This application is a continuation-in-part of U.S. patent application Serial No. 08/145,688 filed October 29, 1993 entitled "Hydraulic Coupling".

The invention relates in general to hydraulic couplers and particularly to one uniquely adapted for use in subsea applications and other harsh environments.

The prior art of hydraulic couplers illustrate the many and varied sealing members that have been used to seal between male and female members. The sealing members have varied from soft materials such as felt, rubber and soft synthetic resinous materials to hard metal materials such as stainless steel and other metal alloys.

These materials have met with varying success and in most instances the use of one material for a given advantage is a trade off because it also has a given disadvantage. For example, the rubbers and soft synthetic resinous materials do not have sufficient strength to withstand high pressure applications and metal seals are so hard as to scratch or mar the surfaces on the male or female member which they engage to provide the seal. The metal seals also have a tendency to interact with sand and/or to scratch the coupler surfaces.

The purpose and object of this invention is to provide a sealing member in combination with a male and female member of a coupler which fits between the extremes outlined above.

An object of the invention is to provide a sealing member which has sufficient strength to handle high pressure applications but will not scratch or otherwise mar the coupler surfaces. Another object of the invention is to provide a sealing member constructed of a polymeric elastomeric

material which has physical characteristics to accomplish the objects stated herein.

Another object of the present invention is to prevent the blowout of the sealing member during disconnection of the male and female members.

The sealing member of the present invention has the correct deformation qualities to provide an excellent seal under pressure but also has the elasticity to return to its normal physical condition after pressure is removed.

In the instant invention, it is desirable that the opening in the sealing member which the male member "sees" be the same diameter each time the male and female member are connected. In the use of metal sealing members or rings the opening gradually becomes larger and larger with each use resulting in a less and less effective seal against flow of fluid along the interface between the sealing member and the movable coupler part .

Description of the Drawings FIGURE 1 is an elevational view of the hydraulic coupler of the present invention partially in section and with the male and female members connected; FIGURE 2 is an enlarged fragmentary section of a portion of the hydraulic coupler illustrated in Figure

1;

FIGURE 3 is a view showing the female coupler members in disconnected condition; FIGURE 4 is a view showing the male coupler in the disconnected condition;

Figure 5 is an enlarged fragmentary sectional view similar to Figure 2 but showing a modification of the invention illustrated in Figure 2; Figure 6 is an enlarged fragmentary section illustrating the sealing member shown in Figure 5 as

applied to a balanced coupler; and

Figure 7 is an enlarged fragmentary view of a still further modification of the invention over that shown in Figures 2 and 5.

Detailed Description of the Invention The hydraulic undersea coupler of the present invention is best illustrated in Figures 1, 3 and 4 of the drawings and has been identified generally by the reference numeral 10. The coupler includes generally a female member 14 and a male member 20 movable between coupled condition illustrated in Figure 1 and uncoupled condition illustrated in Figures 3 and 4. The female member includes a main body 14 and internal insert member 15 which is threadably secured in place by thread 16 as shown in Figures 1 and 3. In similar fashion, the male member includes a main body 20 and includes an internal insert member 24 which is threadably secured in the position shown in Figures 1 and 4 by means of threads 25.

First wall means 23 define a first passage or bore through the female member 14 which provides for the flow of fluid from one open end of the female member through the passage and to the other end of the female member. In like fashion, second wall means 26 are provided in the male member to define a second passage or bore through the male member to provide for the flow of fluid through one end of the male member to the other end thereof. A first check valve 80 is provided in the female member as shown in Figures 1 and 3 and a spring 81 normally biases the first check valve to its closed condition as illustrated in Figure 3. A valve seat 83 is provided in the passage of a bore 23 in the female member and this is essentially a surface which is engaged by the check valve and particularly an

elastomeric portion 84 on the check valve. The check valve 80 is provided with a plurality of annularly spaced ports 82 which provide for the flow of fluid through the check valve when it is in its open condition as illustrated in Figure 1.

In like fashion, the male member is provided with a second check valve 86 which is constantly biased or urged to closed condition by a spring 87. The open condition of the check valve 86 is illustrated in Figure 1 and its closed condition is shown in Figure 4. The passage or bore 26 of the male member is provided with a valve seat 89 which engages the check valve 86 and particularly an elastomeric portion 90 carried by the check valve when it is in closed position as shown in Figure 4. The check valve 86 is provided with a plurality of circumferentially spaced ports 88 which provide for the passage of fluid through check valve 86 in its open condition as shown in Figure 1.

The first wall means 23 which defines the first passage or first bore in the female member 14 in the end of the female member closest to where the male member 20 is inserted into the female member is provided with a shoulder 30 which is generally shown in Figures 1 and 3 and is shown in substantial detail in the enlarged fragmentary view of Figure 2.

The shoulder 30 is defined by first and second radially spaced and axially extending surfaces 32 and 34 and first and second axially spaced and radially extending surfaces 36 and 38. The male member 20 has a first end portion 21 (Figure 2) which resides in the first passage or bore 23 of the female member 14 in the coupled condition of the coupler as illustrated in Figure 1.

The first end portion 21 has an external circumferentially extending surface 22 spaced from the first axially extending surface 32 and located close to

the second axially extending surface 34 in the coupled condition best shown in Figures 1 and 2. The external surface 22, the first axially extending surface 32 and the first radially extending surface 36 define an annularly extending space or annulus 42. An annularly extending sealing member or seal 50 resides in the space 42. As seen in all of the figures, particularly in Figure 2, this annularly extending sealing member in cross section is generally rectangularly shaped and as mentioned before, resides in the space 42. The sealing member 50 has inner and outer circumferentially extending surfaces 54 and 55, respectively, lying adjacent the external surface 22 of the male member and the first axially extending surface 32, respectively. The sealing member 50 also has first and second end surfaces 60 and 61, respectively, with the first end surface being located adjacent the first radially extending surface 36.

An annularly extending annular retainer 64 is provided as shown which has first and second axially spaced end surfaces 66 and 67, respectively, (FIGS. 2 and 3) with the first end surface 66 being located adjacent the second end surface 61 of the sealing member to hold the sealing member in the annular space 42. An adaptor 69 (FIGS. 1 and 3) is threadably connected by means of threads 73 to the body 14 of the female member and serves to hold the annular retainer 64 and the sealing member 50 in the position illustrated in the figures of the drawings. A channel shaped seal 68 which extends annularly around the coupler is interposed between the adaptor 69 and the annular retainer 64 to assist in sealing against the escape of fluid pressure. As best seen in Figure 2, a first wall 70 extends into the first end surface 60 of the sealing member 50 and defines a first cavity 71 which faces the first radially extending surface 36 of the shoulder and creates a

generally C-shaped appearance in cross section. In similar manner, a second wall 76 extends into the outer circumferentially extending surface 55 of the sealing member 50 and defines a second cavity 77 facing the first axially extending surface 32 of the shoulder and creating a generally U-shaped appearance in cross section. The sealing member 50 of the present invention is constructed of a polymeric elastomeric material which accomplishes the objects that have been stated hereinabove in a manner consistent with accomplishing the teachings of the present disclosure.

In operation and assuming the coupler is in the uncoupled condition as illustrated in Figures 3 and 4, and in this condition, the check valves 80 and 86 are in the closed condition preventing fluid flow through the female member and the male members.

As the male and female members are brought towards coupled condition, the extreme ends of the check valves 80 and 86 engage each other and move each other to the open condition shown in Figure 1 against the force or bias of springs 81 and 87. The male and female members are maintained mechanically in this connected position by a means not shown or illustrated herein but well understood by those skilled in the art. In many instances, the male members are fixedly mounted subsea on a physical support member and a corresponding plurality of the female members are lowered subsea into the connected position of Figure 1 and held together by a means not illustrated herein. As the end portion 21 of the male member 20 passes through the inner diameter of the sealing member 50, the external surface 22 of the male member travels closely adjacent the inner surface 54 of the sealing member. After the male and female member reach their coupled condition as illustrated in Figure 1 with their respective check valves in open condition, fluid

pressure such as hydraulic fluid is caused to flow, for example, from the left end of the female member 14 as viewed in Figure 1 through the bore 23, through ports 82 and out through the male member through ports 88 and bore 26 in the male member.

In most circumstances, hydraulic couplers of the type illustrated herein deal with relatively high hydraulic fluid pressure, for example, of on the order of four or five thousand psi up to 10,000 psi. Referring to Figure 2, this fluid pressure finds its way along surfaces 38, 34 and 36 into the generally C-shaped cavity 71. This fluid pressure causes the upper and lower portions of the C-shape to tightly and firmly engage surfaces 32 and 22 respectively preventing the escape of hydraulic fluid along surfaces 32 and 22. The U-shaped cavity 77 which is provided in the sealing member 50 performs the function of assisting and preventing the escape of fluid pressure along surfaces 32 and 61 under some circumstances. It happens in the operation of couplers such as these which are used subsea that the male member when inserted into the female member may be slightly "cocked" because the axis of the male member is not exactly concentric with the axis of the female member. When this happens, the sealing member may also be cocked or twisted in the annular space 42 so that fluid pressure may travel along surfaces 36 and 32 tending to escape past the sealing member. In these circumstances the fluid pressure will be transmitted to the U-shaped cavity 77 which forces the right most leg of the U into firm contact with surface 66 and tends to press surface 55 into engagement with surface 32 tending to provide a better fluid seal under these circumstances. Obviously the U-shaped portion of the seal is an adjunct or addition to the sealing member and is not a necessary inclusion into the sealing member formed by the C-shaped portion of the

sealing member which has been defined hereinabove.

Figure 5 illustrates a modification of the invention and shows a sealing member 150 residing in the space 42. In similar fashion, it is generally rectangularly shaped and the inner and outer circumferentially extending surfaces in this embodiment have been identified by the reference numerals 154 and 155, respectively, and they lie respectively adjacent the surfaces 22 and 32. The first and second end surfaces of the sealing member 150 in this embodiment, have been identified by the reference numerals 160 and 161, respectively. The end surface 161 is located adjacent the retainer 64.

A first wall 170 extends into the sealing member 160 and defines a first cavity 171 which faces the surface 36 and creates a generally C-shaped appearance in cross-section. This is quite similar to the construction shown in Figure 2. A second wall 176 extends into the inner circumferentially extending surface 154 of the sealing member 150 and defines a second cavity 177 which faces the external surface 22 of the male member 20. The cavity 177 creates a generally U-shaped appearance in cross-section which may be referred to more properly as an inverted U-shape. The structure and function of the device within which the seal of Figure 5 is incorporated, namely that of the male and female members, is essentially as described in the functioning of the coupler parts illustrated in Figures 1, 3 and 4. When the male and female members are coupled together in connection with the structure illustrated in Figure 5, the C-shaped cavity 171 which is formed in the sealing member 150 functions essentially in the same manner as described in connection with the C-shaped cavity 71 which is illustrated in Figure 2.

The inverted U-shaped cavity 177 which is formed in

the sealing member 150 performs a general sealing function; however, it is particularly useful in preventing the entrance of seawater into the internal passages in the male and female members. At times there may be a tendency for seawater to attempt to gain entrance to the internal passageway formed in the coupler members, for example, through the space identified by the reference numeral 180 in Figure 5 which depending upon the tolerance may provide a clearance between the retainer 64 and the male member 20 and particularly the first end portion 21 thereof. In the event seawater, which is under a relatively high pressure, gains entrance through the space 180 to cavity 177 the pressure which enters cavity 177 has a tendency to force what is referred herein as a leg or leg portion formed by the second cavity 177 into engagement with the wall of the retainer 64 preventing seawater from travelling around the sealing member, for example, to the space between surfaces 32 and 155. Figure 6 illustrates use of the specific embodiment shown in Figure 5 in a balanced coupler which balanced coupler constructions are known to those skilled in the art and may be generally of the type shown in U.S. patent No. 5,072,755 issued December 17, 1991. Referring specifically to Figure 6 there is shown and illustrated a balanced coupler which includes a female member 187 and a male member 189 shown in assembled or connected position. The female member is provided with a passageway 192 and the male is formed with passageway 196. Port 200 in the passageway 196 in the male member and port 201 in the passageway 192 in the female member provide for the passage of fluid between the two members. Figure 6 illustrates two sealing members 150, more specifically described in connection with Figure 5, illustrated and located in shoulders formed in the female member so as to provide

sealing engagement between the outer circumferential surface of the male member 189 and a bore formed in the female member 187. A flow port or spacer 198 which has a port 202 for the passage of fluid is provided and located between the two sealing members 150. The spacer 198 is provided with legs 199 on each side which reside in the cavity 171 in the sealing members 150.

The functioning of the sealing members 150 in the balanced coupler 185 is essentially that as described in connection with the description given in connection with Figure 5.

It will also be apparent to those skilled in the art that the embodiment of the seal more specifically described in connection with Figure 2 may also be utilized in connection with the balanced coupler disclosed and described in connection with Figure 6.

Figure 7 illustrates another modification of the present invention and more particularly a modification of that illustrated in Figures 2 and in Figure 5. In the embodiment of Figure 7 there is illustrated an annularly extending sealing member 250 which resides in the space again generally referred to as space 42. The sealing member 250 is provided with inner and outer surfaces 254 and 255 which lie respectively adjacent the surfaces 22 and 32. The sealing member 250 in like fashion has first and second end surfaces 260 and 261, respectively, and the first end surface 260 is located adjacent the surface 36.

In this embodiment the annular retainer is identified by the reference numeral 264 and the first end surface of the retainer is identified by the reference numeral 266.

A first wall 270 extends into the sealing member and defines a first cavity 271. The cavity 271 which is defined is quite similar to the cavity 171 which has been discussed in connection with Figure 5 and the

cavity 71 which has been discussed in connection with Figure 2.

A second wall 276 extends into the inner surface 254 of sealing member 250 and defines a second cavity 277 which faces the circumferentially extending surface 22 of the end portion 21 of male member 20. The cavity 277 defines generally a U-shape or more properly an inverted U-shape.

The right most end of the sealing member 250 as viewed in Figure 7 is provided with a generally radially extending flange 280. The flange resides in what is referred to as a recess 282 which has been formed in the female member illustrated in this embodiment.

In this particular embodiment illustrated in Figure 7, the flange as located in the recess 282 and in combination with the annular retainer 264 provides an additional sealing function which prevents the passage of or leakage of fluid along the connection between the male and female members. In this particular embodiment, it is possible to not use the second cavity 277 which has been illustrated herein and the flange and cavity 271 will function together to provide a satisfactory and suitable sealing arrangement.

It has been found that in order to bring about the objects of the present invention as stated hereinabove that it is necessary that all of the sealing members of this invention be constructed of a polymeric elastomeric material which has a tensile strength of at least 5000 psi and a flexural modulus of elasticity of at least 300,000 psi. It is also desirable that the polymeric material have a high chemical resistance to acids, alkalis, hydrocarbons, ketones, ethers, esters, alcohols, salt solutions or a combination of chemicals normally found in oil exploration. The particular materials that have been found to meet the objects of the present invention and to meet

these specified and desired physical and chemical characteristics are found in the following chart:

Material Tensile Elongation Flexural Chemical Hardness Modulus Resist- Rockwell) of Elas- ance ticity

1. Poly- 14500 150% 5 55500000000 1 M99 (aryl psi psi ether- ketone)

2. Poly- 12000 20-25% 5 54400000000-' 1 M93 pheny- psi 600000 psi lene sulfide

3. Poly- 16000 5-18% 1 1,,000000,,0( 30000 2 M119 amide- psi psi imide

4. Molybe- 8000 5-150% 4 40000000000 ppssii 3 R110 nu psi disul- phide filled nylon

With the use of a sealing member having the herein described physical and chemical characteristic in combination with the male and female members of a hydraulic coupler bring about the desired objects as expressed hereinabove. The major accomplishment is that the opening in the sealing member 50 or in other words the inner diameter of the sealing member which the male member "sees" is essentially the same diameter each time the male member enters the female member as they are moved from uncoupled to coupled condition. As a result the same consistent seal is provided because the sealing member of the present invention has the qualities to return to the same consistent diameter when the members are uncoupled. This overcomes the disadvantage found in metal sealing members or rings where the opening gradually becomes larger and larger

with each uncoupling or use resulting in a less and less effective seal against fluid flow along inner face between the sealing member and the movable coupler parts. Material number 1 in the chart is sold under the trademark VICTREX PEEK by ICI Americas Inc. of Wilmington, Delaware. Material number 2 is sold under the trademark TECHTRON by The Polymer Corporation of Reading, Pennsylvania. Material number 3 is sold under the trademark TORLON by Amoco Chemical Corporation.

Material number 4 is sold under the trademark NYLATRON by The Polymer Corporation of Reading, Pennsylvania.

The present invention prevents the blowout of the sealing member 50 during separation of the male and female members.

While the invention has been described in combination with embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and scope of the appended claims.