pitch, etc. of the one or more seal grooves 160 and one or more seals 165 may vary greatly and remain within the scope of the disclosure. Nevertheless, in at least one embodiment, the first stem overlap region 155a includes N (number) seal grooves 160 and seals 165, wherein N rages from one to thirty seal grooves 160 and seals 165, if not from two to sixteen seal grooves 160 and seals 165, if not from three to ten seal grooves 160 and seals 165. Moreover, in at least one embodiment, the seal grooves 160 having a seal width (Lse), and a seal groove spacing (Lsv). Further to the embodiment shown, the seals 165 may have a seal radial offset (OSR).

[0024] The second stem overlap region 155b, in one or more embodiments, includes a second stem overlap region length (Lss), a second stem overlap region outer diameter (ODss), a second stem overlap region inner diameter (IDss), and a second stem overlap region thickness (Tss).

[0025] The stem outer overlap region 180, in the illustrated embodiment, is formed between the stem reinforcement anchor region 120 and the stem outboard end 110. The stem outer overlap region 180, in one or more embodiments, includes a stem outer overlap region length (Lss), a stem outer overlap region outer diameter (ODss), a stem outer overlap region inner diameter (IDss), and a stem outer overlap region thickness (Tss).

[0026] The stem exposed region 190, in the illustrated embodiment, is formed between the stem outer overlap region 180 and the stem outboard end 110. The stem exposed region 190, in one or more embodiments, includes a stem exposed region length (Lsg), a stem exposed region outer diameter (ODsg), a stem exposed region inner diameter (IDsg), and a stem exposed region thickness (TS9).

[0027] The present disclosure has determined, for example through extensive testing, that a ratio of the seal groove width (Lse) times the number of seals 165 in relation to the second stem overlap region outer diameter (ODss) (e.g., (Lse x N) / ODss) is at least 0.05. In yet another embodiment, the ratio of the seal groove width (Lse) times the number of seals 165 in relation to the second stem overlap region outer diameter (ODss) (e.g., (Lse x N) / ODss) is at least 0.1. In even yet another embodiment, the ratio of the seal groove width (Lse) times the number of seals 165 in relation tothe second stem overlap region outer diameter (ODss) (e.g., (Lse x N) / ODss) is at least 0.15, if not at least 0.2.

[0028] The present disclosure has determined, for example through extensive testing, that a ratio of the seal radial offset (OSR) to the seal region inner diameter (IDs4) (e.g., OSR / IDs4) is at least 0.0006, if not at least 0.0025. In yet another embodiment, the ratio of the seal radial offset (OSR) to the seal region inner diameter (IDs4) (e.g., OSR / IDs4) is at least 0.01. In even yet another embodiment, the ratio of the seal radial offset (OSR) to the seal region inner diameter (IDs4) (e.g., OSR / IDs4) is at least 0.05, if not at least 0.1.

[0029] The present disclosure has determined, for example through extensive testing, that a ratio of the first stem length (Lsi) to the second stem overlap region outer diameter (ODss) (e.g., Lsi I ODss) ranges from 0.05 to 5.0. In yet another embodiment, the ratio of the first stem length (Lsi) to the second stem overlap region outer diameter (ODss) (e.g., Lsi / ODss) ranges from 0.1 to 3.0. In even yet another embodiment, the ratio of the first stem length (Lsi) to the second stem overlap region outer diameter (ODss) (e.g., Lsi / ODss) ranges from 0.17 to 1.5, if not from 0.2 to 1.0. In yet another embodiment, the ratio of the first stem length (Lsi) to second stem overlap region outer diameter (ODss) (e.g., Lsi I ODss) should be at least 0.3. In even yet another embodiment, the ratio of the first stem length (Lsi) to second stem overlap region outer diameter (ODss) (e.g., Lsi I ODss) should be at least 0.5, if not at least 1.0.

[0030] The present disclosure has determined, for example through extensive testing, that a ratio of the seal region outer diameter (ODs4) to the second stem overlap region outer diameter (ODss) (e.g., ODS4 / ODss) is at least 0.7. In yet another embodiment, the ratio of the seal region outer diameter (ODs4) to the second stem overlap region outer diameter (ODss) (e.g., ODs4 I ODss) ranges from 0.75 to 1.0. In yet another embodiment, the ratio of the seal region outer diameter (ODS4) to the second stem overlap region outer diameter (ODss) (e.g., ODs4 / ODss) ranges from 0.85 to 0.99. In even yet another embodiment, the ratio of the seal region outer diameter (ODs4) to the second stem overlap region outer diameter (ODss) (e.g., ODs4 / ODss) ranges from 0.9 to 0.98, if not from 0.94 to 0.97.

[0031] The present disclosure has determined, for example through extensive testing, that a ratio of the second stem overlap region length (Lss) to second stem overlap region outer diameter (ODss) (e.g., Lss I ODss) should be at least 0.05. In yet another embodiment, the ratio of the second stem overlap region length (Lss) to second stem overlap region outer diameter (ODss) (e.g., Lss / ODss)should be at least 0.1. In even yet another embodiment, the ratio of the second stem overlap region length (Lss) to second stem overlap region outer diameter (ODss) (e.g., Lss I ODss) should be at least 0.16, if not at least 0.25, if not at least 0.5.

[0032] The present disclosure has determined, for example through extensive testing, that a ratio of the stem outer overlap region length (Lss) to the first stem length (Lsi) (e.g., Lss / Lsi) should range from 0.5 to 2.0. In yet another embodiment, the ratio of the stem outer overlap region length (Lss) to the first stem length (Lsi) (e.g., Lss / Lsi) should range from 0.75 to 1.75. In even yet another embodiment, the ratio of the stem outer overlap region length (Lss) to the first stem length (Lsi) (e.g., Lss / Lsi) should range from 1.0 to 1.50.

[0033] The present disclosure has determined, for example through extensive testing, that the seal groove width (Lse) should be at least 0.5 mm, if not at least 1.0 mm. In even yet another embodiment, the seal groove width (Lse) should be at least 3 times the second stem overlap region outer diameter (ODss). In even yet another embodiment, the seal groove width (Lse) should be no more than least 4 times the second stem overlap region outer diameter (ODss).

[0034] Turning to FIGs. 2A and 2B, illustrated are various different cross-sectional views of a ferrule 200, for example as might form part of an end connector for a hose, designed, manufactured and / or operated according to one or more embodiments of the disclosure. The ferrule 200, in the illustrated embodiment, includes a ferrule outboard end 210 and ferrule inboard end 215, for example separated by a ferrule length (LFO). The ferrule 200, in the illustrated embodiment, additionally includes a ferrule outer diameter (ODF), and a ferrule inner diameter (IDF).

[0035] In one or more embodiment, the ferrule 200 may be broken into a number of different regions. For example, in one or more embodiments, the ferrule 200 includes a ferrule reinforcement anchor region 220 and a smooth ferrule overlap region 250. In yet other embodiments, the ferrule 200 may additionally include a ferrule inboard end region 280, and a ferrule outboard end region 290. In at least one embodiment, the ferrule reinforcement anchor region 220 is formed in the ferrule inner diameter (IDF) between the ferrule outboard end 210 and the ferrule inboard end 215. In the disclosed embodiment, the ferrule reinforcement anchor region 220 includes a first ferrule length (LFI), a first ferrule inner diameter (IDFI), and a first ferrule thickness (TFI).

[0036] In the illustrated embodiment, the ferrule reinforcement anchor region 220 is not free of protrusions, but in contrast includes one or more ferrule engaging features 225 (e.g., teeth, barbs,bumps, flutes, lands, spines, etc.) that are configured to prevent a hose located within the end connector from axially moving therein. The number, size, period, etc. of the ferrule engaging features 225 may vary greatly and remain within the scope of the disclosure. For example, the number, size, period, etc. of the ferrule engaging features 225 may vary greatly, for example based upon what type of hose is coupling with the ferrule 200.

[0037] In at least one embodiment, the ferrule engaging features 225 include a ferrule tooth width (Wft) and a ferrule tooth depth (Da). The present disclosure has determined, for example through extensive testing, that a ratio of the ferrule tooth width (Wft) to diameter of the reinforcement wire used in the hose (dr) (e.g., Wft I dr), is quite important to the design of the stem 100. In at least one embodiment, Wft / drranges from 0.1 to 1.2. In yet another embodiment, Wft I drranges from 0.15 to 1.0, and in even yet another embodiment Wft / drranges from 0.25 to 0.75. The present disclosure in yet another embodiment has determined, for example through extensive testing, that a ratio of the ferrule tooth depth (Da) to diameter of the reinforcement wire used in the hose (dr) (e.g., Da I dr), is quite important to the design of the ferrule 200. In at least one embodiment, Da I drranges from 0.05 to 1.3. In yet another embodiment, Da / drranges from 0.1 to 1.2, and in even yet another embodiment Da / drranges from 0.25 to 0.9.

[0038] The smooth ferrule overlap region 250, in the illustrated embodiment, is formed in the ferrule inner diameter (IDF) between the ferrule reinforcement anchor region 220 and the ferrule inboard end region 280. In at least one embodiment, the smooth ferrule overlap region 250 has a second ferrule length (Lro) entirely free of protrusions. In at least one other embodiment, the smooth ferrule overlap region 250 includes a second ferrule inner diameter (IDF2), and a second ferrule thickness (Tro).

[0039] The ferrule inboard end region 280, in the illustrated embodiment, is formed between the smooth ferrule overlap region 250 and the ferrule inboard end 215. In at least one embodiment, the ferrule inboard end region 280 has a third ferrule length (LF3), a third ferrule inner diameter (IDF3), and a third ferrule thickness (TF3). The ferrule inboard end region 280, in at least one embodiment, includes a ferrule inboard end region shelf 285, the ferrule inboard end region shelf 285 configured to engage with an outer cover of the hose that the ferrule 200 is configured to engage with.

[0040] The ferrule outboard end region 290, in the illustrated embodiment, is formed between the ferrule reinforcement anchor region 220 and the ferrule outboard end 210. In at least oneembodiment, the ferrule outboard end region 290 has a fourth ferrule length (LF4), a fourth ferrule inner diameter (IDF4), and a fourth ferrule thickness (TF4). The ferrule outboard end region 290, in at least one embodiment, includes a coupling point 295, the coupling point 295 configured to engage with the stem it is configured to engage with.

[0041] The present disclosure has determined, for example through extensive testing, that a ratio of the first ferrule length (LFI) to the seal region length (Ls4) (e.g., LFI I LS4) should range between 0.8 and 4.0. In yet another embodiment, the ratio of the first ferrule length (LFI) to the seal region length (LS4) (e.g., LFI I Ls4) should range between 0.85 and 3.0. In even yet another embodiment, the ratio of the first ferrule length (LFI) to the seal region length (Ls4) (e.g., LFI / LS4) should range between 0.9 and 2.0, if not betweenl.O and 1.5, if not between 1.3 and 1.4.

[0042] The present disclosure has determined, for example through extensive testing, that a ratio of the fourth ferrule length (LF4) to the stem outer overlap region length (Lss) (e.g., LF4 / Lss) should range between 0.8 and 1.2. In yet another embodiment, the ratio of the fourth ferrule length (LF4) to the stem outer overlap region length (Lss) (e.g., LF4 I Lss) should range between 0.85 and 1.15. In even yet another embodiment, the ratio of the fourth ferrule length (LF4) to the stem outer overlap region length (Lss) (e.g., LF4 / Lss) should range between 0.9 and 1.1, if not between 0.92 and 1.08.

[0043] Turning to FIG. 3, illustrated is a cross-sectional view of an end connector 300, for example as might be used with a hose, designed, manufactured and / or operated according to one or more embodiments of the disclosure. The end connector 300, in one or more embodiments, includes a stem 310 and a ferrule 320, both of which are designed and / or manufactured according to this disclosure. In fact, the stem 310, and the ferrule 320 share many of the same features as the stem 100 and the ferrule 200 disclosed above. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0044] In the illustrated embodiment, the stem 310 and the ferrule 320 engage one another where the stem exposed region 190 of the stem 100 meets the coupling point 295 of the ferrule 200. Furthermore, as shown in the embodiment of FIG. 3, the stem 310 and ferrule 320 may couple together using an attachment feature 330. The attachment feature 330 may comprise a variety of different features and remain within the scope of the disclosure. Nevertheless, in at least one embodiment, the attachment feature 330 is a weld (e.g., spot weld, bead weld, etc.). Notwithstanding, the present disclosure should not be limited to any specific attachment feature330. In at least one embodiment, the coupling of the stem 310 and the ferrule 320, and specifically the stem outer diameter (ODs) and ferrule inner diameter (IDF), form a cavity 340 that extends from the coupling point 295 to the ferrule inboard end 215. It is this cavity 340, that provides the space necessary to receive an end of a hose.

[0045] In at least one embodiment, when coupled, the smooth stem overlap region 150 at least partially radially aligns with the smooth ferrule overlap region 250. The phrase “at least partially radially aligns,” as used herein, means that at least 25 percent of the second stem length (Ls2) overlaps with the second ferrule length (LF2). In yet another embodiment, the smooth stem overlap region 150 at least substantially radially aligns with the smooth ferrule overlap region 250. The phrase “at least substantially radially aligns,” as used herein, means that at least 50 percent of the second stem length (Ls2) overlaps with the second ferrule length (LF2). In yet another embodiment, the smooth stem overlap region 150 at least significantly radially aligns with the smooth ferrule overlap region 250. The phrase “at least significantly radially aligns,” as used herein, means that at least 80 percent of the second stem length (Ls2) overlaps with the second ferrule length (LF2). In yet another embodiment, the smooth stem overlap region 150 at least greatly radially aligns with the smooth ferrule overlap region 250. The phrase “at least greatly radially aligns,” as used herein, means that at least 90 percent of the second stem length (Ls2) overlaps with the second ferrule length (LF2). In yet another embodiment, the smooth stem overlap region 150 at least perfectly radially aligns with the smooth ferrule overlap region 250. The phrase “at least perfectly radially aligns,” as used herein, means that at least 98 percent of the second stem length (Ls2) overlaps with the second ferrule length (LF2). In yet another embodiment, the smooth stem overlap region 150 exactly radially aligns with the smooth ferrule overlap region 250. The phrase “exactly radially aligns,” as used herein, means that 100 percent of the second stem length (Ls2) overlaps with the second ferrule length (LF2).

[0046] Turning to FIGs. 4A and 4B, illustrated are various different cross-sectional views of the end connector 300 of FIG. 3 having a hose 400 (e.g., reinforced hose) positioned within the cavity 340. In the illustrated embodiment, the hose 400 includes an inner liner 410, a reinforcement layer 420 (e.g., including wire or other like elements), and an outer cover 430. In the illustrated embodiment, the hose 400 has been skived, such that a portion of the reinforcement layer 420 is fully exposed (e.g., no inner liner 410 or outer cover 430 bounding it), the skived portion of the reinforcement layer 420 extending into the stem reinforcement anchor region 120 and ferrulereinforcement anchor region 220. Furthermore, the inner liner 410 has been shortened such that it can nestle within the liner dam 157 of the smooth stem overlap region 150.

[0047] Turning now to FIG. 5, illustrated is a cross-sectional view of the end connector 300 and hose 400 of FIGs. 4A and 4B after a ferrule forming process (e.g., one or more ferrule forming processes) and an optional stem expansion process have been conducted, thereby forming a completed hose assembly 500. When used, the expansion process may be conducted prior to any ferrule forming process and may be conducted using known expansion processes for expanding the stem 310. In one embodiment, the expansion process is beneficial in that it expands the seal region inner diameter (IDs4) of the first stem overlap region 155a such that it can be approximately the same dimension as the stem overlap region inner diameter (IDss) of the second stem overlap region 155b, and potentially the same dimension as the first stem inner diameter (IDsi) of the stem reinforcement anchor region 120.

[0048] In at least one embodiment, the expansion process creates a stem expansion offset (OSE). The present disclosure has determined, for example through extensive testing, that a ratio of the stem expansion offset (OSE) to second stem overlap region outer diameter (ODss) (e.g., OSE / ODss) is quite important to the function of the ultimate hose assembly. In at least one embodiment, OSE I ODss is greater than 0.0025. In at least one other embodiment, OSE / ODss is greater than 0.01, if not greater than 0.025.

[0049] As indicated above, the ferrule forming process may, in certain embodiments, be broken into one or more ferrule forming processes. In at least one embodiment, the first ferrule forming process bends the ferrule 320 at a swaging point 510. However, at this moment, the first ferrule forming process does not cause the stem reinforcement anchor region 120 and ferrule reinforcement anchor region 220, to contact the reinforcement layer 420, but brings them into very close proximity to the reinforcement layer 420. This first ferrule forming action reduces compressional damage to the hose 400 because it allows the axial elongation caused by the ferrule. Thereafter, a second ferrule forming process may be conducted. It should be noted that in some embodiments, only the second ferrule forming process is used, due to the dimensions of the type of hose being used, making the first forming process unnecessary, while still resulting in a low compressed hose within the end connector 300. The second ferrule forming process further bends the ferrule 320 at crimping point 520. However, unlike the first ferrule forming process, if present, the second ferrule forming process firmly drives the stem reinforcement anchor region 120 andferrule reinforcement anchor region 220, respectively, into the reinforcement layer 420, to effectively lock the reinforcement layer 420 into place within the stem reinforcement anchor region 120 and ferrule reinforcement anchor region 220, without causing compressional damage to the hose 400. In one embodiment, the reinforcement layer 420 comprises a metal, such as a woven steel cable, however, in other embodiments, the reinforcement layer 420 can be made of any hose material that will not be cut, sheared or pulverized by the compression between the stem reinforcement anchor region 120 and ferrule reinforcement anchor region 220. This gripping action gives resistance to pump-off force on the fitting caused by internal pressure within the hose 400.

[0050] The second ferrule forming process additionally seals the smooth stem overlap region 150 and the smooth ferrule overlap region 250 about the inner liner 410 and the reinforcement layer 420 by engaging the seals 165 with the inner liner 410. As indicated above, the lack of protrusions in the smooth stem overlap region 150 and the smooth ferrule overlap region 250, and thus the seal, allows for the hose assembly 500 to accommodate the high frequency pressure cycles often experienced today.

[0051] In at least one embodiment, the ferrule forming process creates a swage / crimp offset (Osc). The present disclosure has determined, for example through extensive testing, that a ratio of the swage / crimp offset (Osc) to second stem overlap region outer diameter (ODss) (e.g., Osc / ODss) is quite important to the function of the ultimate hose assembly. In at least one embodiment, Osc I ODs5 ranges from 0.15 to 0.5. In at least one other embodiment, Osc I ODss ranges from 0.2 to 0.45, if not between 0.25 to 0.4.

[0052] Turning to FIG. 6, illustrated is a cross-sectional view of a hose assembly 600 designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure. The hose assembly 600 of FIG. 6 includes end connectors 610 disposed on opposing ends of a hose 620. In at least one embodiment, the end connectors 610 and hose 620, as well as the method for connecting the end connectors 610 to the hose 620, may be similar to that disclosed above.

[0053] Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.

Claims

WHAT IS CLAIMED IS:

1. An end connector for a hose, comprising: a stem, the stem including: a stem outboard end and stem inboard end separated by a stem length (Lso); a stem outer diameter (ODs); a stem inner diameter (IDs), the stem inner diameter (IDs) defining a fluid passageway between the stem outboard end and the stem inboard end; a stem reinforcement anchor region formed in the stem outer diameter (ODs) between the stem outboard end and the stem inboard end, the stem reinforcement anchor region having a first stem length (Lsi); a smooth stem overlap region formed in the stem outer diameter (ODs) between the stem reinforcement anchor region and the stem inboard end, the smooth stem overlap region having a second stem length (Ls2) entirely free of protrusions; and(N) seal grooves for sealing elements formed in the stem outer diameter (ODs) of the smooth stem overlap region, the seal grooves having a seal groove width (Lse), wherein a ratio of (Lse x N) / ODss is at least 0.05 ; and a ferrule coupled to the stem at a coupling point, the ferrule including: a ferrule outboard end and ferrule inboard end separated by a ferrule length (LFO); a ferrule outer diameter (ODF); a ferrule inner diameter (IDF); a ferrule reinforcement anchor region formed in the ferrule inner diameter (IDF) between the ferrule outboard end and the ferrule inboard end, the ferrule reinforcement anchor region having a first ferrule length (LFI); and a smooth ferrule overlap region formed in the ferrule inner diameter (IDF) between the ferrule reinforcement anchor region and the ferrule inboard end, the smooth ferrule overlap region having a second ferrule length (LF2) entirely free of protrusions, the smooth ferrule overlap region at least partially radially aligns with the smooth stem overlap region, wherein the stem outer diameter (ODs) and ferrule inner diameter (IDF) form a cavity that extends from the coupling point to the ferrule inboard end, the cavity configured to receive an end of a hose therein.

2. The end connector as recited in Claim 1 , wherein the ratio of (Lse x N) / ODss is at least 0.1.

3. The end connector as recited in Claim 1, wherein the stem includes a seal region inner diameter (IDs4), and (N) sealing elements located in the (N) seal grooves, the sealing elements having a seal radial offset (OSR), and further wherein a ratio of OSR I IDs4 is at least 0.0006.

4. The end connector as recited in Claim 1, wherein the stem includes a seal region inner diameter (IDs4), and (N) sealing elements located in the (N) seal grooves, the sealing elements having a seal radial offset (OSR), and further wherein a ratio of OSR I IDs4 is at least 0.01.

5. The end connector as recited in Claim 1, wherein the stem includes a seal region inner diameter (IDs4), and (N) sealing elements located in the (N) seal grooves, the sealing elements having a seal radial offset (OSR), and further wherein a ratio of OSR I IDs4 is at least 0.05.

6. The end connector as recited in Claim 1, wherein the smooth stem overlap region includes a first stem overlap region located between the stem reinforcement anchor region and the stem inboard end, and a second stem overlap region located between the first stem overlap region and the stem inboard end, the first stem overlap region including first and second end lengths (Ls3a, Ls3b), a seal region length (Ls4), a seal region outer diameter (ODS4), a seal region inner diameter (IDS4), and a seal region thickness (Ts4), and the second stem overlap region having a second stem overlap region length (Lss), a second stem overlap region outer diameter (ODss), a second stem overlap region inner diameter (IDss), and a second stem overlap region thickness (Tss).

7. The end connector as recited in Claim 6, wherein a ratio of Lsi I ODss ranges from 0.05 to 5.0.

8. The end connector as recited in Claim 7, wherein the ratio of Lsi / ODss ranges from 0.1 to 3.0.

9. The end connector as recited in Claim 6, wherein a ratio of ODs4 / ODss is at least 0.7.

10. The end connector as recited in Claim 9, wherein the ratio ODs4 / ODss ranges from 1.0.

11. A hose assembly for a hose, comprising: an end connector, the end connection including: a stem, the stem including: a stem outboard end and stem inboard end separated by a stem length (Lso); a stem outer diameter (ODs); a stem inner diameter (IDs), the stem inner diameter (IDs) defining a fluid passageway between the stem outboard end and the stem inboard end; a stem reinforcement anchor region formed in the stem outer diameter (ODs) between the stem outboard end and the stem inboard end, the stem reinforcement anchor region having a first stem length (Lsi); a smooth stem overlap region formed in the stem outer diameter (ODs) between the stem reinforcement anchor region and the stem inboard end, the smooth stem overlap region having a second stem length (Lsi) entirely free of protrusions; and(N) seal grooves formed in the stem outer diameter (ODs) of the smooth stem overlap region, the seal grooves having a seal groove width (Lse), wherein a ratio of (Lse x N) / ODss is at least 0.05; ones of sealing elements formed in each of the (N) seal grooves; and a ferrule coupled to the stem at a coupling point, the ferrule including: a ferrule outboard end and ferrule inboard end separated by a ferrule length (LFO); a ferrule outer diameter (ODF); a ferrule inner diameter (IDF); a ferrule reinforcement anchor region formed in the ferrule inner diameter (IDF) between the ferrule outboard end and the ferrule inboard end, the ferrule reinforcement anchor region having a first ferrule length (LFI); and a smooth ferrule overlap region formed in the ferrule inner diameter (IDF) between the ferrule reinforcement anchor region and the ferrule inboard end, thesmooth ferrule overlap region having a second ferrule length (LF2) entirely free of protrusions, the smooth ferrule overlap region at least partially radially aligns with the smooth stem overlap region, wherein the stem outer diameter (ODs) and ferrule inner diameter (IDF) form a cavity that extends from the coupling point to the ferrule inboard end, the cavity configured to receive an end of a hose therein; and a hose coupled to the end connector and having, an inner liner, an outer cover, and a reinforcement layer located between the inner liner and the outer cover, a first end of the reinforced hose having a skived section that exposes a portion of the reinforcement layer, the first end being received within the cavity such that the exposed reinforcement layer is gripped by the stem reinforcement anchor region and the ferrule reinforcement anchor region, the inner liner engaging the ones of sealing elements.

12. The hose assembly as recited in Claim 11, wherein the ratio of (Ls6 x N) / ODss is at least 0.

113. The hose assembly as recited in Claim 11, wherein the stem includes a seal region inner diameter (IDs4), and (N) sealing elements located in the (N) seal grooves, the sealing elements having a seal radial offset (OSR), and further wherein a ratio of OSR / IDs4 is at least 0.0006.

14. The hose assembly as recited in Claim 11, wherein the stem includes a seal region inner diameter (IDs4), and (N) sealing elements located in the (N) seal grooves, the sealing elements having a seal radial offset (OSR), and further wherein a ratio of OSR I IDs4 is at least 0.01.

15. The hose assembly as recited in Claim 11, wherein the stem includes a seal region inner diameter (IDs4), and (N) sealing elements located in the (N) seal grooves, the sealing elements having a seal radial offset (OSR), and further wherein a ratio of e.g., OSR I IDs4 is at least 0.05.

16. The hose assembly as recited in Claim 11, wherein the smooth stem overlap region includes a first stem overlap region located between the stem reinforcement anchor region and thestem inboard end, and a second stem overlap region located between the first stem overlap region and the stem inboard end, the first stem overlap region including first and second end lengths (Ls3a, Ls3b), a seal region length (Ls4), a seal region outer diameter (ODs4), a seal region inner diameter (IDS4), and a seal region thickness (Ts4), and the second stem overlap region having a second stem overlap region length (Lss), a second stem overlap region outer diameter (ODss), a second stem overlap region inner diameter (IDss), and a second stem overlap region thickness (Tss) •17. The hose assembly as recited in Claim 16, wherein a ratio of Lsi / ODss ranges from 0.05 to 5.0.

18. The hose assembly as recited in Claim 17, wherein the ratio of Lsi I ODss ranges from 0.1 to 3.0.

19. The hose assembly as recited in Claim 16, wherein a ratio of ODs4 / ODss is at least 0.7.

20. The hose assembly as recited in Claim 19, wherein the ratio of ODS / ODss ranges from 0.75 to 1.0.

21. The hose assembly as recited in Claim 11, wherein the stem reinforcement anchor region includes one or more stem engaging features having a stem tooth width (Wst) and a stem tooth depth (Dst), and further wherein the reinforcement layer of the hose includes one or more reinforcement wires located therein and having a reinforcement wire diameter (dr).

22. The hose assembly as recited in Claim 21, wherein a ratio of Wst / drranges from 0.1 to 1.2.

23. The hose assembly as recited in Claim 21, wherein a ratio of DstI drranges from 0.05 to 1.3.

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