Composite fluid coupling

Abstract

A composite internal waterway for a fluid coupling assembly is arranged generally circumferentially about a fluid axis, and includes first and second pluralities of layers. The first plurality of layers defines a fluid-facing internal surface of the composite internal waterway. The second plurality of layers is formed of an impact-resistant second fiber material, and is situated radially outward of the fluid-facing internal surface of the composite internal waterway. The first and second pluralities of fibers each include warp and weft fibers. At least some of the warp fibers are oriented circumferentially relative to fluid axis, and at least some of the weft fibers are oriented axially relative to the fluid axis. At least one of the first and second pluralities of fiber layers is oriented at a nonzero first conical angle relative to the fluid axis

Description

[0001] COMPOSITE FLUID COUPLING

[0002] CROSS-REFERENCE TO RELATED APPLICATION(S) This application claims the benefit of U.S. Provisional Application No.

[0003] 63 / 710,337 filed October 22, 2024 for “Composite Fluid Coupling” by Kyle Victor Chandler.

[0004] BACKGROUND

[0005] This application relates to fluid handling hardware, and more specifically to resilient, lightweight, non-corrosive fluid couplings.

[0006] Industrial water transfer systems increasingly encounter highly corrosive fluid requirements. Systems originally designed for fresh water utilize commodity metals such as iron and aluminum, whether for pump(s) or necessary fluid couplings. Fluid couplings designed for large diameter layflat hose (LDH) are used for extremely large industrial fluid transfer operations typically found in large-scale firefighting and oil and gas exploration. These couplings are manually handled and installed in the field, requiring them to be relatively lightweight and simple to connect. As LDH already exists within the global firefighting market with standard quick coupling designs, manufacturers have enlarged those designs to accommodate higher volumetric flow conditions of industrial markets to expedite their time to market. Manufactured from hardcoat anodized aluminum, these fluid couplings use a variety of locking mechanisms to quickly and effectively connect two couplings.

[0007] The most ubiquitous coupling type, the Storz, is a sexless coupling (each coupling is identical), allowing for a simple locking rotational lug design that is both lightweight and durable. Storz couplings are used throughout the world in both firefighting and industrial water movement. However, water transfer operations have recently seen greatly increased use with high salinity waters, such as brine (salt concentrations in excess of 3.5%), to fulfill industrial use requirements. For example, hydraulic fracturing operations use and / or produce significant sources of brine water, including many other dissolved contaminants, which need to be transported many miles to temporary storage basins for disposal. This fluid is pumped through miles of LDH segments, all connected with quick connect couplings like the previously mentioned Storz or Victaulic®, a groove-lock collared coupling.

[0008] Storz couplings are traditionally manufactured from aluminum with a Type-III hardcoat anodized finish. The anodized aluminum surface of the couplings is highly durable, but nevertheless undergoes mechanical wear. This wear is greatly accelerated by dissolved solids within the fluid stream eroding the surface or the seemingly innocuous scratch or marring of the surface from its rough use in the field. Once the protective anodized surface is worn or damaged, saltwater begins to corrode the underlying aluminum. As a result of surface degradation, the coupling will begin to leak through various stationary sealing faces of the coupling. Although minor leakage may be acceptable in a developing firefighting response scenario, industrial water transport does not have this flexibility. Contaminated waters cause serious environmental damage to surface soil and water sources, requiring careful management from fluid transfer operators and environmental regulators alike. Similarly, Victaulic® couplings are traditionally manufactured from painted iron, and - much like the aluminum Storz - are highly vulnerable to corrosion once the underlying structural material is exposed to the saltwater.

[0009] Current fluid handling approaches address the aforementioned challenges with aggressive preventative maintenance plans that seek to inspect couplings and rotate in new replacement components as couplings reach their end-of-life. Based on the service conditions as well as inspection prowess, this can be a cost-prohibitive endeavor as an operator may have thousands of couplings in service at any one time. Moreover, the adaptation of more durable materials such as stainless steels is not feasible due to the much higher raw material pricing, increased demand on machining operations, labor, and prohibitive weight increase to the overall coupling.

[0010] SUMMARY

[0011] In one aspect, the present disclosure is directed to a composite internal waterway for a fluid coupling assembly. This composite internal waterway is arranged generally circumferentially about a fluid axis, and includes first and second pluralities of layers. The first plurality of layers defines a fluid-facing internal surface of the composite internal waterway. The second plurality of layers is formed of an impact-resistant second fiber material, and is situated radially outward of the fluid-facing internal surface of the composite internal waterway. The first and second pluralities of fibers each include warp and weft fibers. At least some of the warp fibers are oriented circumferentially relative to fluid axis, and at least some of the weft fibers are oriented axially relative to the fluid axis. At least one of the first and second pluralities of fiber layers is oriented at a nonzero first conical angle relative to the fluid axis

[0012] The present summary is provided only by way of example, and not limitation. Other aspects of the present disclosure will be appreciated in view of the entirety of the present disclosure, including the entire text, claims, and accompanying figures.

[0013] BRIEF DESCRIPTION OF THE DRAWINGS FIG. la is a side view of a fluid coupling assembly, illustrating section line 1—1.

[0014] FIG. lb is a cross-sectional view of the fluid coupling assembly of FIG. la, through section line 1 — 1.

[0015] FIG. 2 is an exploded view of a portion of the fluid coupling assembly of FIGs. la-c.

[0016] FIG. 3a is a side view of a composite internal waterway of the fluid coupling assembly portion of FIG. 2, illustrating section line 3 — 3.

[0017] FIG. 3b is a cross-sectional view of the composite internal waterway of FIG.

[0018] 3b through section line 3 — 3, illustrating region R.

[0019] FIG. 3c is a close-up partial sectional view of the region R of the composite internal waterway of FIGs. 2a and 3b.

[0020] While the above-identified figures set forth one or more embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the invention. The figures may not be drawn to scale, and applications and embodiments of the present invention may include features and components not specifically shown in the drawings.

[0021] DETAILED DESCRIPTION

[0022] This disclosure presents a composite fluid coupling (CFC) for use in industrial and other large-scale fluid handling operations. This CFC provides a solution to corrosion challenges in fluid coupling maintenance, extending part lifetimes. The CFC described herein improves on current quick coupling designs by replacing only the internal wetted waterway component of the fluid coupling assembly with a corrosion-proof composite component. Constructed of either fiber-reinforced thermoplastic or thermosetting polymer, this CFC is completely inert within a brine environment. Although still susceptible to mechanical erosion much like its metal counterpart, corrosion propagation (such as pitting corrosion) is impossible, greatly increasing its lifetime effectiveness. Additionally, being composite, it is at least as lightweight as aluminum and far more rugged, capable of surviving ground dropping impact without plastic deformation (permanent deformation).

[0023] FIG. la is a side view of CFC assembly 10 illustrating section line 1 — 1. FIG. lb is a cross-sectional view of CFC assembly 10 through section line 1 — 1. FIGs. la and lb are described together.

[0024] CFC assembly 10 is a fluid coupling assembly including multiple distinct coupling elements secured together to secure and form a closed fluid connection between hoses. In some embodiments, CFC assembly 10 can be a Storz or Victaulic® coupling assembly, as mentioned above. An embodiment of CFC assembly 10 as a Storz coupling assembly is illustrated in FIGs. la-3c. More generally, however, the structures and corresponding advantages described herein can be applied to any appropriate coupling geometry for connecting LDH segments or other hoses, and is particularly advantageous in couplings intended for use with corrosive or oxidizing materials. CFC assembly 10 can be, generally, a sexless coupling for connecting segments of hose. Although FIGs. la-3c illustrate an embodiment of CFC assembly 10 with Storz coupling architecture, internal waterways as disclosed herein are also suitable for other architectures, such as groove-style couplings (e.g. Victaulic®) as explained further below.

[0025] As illustrated in FIGs la and lb, CFC assembly 10 includes coupling head 100 (with coupling elements 102 and 104), hose locking collars 200a and 200b (collectively and / or generically locking collar(s) 200), internal waterways 300a and 300b (collectively and / or generically internal waterway(s) 300), and seal ring 400. CFC assembly is illustrated with hoses 20 and 22 (in FIG. la; hose 20 only in FIG. lb). Hoses 20 and 22 can, for example, be LDH hose segments, and coupling head 100, locking collars 200, internal waterways 300, and seal ring 400 are illustrated with geometry consistent with conventional Storz couplings. Accordingly, internal waterways 300 each have external surfaces 310 (with external ridges 312, 314, 316, and 318), generally cylindrical internal surfaces 320, narrow hose-facing ends 330, and coupling ends 340 (with thickened regions 342 disposed to receive seal ring 400. Internal waterways 300 and seal ring 400 are fluid-facing components, while other structural components of CFC assembly 10 are isolated from fluid flow through hoses 20, 22.

[0026] Coupling elements 102 and 104 are rotatably lockable together via a locking mechanism, as shown, to form coupling head 100, thereby anchoring facing coupling ends 340 of adjacent internal waterways 300 together in compression about seal ring 400. In this most general case, this locking mechanism can be any sort of mechanism of coupling head 100 or structural feature of coupling elements 102 and / or 104 operable to secure coupling element 102 to coupling element 104, e.g., via rotation of one relative to the other, or via latches, or by any other suitable means. Seal ring 400 can, for example, be a compressible polymer ring. Coupling head 100 is fitted about and axially secured to internal waterways 300 via fasteners 110, as shown.

[0027] In the illustrated embodiment, external ridges 312, 314, 316, and 318 on external surface 310 of internal waterways 300 face corresponding radial grooves or recesses in locking collars 200 to clamp hoses 20 / 22 to external surface 310 in multiple circumferential seals, thereby creating a redundant fluid seal preventing fluid from escaping CFC assembly 10 or impinging on non-fluid-facing components (e.g., locking collars 200) of CFC assembly 10. In alternative embodiments, e.g. for use with Victaulic® style groovelock assemblies, grooves defined between ridges (e.g., 312) and other protrusions on external surface 310 can be adapted to receive clamps to lock together abutting internal waterways in place of coupling head 100. Locking collars 200 are formed from multiple circumferential segments 210, 12, 214, etc. secured together as shown by fasteners 220 in a sealing fit about hose ends 330 of internal waterways 300. Once hoses 20, 22 are secured to internal waterways 300 via locking collars 200, hose segments can be coupled or decoupled by rotational locking or unlocking, respectively, of coupling head 100. In the illustrated embodiment, coupling head 100 is a Storz-style rotating lock with interlocking hooks and flanges. Each hose 20 / 22 (e.g., layflat LDH hose segment) is clamped to its tail while its face, with an embedded face seal, is compressed to another mating shank’s face seal. This compression provides a leak free fluid passageway between adjoining hoses 20 / 22. Although a Storz coupling is illustrated in the present figures, Victaulic® and other couplings operates in much the same way. More generally, although the coupling embodiments described herein are sexless, the composite internal waterway structure described above can also be adapted to gendered hose and / or pips couplings.

[0028] Fluid-facing components of CFC assembly 10, and especially components facing fluid flow, are formed of corrosion- and oxidation-resistant materials. As discussed in greater detail below, internal waterway 300 is a solid composite tube or tubular structure formed of multiple fiber-based or fiber-impregnated materials. Different portions of internal waterway 300 can be formed of fiber composite materials that differ end composition and / or fiber orientation.

[0029] FIG. 2 is an exploded view of a portion of the CFC assembly 10 associated with one hose. FIG. 3 illustrates coupling element 102 of coupling head 100 (with fasteners 110 exploded from corresponding fastener holes 112), locking collar 200a (with fasteners 220), internal waterway 300a (with external ridges 312, 314, 316, and 318 on external surface 310, internal surface 320, and coupling end 340 with thickened region 342 including sealing slot 344). Fastener holes 212 are radial recesses in coupling head 100 (here, coupling element 102) disposed to receive and axially retain fasteners 110, thereby axially securing internal waterway 300a relative to coupling element 102. Thickened region 342 of coupling end 340 accommodates sealing slot 344, which receives seal ring 400. Hose 22 is not illustrated in FIG. 2, but would be installed in a clamped fit between internal waterway 300a and locking collar 200a. CFC assembly 10 as shown in FIG. 2 is otherwise as described above with reference to FIGs. la and lb.

[0030] CFC assembly 10 directly replaces all-aluminum Storz coupling waterways with internal waterway 300 formed of composite fiber composite materials. In some embodiments outer fluid coupling lug heads not exposed to fluid flow, such as coupling head 100 and locking collars 200, can be formed of aluminum, painted iron, or other convention constructions. Coupling head 100 is used for mechanical locking only and not continuously exposed to the internal flowing fluid, and is therefore relatively insensitive to corrosion and / or oxidation. Locking collars 200 are entirely isolated from fluid flow through CFC assembly 10, and are likewise not susceptible to degradation due to fluid flow through CFC assembly 10. By contrast, internal waterway 300 defines the core fluid passage through CFC assembly, and can be exposed regularly or continuously to flow of brine solutions, acidic solutions, basic solutions and other corrosive fluids. To accommodate these harsh conditions without degradation, internal waterway 300 is advantageously formed of composite materials resistant to chemical corrosion. Although non-flow-facing components of CFC assembly 10 can be formed of materials less resistant to chemical corrosion, in some embodiments any / all such components may also be formed of fiber composite materials where adequate to handle expected mechanical loads and stresses.

[0031] FIGs 3a-c illustrate internal waterway 300. FIG. 3a is a side view illustrating section line 3 — 3, while FIG. 3b is a cross-sectional view through section line 3 — 3 identifying region R. FIG. 3c is a close-up cross-sectional view of region R of internal waterway 300, and illustrates external surface 310, external ridges 312, 314, 316, and 318, internal surface 320, coupling end 340, thickened region 342, and sealing slot 344 as described above. FIG. 3c also identifies inner fiber weave region 350, outer fiber weave region 360, embedded fiber weave region 370, and zones Z1 and Z2. As noted above, internal waterways 300 are formed of woven fiber composite materials. More specifically, regions and zones of internal waterway can be formed of different materials and / or with different fiber orientations. Each internal waterway 300 uses multiple fiber types to benefit from their combined characteristics. Carbon-fiber is used primarily for its high strength-to-weight ratio and rigidity while aramid-fiber (or similar) is used to increase the overall structure’s toughness. Additionally, the woven structure of internal waterway 300 is oriented with fiber filaments aligned along the principal stress directions, circumferential and axial (both types of stresses are apparent when the coupling assembly is under pressure).

[0032] As delineated in FIG. 3a, internal waterway 300 includes inner fiber weave region 350, outer fiber weave region 360, and embedded fiber weave region 370. These regions illustratively define portions of internal waterway 300 that can advantageously be formed of different materials. Internal waterway 300 can be formed via radial stacking of successive layers of fiber layup.

[0033] Inner fiber weave region 350 consists of a portion of internal waterway 300 including or proximate internal surface 320. In at least some embodiments, inner fiber weave region 350 can be formed of a wear resistant fiber material selected to protect against highly abrasive materials (such as slurries and / or high turbidity water) moving through the waterway. Generally, a fluid facing portion of internal waterway 300 described by inner fiber weave region 350 is preferably formed of a fiber composite insensitive to water, and having higher abrasive resistance than carbon fiber. In some such examples, region 350 of internal waterway 300 can be formed of one or more layers of including or consisting of ultra-high-molecular- weight polyethylene (UHMWPE). These layers protect the remainder of internal waterway 300 from damage due to highly abrasive fluid flow. More specifically, the gel-spun, multi filament UHMWPE fiber has extremely long and tightly packed parallel molecular chains that effectively dissipate forces from high hardness abrasives, making it resistant to abrasion and tearing. Furthermore, its low coefficient of friction makes for a slippery surface, lowering the incidence of "snagging" of fiber of sharp materials. In other examples, a melt-spun, highly oriented, and highly crystalline isotactic polypropylene (e.g., Innegra®) can be used in inner fiber weave region. More generally, the material of inner fiber weave region 350 is selected for its improved abrasive resistance relative to materials of fiber weave regions 360 and 370.

[0034] Outer fiber weave region 360 consists of a portion of internal waterway 300 radially outward of inner fiber weave region 350 and including external surface 310. In at least some embodiments, outer fiber weave region 360 can be formed of carbon fiber, e.g., by fiber layup abutting layers of inner fiber weave region 350.

[0035] Embedded fiber region 370 is encapsulated fully within or between inner and / or outer fiber weave regions 350, 360 and consequently not exposed directly to fluid. In the illustrated embodiment, embedded fiber region 370 is fully embedded within inner fiber weave region 350, alone. More generally, embedded fiber region 370 is preferably incorporated in an intermediate thickness of internal waterway 300 near an internal diameter of the waterway, but not directly facing fluid. Embedded fiber region 370 is formed of an impact-resistant material. In at least some embodiments, embedded fiber region 370 can be formed of aramid and / or para-aramid fibers, such as Kevlar®.

[0036] The different materials of fiber regions 350, 360, and 370 cooperatively provide advantageous or necessary characteristics to internal waterway 300, as a whole. Embedded fiber region 370 provides failure-proofing against catastrophic rupture, while inner fiber region 350 provides a wear-resistant surface suitable for carrying corrosive solutions. Outer fiber region 360 provides general structural integrity against tensile, shear, and compressive strain, and defines complex contours of internal waterway 300, including external ridges 312, 314, 316, and 318 of external surface 310 and sealing slot 344 in thickened region 342 at coupling end 340. In some embodiments, as shown with the chamfered and curved edges of internal surface 320, inner fiber region 350 can also exhibit non-cylindrical geometry.

[0037] Cylindrical fiber layup can preferably consist of woven axially- and cylindrically-extending fibers, e.g., an axially-reinforcing warp fiber with a circumferentially-reinforcing weft fiber. Warp and weft fibers need not be included in equal number. In instances where hoop stress is a greater expected strain on internal waterway 300 than axial load, for example, cylindrically-extending weft fibers may outnumber axially extending warp fibers. Warp and weft directions of fibers of internal waterway 300 are preferably selected to align with expected principal loads on internal waterway 300 along circumferential and axial directions, rather than at oblique angles to those loads. Consequently, fibers of most layers of internal waterway 300 can be arranged in an orthogonal weave. In or adjacent regions of internal waterway 300 for which torsional loads may be expected, however, warp and / or weft may be angled relative to axial and / or circumferential directions, and / or may be nonorthogonal.

[0038] Fiber layup of internal waterway 300 can be approximately cylindrical in portions of fiber regions 350, 360, and 370, but is conically angled relative to a cylindrical axis of internal waterway 300 in at least some portions. Sandwiched woven layers of internal waterways 300 incorporate a nominal internal draft to prevent inter-layer delamination during high axial load. Woven layers of internal waterways 300 are preferably formed with a positive draft bias, increasing in diameter as they approach the intersection of two sexless couplings at coupling end 340. This cone structure prevents parallel plane delamination, as each layer is mechanically interlocked against tensile forces in the axial direction. Differences in angle are exaggerated in FIG. 3a, not drawn to scale. Schematically illustrated layers in zone Z1 illustrate depict fibers disposed at a shallow conical angle relative to a cylindrical axis of internal waterway 300, while schematically illustrated layers in zone Z2 illustrate a larger conical angle relative to the cylindrical axis. Fibers in outer fiber region 360 can advantageously be arranged at a greater conical angle (e.g., 2-5°) to avoid delamination at an outer diameter of internal waterway 300 near coupling end 340, relative to a shallower angle (e.g., 1.5°, or <2°) in inner fiber region 350. Fibers in fiber region 370, situated within inner fiber region 350, can have identical conical angle to surrounding layup in inner fiber region 350. Conical fiber layer angles can be accommodated by including some layers extending only a portion of an axial extent of the zone to produce layers flared frustoconically relative to internal surface 320 and a remainder of fiber layers of internal waterway 300. The resulting flared (warp) angle relative to and extending into fibers located immediately radially inward on internal waterway 300 to act as a wedge lock for the fibers strengthening outer portions of internal waterway 300 against axial forces.

[0039] Although FIGs. la-3b illustrate CFC assembly 10 as a Storz fluid coupling assembly, the composite structure of internal waterway 300 is applicable to other coupling geometries as well, including groove-lock style (e.g. Victaulic®) couplings. Embodiments of internal waterway 300 for use with groove-lock style fluid coupling assembly can omit sealing slot 344 and include one or more grooves on external surface 310 as discussed above, but operate generally as described above with reference to FIG. 3c.

[0040] Internal waterway 300 of CFC assembly 10 substitutes the metallic component in contact with a working fluid with a functionally identical but chemically inert fiber-reinforced polymer composite component, thereby increasing the resilience of CFC assembly 10 when carrying brine solutions, acidic solutions, basic solutions and other corrosive fluids where water is the primary solvent. Internal waterway 300 advantageously benefits from the high tensile strength, rigidity, and low weight of carbon-fiber to increase its mechanical performance and reduce its weight compared to its structurally analogous metal counterparts. Furthermore, the inclusion of aramid-fiber (or similar) elements in internal waterway 300 provides increased impact resistance and prevents catastrophic failure of the carbon-fiber reinforcement if accidentally crushed during operation. Impact resistance of internal waterway 300 is further improved by the an energy absorbent polymer matrix.

[0041] Discussion of Possible Embodiments

[0042] The following are non-exclusive descriptions of possible embodiments of the present invention.

[0043] A composite internal waterway of a fluid coupling assembly, the composite internal waterway being arranged generally circumferentially about a fluid axis and comprising: a first plurality of layers of a first fiber material defining a fluid-facing internal surface of the composite internal waterway; and a second plurality of layers formed of an impact-resistant second fiber material different from the first fiber material, and situated radially outward of the fluid-facing internal surface of the composite internal waterway; wherein the first and second pluralities of fibers each comprise warp and weft fibers, at least a subset of the warp fibers oriented circumferentially relative to fluid axis and at least a subset of the weft fibers oriented axially relative to the fluid axis, and wherein at least one of the first and second pluralities of fiber layers is oriented at a first conical angle relative to the fluid axis.

[0044] The composite internal waterway of the preceding paragraph can optionally include, additionally and / or alternatively, any one or more of the following features, configurations and / or additional components:

[0045] A further embodiment of the foregoing composite internal waterway, further comprising a third plurality of layers disposed radially outward of the first plurality of layers and defining a radially outer surface of the composite internal waterway, the radially outer surface of the composite internal waterway having noncylindrical features.

[0046] A further embodiment of the foregoing composite internal waterway, wherein the third plurality of layers comprise carbon fiber.

[0047] A further embodiment of the foregoing composite internal waterway, wherein the first plurality of layers comprise a material with improved abrasive resistance relative to the second and third pluralities of layers.

[0048] A further embodiment of the foregoing composite internal waterway, wherein at least some of the third plurality of fiber layers is oriented at a second conical angle relative to the fluid axis greater than the first conical angle. A further embodiment of the foregoing composite internal waterway, wherein the second conical angle is between 2 and 5 degrees.

[0049] A further embodiment of the foregoing composite internal waterway, wherein the first fiber material is insensitive to water and has higher abrasive resistance than carbon fiber.

[0050] A further embodiment of the foregoing composite internal waterway, wherein the first fiber material is ultra-high-molecular-weight polyethylene (UHMWPE).

[0051] A further embodiment of the foregoing composite internal waterway, wherein the first fiber material is a melt-spun, highly oriented, and highly crystalline isotactic polypropylene.

[0052] A further embodiment of the foregoing composite internal waterway, wherein the second plurality of layers comprise aramid or para-aramid material.

[0053] A further embodiment of the foregoing composite internal waterway, wherein the second plurality of layers is encapsulated within the composite internal waterway without exposure to an exterior of the composite internal waterway.

[0054] A hose coupling assembly configured to fluidly connect a first and a second hose, the hose coupling assembly comprising: a first composite internal waterway as set forth above; a second composite internal waterway also as set forth above; a first locking ring securable radially outward of the first composite internal waterway to lock the first hose therebetween; a second locking ring securable radially outward of the second composite internal waterway to lock the first hose therebetween; and a coupling head comprising: a first coupling element anchored radially to and radially outward of the first composite internal waterway; a second coupling element anchored radially to and radially outward of the first composite internal waterway; and a locking mechanism operable to secure the first coupling element to the second coupling element, thereby forming a continuous fluid passage between the first hose, the first composite internal waterway, the second composite internal waterway, and the second hose.

[0055] A further embodiment of the foregoing hose coupling assembly, wherein the hose coupling assembly is sexless.

[0056] A further embodiment of the foregoing hose coupling assembly, wherein the hose coupling assembly is a Storz coupling characterized by interlocking hooks and flanges as the locking mechanism.

[0057] A further embodiment of the foregoing hose coupling assembly, wherein the hose coupling assembly is a groove-lock coupling mechanism. Summation

[0058] Any relative terms or terms of degree used herein, such as “substantially,” “essentially,” “generally,” “approximately,” and the like, should be interpreted in accordance with and subject to any applicable definitions or limits expressly stated herein. In all instances, any relative terms or terms of degree used herein should be interpreted to broadly encompass any relevant disclosed embodiments as well as such ranges or variations as would be understood by a person of ordinary skill in the art in view of the entirety of the present disclosure, such as to encompass ordinary manufacturing tolerance variations, incidental alignment variations, alignment or shape variations induced by thermal, rotational or vibrational operational conditions, and the like.

[0059] While the invention has been described with reference to an exemplary embodiments), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.

Claims

CLAIMS:

1. A composite internal waterway of a fluid coupling assembly, the composite internal waterway being arranged generally circumferentially about a fluid axis and comprising:a first plurality of layers of a first fiber material defining a fluid-facing internal surface of the composite internal waterway; anda second plurality of layers formed of an impact-resistant second fiber material different from the first fiber material, and situated radially outward of the fluid-facing internal surface of the composite internal waterway;wherein the first and second pluralities of fibers each comprise warp and weft fibers, at least a subset of the warp fibers oriented circumferentially relative to fluid axis and at least a subset of the weft fibers oriented axially relative to the fluid axis, and wherein at least one of the first and second pluralities of fiber layers is oriented at a nonzero first conical angle relative to the fluid axis.

2. The composite internal waterway of claim 1, further comprising a third plurality of layers disposed radially outward of the first plurality of layers and defining a radially outer surface of the composite internal waterway, the radially outer surface of the composite internal waterway having noncylindrical features.

3. The composite internal waterway of claim 2, wherein the third plurality of layers comprise carbon fiber.

4. The composite internal waterway of claim 2, wherein the first plurality of layers comprise a material with improved abrasive resistance relative to the second and third pluralities of layers.

5. The composite internal waterway of claim 1, wherein at least some of the third plurality of fiber layers is oriented at a second conical angle relative to the fluid axis greater than the first conical angle.

6. The composite internal waterway of claim 1, wherein the second conical angle is between 2 and 5 degrees.

7. The composite internal waterway of claim 1, wherein the first fiber material is insensitive to water and has higher abrasive resistance than carbon fiber.

8. The composite internal waterway of claim 7, wherein the first fiber material is ultra-high-molecular-weight polyethylene (UHMWPE).

9. The composite internal waterway of claim 7, wherein the first fiber material is a melt-spun, highly oriented, and highly crystalline isotactic polypropylene.

10. The composite internal waterway of claim 1, wherein the second plurality of layers comprise aramid or para-aramid material.

11. The composite internal waterway of claim 10, wherein the second plurality of layers is encapsulated within the composite internal waterway without exposure to an exterior of the composite internal waterway.

12. A hose coupling assembly configured to fluidly connect a first and a second hose, the hose coupling assembly comprising:a first composite internal waterway as set forth in claim 1;a second composite internal waterway also as set forth in claim 1;a first locking ring securable radially outward of the first composite internal waterway to lock the first hose therebetween;a second locking ring securable radially outward of the second composite internal waterway to lock the first hose therebetween; and a coupling head comprising:a first coupling element anchored radially to and radially outward of the first composite internal waterway;a second coupling element anchored radially to and radially outward of the first composite internal waterway; anda locking mechanism operable to secure the first coupling element to the second coupling element, thereby forming a continuous fluid passage between the first hose, the first composite internal waterway, the second composite internal waterway, and the second hose.

13. The hose coupling assembly of claim 12, wherein the hose coupling assembly is sexless.

14. The hose coupling assembly of claim 13, wherein the hose coupling assembly is a Storz coupling characterized by interlocking hooks and flanges as the locking mechanism.

15. The hose coupling assembly of claim 13, wherein the hose coupling assembly is a groove-lock coupling mechanism.

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