PRIORITY CLAIM 
       [0001]    Applicant claims the benefit of the filing date of Aug. 21, 2014 of U.S. Provisional Patent Application Ser. No. 62/040,138, which application is incorporated herein by express reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to flexible “flex” couplings or joints for use with pipes in environments of noise, vibration or harshness (NVH) such as the exhaust pipes or conduits of an internal combustion engine. More particularly, this invention relates to load rings facilitating use and longevity of braid-covered bellows and the like wherein an outer braid sleeve could, without the invention, contact or load a surrounded bellows and unduly wear, permanently deform and/or fatigue it where the bellow is exposed to an unsupported load. 
       BACKGROUND OF THE INVENTION 
       [0003]    Known flexible couplings typically include a convoluted bellows surrounded by a flexible braided sleeve. In an effort to prevent exerting loads on the bellows resulting from braid contact when environmental loads are imposed at the coupling, the coupling is designed to accept or include load rings cooperating with end components of the couplings. 
         [0004]    The disadvantage of such known couplings appears in the requirement of different end components at the end of the coupling between a load supporting and non-load supporting version of the flexible element. A flexible element or coupling with load-supporting properties requires a load ring placed in between the bellows and braid, while the non-load supporting coupling does not. The end of the load-supporting flexible element has the load ring mounted on the bellows neck, then the braid is placed over this ring and finally an end ring cap is placed on top of all components. This configuration requires a different end ring cap when building a non-load supporting flexible coupling due to the empty gap created by the absence of the load ring in the non-load supporting coupling. Thus the couplings are particularly designed to accept the load rings and it is either difficult or not practical to provide non-load supporting couplings with load rings where the coupling is not initially designed to accept them. This requires more inventory and prevents provision of load rings to existing non-load supporting coupling configurations. Said in another way, existing ring designs require modification or re-design of end components to accommodate any prior load ring. 
       SUMMARY OF THE INVENTION 
       [0005]    The invention comprises a floating load ring placed in between the bellows and the braid. The load ring is held in place upon all the components at the end of the flex coupling being secured together. The load ring will not be attached to the adjoining pipes or coupling bellows by any weld as are the other components at the end of the coupling. The load ring can take infinite shapes and geometry. The invention contemplates integration of a floating load ring into the flexible coupling without needing to modify any of the existing coupling elements or components. The materials used for the ring components can be solid metal, compressed steel mesh wires, polymers, composites, or other suitable materials. 
         [0006]    The main advantage of this invention is that it can be added to existing non-load supporting flexible couplings and transform them into load-supporting flexible couplings without changing the design of any of the existing components in the flexible coupling and without manufacturing steps to attach the load rings in place. The invention reduces the costs and complexity of manufacturing interchangeability between load supporting and non-load supporting capability in the flexible coupling design. Also, the invention can be added to existing flex elements of the load-bearing type couplings to achieve similar benefits as those herein noted, i.e. reducing loads and wear on the bellows. 
         [0007]    The present invention improves the durability of the flexible coupling when exposed to dynamic unsupported loads by distributing the loads onto the floating rings at the end of the coupling rather than concentrating them on the surfaces of the convoluted bellows. 
         [0008]    The invention thus presents structures and methods for effectively compensating static and dynamic loads, and motion initiated by thermal and mechanical origins as well as noise, vibration and harshness (NVH), and other such concerns. The independent nature of the floating rings promotes lower cost products by reducing the variation between the component designs required at the end of the flexible coupling. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a cross-section view of one embodiment of the invention shown integrated into a full assembly of the load-supporting capable flexible element coupling; 
           [0010]      FIG. 2  is an isometric view of the invention in  FIG. 1  with the over braid illustrated in phantom; 
           [0011]      FIG. 3  is a cross-section of an embodiment of a load ring of the invention as in  FIG. 1 ; 
           [0012]      FIG. 4  is a cross-section of the invention in  FIG. 3  shown in place in an end of a full flexible coupling assembly; 
           [0013]      FIG. 5  is a cross-section of an alternate embodiment of a load ring of the invention; 
           [0014]      FIG. 6  is a cross-section of the invention in  FIG. 5  shown in place in an end of a full flexible coupling assembly; 
           [0015]      FIG. 7  is a cross-section of an alternate embodiment of a load ring of the invention; 
           [0016]      FIG. 8  is a cross-section of the invention in  FIG. 7  shown in place in an end of a full flexible coupling assembly; 
           [0017]      FIG. 9  is a cross-section of an alternate embodiment of a load ring of the invention; 
           [0018]      FIG. 10  is a cross-section of the invention in  FIG. 9  shown in place in an end of a full flexible coupling assembly; 
           [0019]      FIG. 11  is a cross-section of an alternate embodiment of a load ring of the invention; 
           [0020]      FIG. 12  is a cross-section of the invention in  FIG. 11  shown in place in an end of a full flexible coupling assembly; 
           [0021]      FIG. 13  is a cross-section of an alternate embodiment of a load ring of the invention; 
           [0022]      FIG. 14  is a cross-section of the invention in  FIG. 13  shown in place in an end of a full flexible coupling assembly; 
           [0023]      FIG. 15  is a cross-section of an alternate embodiment of a load ring of the invention; 
           [0024]      FIG. 16  is a cross-section of the invention in  FIG. 15  shown in place in an end of a full flexible coupling assembly; 
           [0025]      FIGS. 17A ,  17 B,  17 C and  17 D illustrate a plurality, in cross-section, of four different alternate embodiments of annular load rings of the invention; 
           [0026]      FIG. 18  is a cross-section of an alternate annular embodiment load ring of the invention; 
           [0027]      FIG. 19  is a cross-section of the invention in  FIG. 18  shown in place in an end of a full flexible coupling assembly; and 
           [0028]      FIG. 20  illustrates in elevational detail a woven mesh sleeve about the ring of  FIGS. 18 and 19 , and showing only the mesh and ring for clarity. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0029]    It should be readily understood that the profile geometry of the invention, as generally described and illustrated in the Figures herein and accompanying text, can be designed in a wide variety of shapes while still utilizing the inventive concept. 
         [0030]    For example, the radii of the loops in the load rings shown in  FIG. 3  and  FIG. 5  can be smaller or larger. Also, a load ring could be a solid piece without any loops and with round or square edges. 
         [0031]    Thus, the following more detailed description of the preferred embodiments of the invention, as presented in the figures and accompanying text, is not intended to limit the scope of the invention, but it is merely to represent the preferred and alternative embodiments of the invention. 
         [0032]    The embodiments of the invention will be best understood by reference to the drawings wherein like parts and configurations are designated by like numerals throughout. In the FIGS., ring and bellows are generally annular about a center-line axis and are generally symmetrical thereabout. 
         [0033]    Also note that the terms “flex” and “coupling” may sometimes be used interchangeably herein. When modified according to the invention, the “flex” or “coupling” includes a flexible bellows of multiple convolutions, an inner interlock liner or tube, a braided sleeve, end fittings and free floating load rings as described. 
         [0034]    Various loads exerted on the couplings described herein are lateral, such as when loads, radially and perpendicularly to the coupling axis, are exerted on the coupling (in the case of parallel but spaced pipes coupled at each end of the coupling); extension loads such as when the coupling ends are biased apart in an axial direction and bending, such as when the coupling is bent along its elongated center axis. 
         [0035]    Without the floating load ring of the invention each of these forces can cause braid to bellows contact, wearing, deforming or fatiguing the coupling. 
         [0036]    Referring to  FIG. 1 , a full coupling assembly according to the invention illustrates a load supporting flexible coupling  10  including braid or mesh  15 , bellows  20 , an inner liner commonly known as interlock  30 , an end ring  40 , and a load ring  50 , such as shown in  FIGS. 2-4 . 
         [0037]    Referring to  FIG. 2 , the floating load ring  50  is integrated at the end of the flexible coupling  10  independently of the diameter of the end ring  40 , and is integrated, without welding, into the existing assembly gaps between the components of the coupling  10 . The ring  50  is secured in the coupling  10  once all the other components are installed and in mere engagement with mesh  15  and end of bellows  20 . The manufacturing advantage of the invention is that it does not require a change of the existing components of the coupling  10  or the tooling/machinery required for assembly. The functional advantage of the invention is that when a high displacement/weight load is applied to the coupling  10 , ring  50  provides a full lock in extension protecting the bellows  20  and interlock liner  30  from being plastically deformed. This is accomplished by dissipating the forces from the braid  15  into the connecting end of the flex hose, as in  FIGS. 2 and 4 , by ring  50 . 
         [0038]    In this embodiment, ring  50  is an annular ring with annular reverse bend flanges or loops  51 ,  52  as shown in  FIG. 3 . Ring  50  carries loads exerted by braid  15 . Loop  52  dissipates the load from loop  51  onto the end of the flexible coupling  10  (i.e. at the annular end  23  of bellows  20  and the interlock liner  30  as in  FIG. 4 ). 
         [0039]    Referring to  FIG. 4 , the end of the flex  10  is shown with ring embodiment  50  integrated into the flexible coupling  10  assembly. Embodiment  50  is held in place against the end  21  of bellows  20  by the end ring  40  and braid  15 . 
         [0040]      FIG. 5  illustrates an alternate embodiment of a floating load ring  60  shown in a flexible coupling  58  ( FIG. 6 ). This embodiment includes two bend flanges formed by loops,  61  and  62 . Loop  61  carries the load from the braid  15 . Loop  62  dissipates the load from loop  61  onto the end  23 ,  30  of the components of flex  10 . 
         [0041]    Referring to  FIG. 6 , the end of the flex  10  is shown with floating load ring  60  integrated into the coupling assembly  58 . Ring  60  is held in place by the end ring  40  and braid  15  against bellow portion  21 . 
         [0042]      FIG. 7  illustrates a further alternate embodiment floating load ring  70  in a flexible coupling  68  ( FIG. 8 ). This embodiment includes two bends,  71  and  72 . Bend  71  carries the load from the braid. Bend  72  dissipates the load from bend  71  into the end of the flex coupling. Flange  73  of ring  70  provides a low stress concentration contact surface to the bellow end  23 . 
         [0043]    Referring to  FIG. 8 , the end of the coupling  68  is shown with ring  70  integrated into the coupling  68  assembly. Ring  70  is held in place against the bellow  20 ,  21  by the end ring  40  and braid  15 . 
         [0044]      FIG. 9  illustrates an alternate embodiment of a floating load ring  80  for a flex coupling  78  ( FIG. 10 ). This embodiment includes loop  81  and bend  82 . Loop  81  carries the load from the braid. Bend  82  dissipates the load from loop  81  onto the end of the flex hose. Flange  83  provides a low stress concentration contact surface to the braid. 
         [0045]    Referring to  FIG. 10 , the end of the flexible coupling  78  is shown with ring  80  integrated into the coupling  78 . Ring  80  is held in place against bellow  20  ( 21 ) by the end ring  40  and braid  15 . 
         [0046]      FIG. 11  illustrates an alternate embodiment of a floating load ring  90  for a flexible coupling  88  ( FIG. 12 ). This embodiment includes bend  91  and loop  92 . Bend  91  carries the load from the braid. Loop  92  dissipates the load from bend  91  into the end of the coupling  88  (i.e. bellows  20  end  23  and interlock liner  30 ). The leg  94  extended from loop  92  can be set with a determined stiffness so that it acts like a spring against the end convolution  21  of bellows  20 . This would add multiple stiffness properties to the coupling  88 . 
         [0047]    Referring to  FIG. 12 , the end of the coupling  88  is shown with ring  90  integrated into the flex hose assembly. Ring  90  is held in place against bellow convolution  21  and braid  15 . 
         [0048]      FIG. 13  illustrates an alternate embodiment of a floating load ring  100  for use in a flexible coupling  98  ( FIG. 14 ). This embodiment includes an integral solid body ring with curved ends or edges  101  and partially curved interior end or edge  102 . End  101  carries the load from the braid  15 . End  102  dissipates the load from end  101  into the end of the coupling  98  (i.e. bellows  20  and interlock  30 ). 
         [0049]    Referring to  FIG. 14 , the end of the coupling  98  is shown with ring  100  integrated into the coupling  98  assembly. Ring  100  is held in place against bellow convolution  21  by the end ring  40  and braid  15 . 
         [0050]      FIG. 15  illustrates an alternate embodiment of a floating integral, solid load ring  110  for a flexible coupling  108  ( FIG. 16 ). This embodiment includes two fully curved ends or edges,  111  and  112 . Curved end  111  carries the load from the braid  15 . End  112  dissipates the load from end  111  into the end of the coupling  108  (i.e. end of bellows  20  and interlock liner  30 ). 
         [0051]    Referring to  FIG. 16 , the end of the coupling  108  is shown with ring  110  integrated into the coupling  108  assembly. Ring  110  is held in place against bellows convolution  21  by the end ring  40  and braid  15 . 
         [0052]      FIG. 17  (i.e.  17 A,  17 B,  17 C and  17 D) illustrate four alternative different embodiments of floating, integral, solid load rings according to the invention and with ends or peripheral edges of various configurations somewhat similar to the integrated rings of  FIGS. 13 and 15 . 
         [0053]    Ring  120  is rectangular in cross-section, ring  130  is rectangular with a clipped annular edge  131 . Ring  140  is generally rectangular in cross-section but with four clipped annular edges  141 - 144 . Ring  150  is generally rectangular in cross-section with two annular clipped edges  151 , 152 . 
         [0054]    Each ring of  FIGS. 13 ,  15  and  17 A- 17 D have outer and inner peripheral edges as shown. 
         [0055]    Each of the floating load rings  120 ,  130 ,  140  and  150  are used in a flexible coupling as in the prior Figures, the respective ring captured with an upper or outer edge supporting a braid  15 , and the lower or inner edge dissipating load from a braid  15  onto an end of a flexible coupling such as onto an annular end  23  of a bellows as shown in prior figures and end of an interlock liner  30  without welding or fixed attachment to any element of the flexible coupling. 
         [0056]      FIGS. 18 ,  19  and  20  show one embodiment of a solid, integral annular load ring  160  circular in cross-section. This embodiment includes a halo-shaped annular ring  160  that is embedded into a mesh  170  by interlacing and alternating the mesh loops around the halo ring  160  near mesh end  171  ( FIG. 20 ). Halo ring  160  carries the load from the mesh  170  when the flex coupling  180  is pulled in extension preventing the mesh  170  from contacting the bellows  20 . In this regard, the loops  171 ,  172  of mesh  170  diverge on either side of ring  160  as shown in  FIG. 17 . 
         [0057]      FIGS. 19 and 20  are illustrative of the encapsulation of a ring  160  within mesh  15 . 
         [0058]    It will thus be appreciated in all embodiments that similar components are referred to by similar numerical designations, and that all the disclosed load rings are universally free-floated, and load dissipating, where loads are exerted by forces in the mesh caused by a variety of forces on the associated couplings, and dissipated by the rings onto end components of the couplings. This function spaces the braids or mesh from the outer crowns or outer surfaces of the bellows convolutions, reducing or preventing undue vibration, wear, fatigue or failure of the flexible coupling and bellows. 
         [0059]    These and other modifications and alternatives will be readily appreciated by those of ordinary skill in the art to which this invention pertains, without departing from the spirit or scope of the invention and applicant intends to be bound only by the claims appreciated hereto. 
         [0060]    Finally it will be appreciated as described herein that the rings as described are held in place in the couplings by engagement of the components facing the rings, such as the braid and the bellows without physical connection of the ring to the coupling such as by welding, crimping, inter-engaging structural interlock or the like, the rings simply being placed in position and held therein by engagement thereof by coupling elements. This permits use of free-floating load bearing rings in coupling without particular coupling modification dependent on a ring or its usage.
A free-floating load ring for assembly into a flexible coupling having a convoluted bellows and a surrounding mesh sleeve, said ring captured by said sleeve at an end of said coupling and spacing said sleeve from said bellows when forces are applied to said coupling. Various ring alternate structures are disclosed, and can be added to existing non-load supporting or flexible couplings having no previous rings. The load ring is retained in place by engagement of coupling components with the ring without physical connection of the ring to any coupling component.