Corrugated Hose End Cuff Welding for Clean Flow Paths

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Solution Overview

Problem

Flexible metal hoses with welded end connections often generate contaminants and entrapment areas due to welds on corrugations and sheath braiding, which can be undesirable in fluid systems, and require skilled labor and longer weld times.

Innovation Solution

A hose assembly design featuring a corrugated metal tube with an outer cuff portion extending radially outward from the endmost corrugation, a nose portion of the end connection inserted into the cuff, and a collar surrounding both, welded together to create a leak-tight connection without entrapment areas, allowing for automatic orbital welding and reduced skill requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welds are applied on corrugations and sheath braiding to create secure connections, then connection strength is improved, but entrapment areas and contaminants are generated

Engineering Contradiction:

Improveconnection strengthVSAvoidentrapment areas and contaminants

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The hose assembly is segmented into distinct zones: a smooth bore section for fluid flow, a transition zone with the outer cuff, and a weld zone at the end connection. This segmentation isolates the harmful weld area from the fluid flow path, eliminating entrapment areas while maintaining connection strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The weld connection is extracted from the corrugated tube and sheath braiding, and relocated to the outer cuff portion and end connection assembly. This extraction removes the source of entrapment areas and contaminants from the fluid flow path while preserving the secure connection function.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If traditional welding methods are used on corrugated hoses, then secure connections are achieved, but skilled labor and longer weld times are required

Engineering Contradiction:

Improveconnection securityVSAvoidweld time and skill requirement

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The outer cuff portion is pre-formed with a smooth, uniform geometry that is specifically designed to facilitate automatic orbital welding. This preliminary preparation of the welding surface eliminates the need for complex positioning and skilled manual welding operations during assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Manual welding operations are replaced with automatic orbital welding technology. The standardized geometry of the outer cuff portion enables the use of automated welding systems, which eliminate the need for skilled welders and significantly reduce weld times.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If welds are performed on corrugated surfaces, then end connections are secured, but cleaning becomes difficult and assembly yields decrease

Engineering Contradiction:

Improveend connection securityVSAvoidcleaning ease and assembly yield

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Different sections of the hose assembly have different surface qualities optimized for their specific functions: the inner bore has a smooth, cleanable surface for fluid flow; the outer cuff has a smooth surface for welding; and the end connection has the necessary geometry for secure attachment. This local differentiation enables easy cleaning while maintaining connection security.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The design converts the potential harm of weld-induced contamination into a benefit by positioning the weld zone externally on the outer cuff and end connection, away from the fluid flow path. This allows the welds to provide secure connections without creating cleaning difficulties or contamination issues in the internal flowpath.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution eliminates entrapment areas, reduces weld times and skill requirements, and ensures a clean internal flowpath by positioning the cuff and sheath outside the weld zone, facilitating easier cleaning and improved assembly yields.

Implementation Method 1

The collar, the outer cuff portion, and the nose portion are welded together

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentUS11808383B2Corrugated hose weld end

Publication Date: 2023.11.07 SWAGELOK CO

AI summary

A hose assembly includes a corrugated metal tube having a plurality of corrugations and an outer cuff portion extending from an endmost one of the plurality of corrugations, radially outward of an inner diameter of the endmost corrugation, an end connection having an outer end defining a fluid connector and an inner end defining a nose portion received in the outer cuff portion of the corrugated metal tube, and a collar surrounding the outer cuff portion of the corrugated metal tube and the nose portion of the end connection. The collar, the outer cuff portion, and the nose portion are welded together.