WO2022005963A1

WO2022005963A1 - Welded ferrule and method of making same

Info

Publication number: WO2022005963A1
Application number: PCT/US2021/039364
Authority: WO
Inventors: Marvin Miller
Original assignee: Gates Corporation
Priority date: 2020-06-30
Filing date: 2021-06-28
Publication date: 2022-01-06
Also published as: TW202219414A

Abstract

A welded ferrule and related methods of manufacturing a welded ferrule include providing a length of material, forming at least one profile member along a surface of the length of material, shearing the length of material into a strip having a length and the at least one profile member, forming the strip into a split ring with opposite ends arranged adjacent to each other and the at least one profile member positioned internal the split ring, and welding the opposite ends together to form the ferrule. The welded ferrule may also be annealed and plated. The welded ferrule may be crimped onto a free end of a hose or other elongate member.

Description

WELDED FERRULE AND METHOD OF MAKING SAME

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0001] This invention relates generally to ferrules for use in crimping onto a hose, and more particularly relates to welded ferrules and related methods of manufacturing welded ferrules.

2. Description of the Prior Art

[0002] Ferrules typically are used for crimping on a hose, such as a hydraulic hose, and include internally positioned ribs that can hold and seal the hose onto a stem. Conventional processes for making ferrules include machining the ferrule from a steel bar or cold headed blank. This required expensive CNC or screw machines, and these machines wear out tooling that must be repaired and/or replaced. Further, the cycle times for creating a ferrule by such machining techniques range from 90 seconds to several minutes in duration for each part. Significant scrap is generated using these methods, typically about 20% scrap for cold headed blanks and about 80% scrap for machining from bar stock.

[0003] There is a need for an improved ferrule and related methods of manufacturing such ferrules that address these and other disadvantages of existing ferrules.

SUMMARY OF THE INVENTION

[0004] The present disclosure is directed to a method of manufacturing a ferrule, and related welded ferrules. One aspect of the present disclosure relates to a method of manufacturing a ferrule that includes providing a profiled metal strip, forming the profiled metal strip into a split ring, and welding the split ring to form a continuous ring-shaped ferrule.

[0005] The profiled metal strip may include a flat surface on a first side, and at least one profile member on a second side, and the at least one profile member may be positioned on an interior of the continuous ring-shaped ferrule. Welding the split ring may include connecting opposite ends of the profiled metal strip along an exterior, radially outward facing surface of the split ring, and opposite ends of the at least one profile member may be disconnected after welding the split ring. The at least one profile member may include a plurality of profile members. The plurality of profile members may include a plurality of ribs, and at least some of the plurality of ribs may have at least one of different sizes, different shapes, or different spacing between adjacent ribs. The method may include coining or otherwise shaping at least one end of the profiled metal strip before forming the profiled metal strip into the split ring. The method may include contacting end surfaces of the split ring prior to welding the split ring. Welding the split ring may include at least one of tungsten inert gas (TIG) welding, plasma welding, laser welding, or brazing with or without filler material. The method may include at least one of heat treating and plating the continuous ring-shaped ferrule. The split ring may include a gap between opposing ends of the profiled metal strip, and the method may include applying a compression force to the split ring to reduce the gap during welding.

[0006] Another aspect of the present disclosure relates to a metal ferrule that includes a smooth outer surface, a pass-through bore, at least one profile member extending circumferentially along an interior surface of the pass-through bore, and a weld extending longitudinally along the outer surface to connect otherwise disconnected edges of the ferrule.

[0007] The at least one profile member may include a plurality of profile members.

The at least one profile member may include profile members having different sizes. The weld may include filler material. The otherwise disconnected edges may include coined or otherwise shaped ends of a profiled metal strip that is formed into a split ring.

[0008] Another aspect of the present disclosure relates to a method of fabricating a metal ferrule, wherein the method includes providing a strip of metal, the strip of metal having a smooth first surface and a profiled second surface, the second surface being arranged opposite the first surface, coining or otherwise shaping opposite ends of the strip of metal, forming the coined shaped strip of metal into a split ring with the opposite ends arranged adjacent to each other, and welding the opposite ends together form the ferrule.

[0009] The method may also include applying a compression force to the split ring to move the ends toward each other prior to welding. Welding may include at least one of tungsten inert gas (TIG) welding, plasma welding, laser welding, or brazing with or without fdler material. The method may include at least one of heat treating and plating the ferrule after welding. The ferrule may include a pass-through bore, and the profiled second surface may include a plurality of profile members arranged circumferentially and spaced apart along a longitudinal axis of the ferrule within the pass-through bore.

[0010] A further aspect of the present disclosure relates to a method of fabricating a ferrule, wherein the method includes providing a length of material, forming at least one profile member along a surface of the length of material, shearing the length of material into a strip having a length and the at least one profile member, forming the strip into a split ring with opposite ends arranged adjacent to each other and the at least one profile member positioned internal the split ring, and welding the opposite ends together to form the ferrule.

[0011] The length of material may include a metal material and connecting the opposite ends may include welding the opposite ends together. The method may include coining or otherwise forming the opposite ends to include a radius before forming the strip into the split ring. Forming the at least one profile member may include forming a plurality of profile members into a primary surface of the length of material. Forming the at least one profile member may include cold rolling the length of material through a plurality of rollers to form a plurality of profile members. Forming the strip into a split ring may include rolling the strip of material to push the strip of material into the split ring. The method may include annealing at least a welded portion of the ferrule. The method may include plating the ferrule after welding. The method may include grinding, sanding, scraping, or flattening a welded portion of the ferrule along an exterior surface of the ferrule.

[0012] Another aspect of the present disclosure relates to a method of fabricating a metal ferrule, wherein the method includes providing a strip of metal, the strip of metal having a smooth first surface and a profiled second surface, the second surface being arranged opposite the first surface, coining or otherwise shaping the strip of metal to form a radius in each of the opposite ends, forming the coined or otherwise shaped strip of metal into a split ring with the opposite ends arranged adjacent to each other, welding the opposite ends together to form a weld portion along a length of the ferrule, and annealing at least the weld portion. Providing the strip of metal may include forming the profiled second surface in a length of metal material, and shearing the length of metal material into the strip of metal.

[0013] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The accompanying drawings, which are incorporated in and form part of the specification in which like numerals designate like parts, illustrate embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:

[0015] FIG. 1 is a perspective view of an example welded ferrule in accordance with the present disclosure.

[0016] FIG. 2 is an end view of the welded ferrule shown in FIG. 1.

[0017] FIG. 3 is a cross-sectional view of the welded ferrule shown in FIG. 2 taken along cross-section indicators 3-3.

[0018] FIG. 4 is a partial cross-sectional view of the ferrule shown in FIG. 1 mounted to a hose and stem prior to crimping. [0019] FIG. 5 is a cross-sectional view of a portion of another example ferrule crimped to a stem and a wire-reinforced hose.

[0020] FIG. 6 is a cross-sectional view of a portion of another example ferrule crimped to a stem and a general purpose hose.

[0021] FIG. 7 is a perspective view showing a cold rolling step to form a profiled strip in accordance with the present disclosure.

[0022] FIG. 8 is a perspective view showing a straightening step to straighten the profiled strip shown in FIG.7;

[0023] FIG. 9 is a perspective view showing a portion of the profiled strip of FIG. 8 cut to length.

[0024] FIG. 10 is a perspective view of the length of profiled strip shown in FIG. 9 with ends of the strip coined or otherwise formed and/or shaped to a desired radius.

[0025] FIG. 11 is a perspective view showing the shaped strip of FIG. 10 formed into a split ferrule.

[0026] FIG. 12 is an end view of the split ferrule shown in FIG. 11 prepared for welding.

[0027] FIG 13 is a perspective view of a welded ferrule in accordance with the present disclosure.

[0028] FIG. 14 shows the welded ferrule of FIG. 13 with the weld strip annealed to increase malleability of the welded ferrule.

[0029] FIG. 15 is a perspective view showing the welded ferrule of FIG. 14 attached to a stem to make a coupling assembly.

[0030] FIG. 16 is a perspective view of the coupling assembly shown in FIG. 15 crimped to a hose.

[0031] FIG. 17 is a flow chart of an embodiment of a method in accordance with the present disclosure. [0032] FIG. 18 is a flow chart of another embodiment of a method in accordance with the present disclosure.

DETAILED DESCRIPTION

[0033] The present disclosure relates to welded ferrules and provides methods and apparatuses for manufacture of welded ferrules. The welded ferrule is produced by a multi- step process. The process may include all or only some of the manufacturing steps disclosed herein. A single manufacturer may perform all or only some of the steps disclosed herein.

[0034] In one example method of manufacturing, an initial step includes forming a profiled strip from a length of stock material. The profiled strip may include, on one side of the strip, a profile that includes a plurality of ribs, grooves and/or protmsions spaced apart across the width of the strip. An opposite side of the profiled strip may include, for example, a smooth surface. The profiled strip may be rolled up onto spools such as a four (4) foot diameter spool for shipping or storage purposes. Collecting the profiled strip onto a spool may create a bend along the length of the profiled strip. The profiled strip may later be straightened by passing the profiled strip through a plurality of rollers. The straightened profiled strip may then be cut or sheared to a desired length. The length of the profiled strip may relate to the completed inner or outer diameter of the resulting ferrule. Opposite ends of the length of the profiled strip may be coined to a desired radius. Other forming methods besides coining may be used to form or otherwise shape the profiled strip into a desired shape. The coined or otherwise shaped strip may then be formed into a split fermle of a desired diameter. The coiled or otherwise shaped ends of the strip may be arranged adjacent to each other. In at least some examples, the ends are arranged touching each other, while in other arrangements a gap exists between the coined or otherwise shaped ends.

[0035] The split ferrule is then welded to connect to the coined or otherwise shaped ends together to form a continuous ferrule. The weld may be annealed to create a more malleable ferrule material that is better suited for crimping. The weld may be ground, sanded, or otherwise smoothed along an exterior surface of the ferrule prior to or after the annealing step. The ferrule may also be plated or otherwise coated. [0036] The completed fermle may be mounted to a stem and/or hose (or other elongate structure such as a cable, wire, rope, or the like). The profile members of the ferrule along its interior surface may mate with features of the stem and/or hose to provide a desired connection therebetween when the ferrule is crimped onto the stem and/or hose. The profile features may be customized for use with different types of hoses, stems, and/or other materials such as a cable, rope, wire, etc. in place of the hose and/or stem.

[0037] Referring now to FIG. 1, an example welded ferrule 10 is shown and described. The ferrule 10 includes a pass-through bore 12 that includes a plurality of profile members 14 exposed within the bore 12. The profile members typically extend circumferentially rather than axially along the length of the bore 12. The ferrule 10 also includes first and second side edges 16, 18, and first and second ends 20, 22. A weld 24 is provided between the first and second sides edges 16, 18. The weld 24 is formed along an outer surface 26 of the ferrule.

The weld 24 may extend through the thickness of the ferrule 10 so as to be exposed along the pass-through bore 12 and/or formed on the profile members 14. The outer surface 26 typically is smooth, but may have surface features formed therein. In at least some examples, the area of the weld 24 along the outer surface 26 is ground, sanded, polished or something similar to match the weld surface with the smooth outer surface 26.

[0038] The ferrule 10 may have an inner diameter Di associated with the pass-through bore 12, and an outer diameter D2, as shown in FIG. 2. The ferrule 10 may also have a length Li as shown in FIG.1. In one example, the inner diameter Di may be in the range of about 0.5 inches to about 4 or more inches. The length may be, in some embodiments, in the range of about 0.5 inches to about 10 inches, and more particularly in the range of about 1 inch to about 3 inches.

[0039] The profile members 14 may have different shapes and sizes, and may be spaced apart from each other at variable distances. FIG. 3 shows a cross-sectional view of the ferrule 10 showing the profile members 14 having various heights, shapes, sizes and spacings. The profile members 14 include a plurality of profile members 14A having a height Fh, and a plurality of smaller profile members 14B having a height of Hi. Each of the profile members has a generally triangular shape. The profile members 14B are spaced apart a distance Si. The profile members 14A are spaced apart a distance S3. The profile members 14 A, 14B positioned closest to each other are spaced apart a distance of S2.

[0040] The spacings Si, S2, S3, heights Hi, ¾, shapes and other parameters for the profile members 14 may vary depending on a variety of conditions. For example, the profile members may be designed for a mating with different types of structures such as hoses, cables, wires, and ropes, different types of materials, such as metal, fabric, polymers, and the like, or different structures such as stem structures, mandrels, hoses, and related mating features on those structures such as grooves, latches, barbs, and other coupling features.

[0041] FIGS. 5 and 6 illustrate different profile configurations for use in mating with various stem and hose devices. FIG. 4 shows the welded ferrule 10 mounted to a hose 30 having a bore 32, and a stem 34 having a bore 36, a groove 38, a seat 40, protrusions 44, and a coupling feature 46. The seat 40 includes a plurality of barbs 42. The hose 30 may be a standard rubber hose, or may be a hose having other features such as fabric reinforcement, polymer materials, or the like. FIG. 5 illustrates a ferrule 100 having a plurality of profile members 114A, 114B, 114C, 114D and made with features of a hose 130 and a stem 134.

The hose 130 includes a bore 132, and the stem 134 includes a bore 136, a groove 138, a seat 140 having barbs 142, and a protrusion 144. One of the profile members 114A engages with the groove 138 in a latch area 102. Other of the profile members 114C engage with the hose 130 in a wire trap area 104. The profile members 114B engage with a hose 130 in a sealing area 106. A final one of the profile members 114D engages with a hose 130 in a weather seal area 108 to prevent exposure to the elements. The hose 130 may be a wire-reinforced hose. The profile members 114A-D may have different cross-sectional shapes and/or sizes to assist in any of the latching, wire retention, sealing, and weatherproofing functions for the ferrule 100 at the interface with the hose 130 and/or stem 134.

[0042] FIG. 6 shows another example ferrule 200 mating with a hose 230 and a stem 234. The ferrule 200 includes a plurality of profile members 214A, 214B. The hose 230 has a bore 232, and the stem 234 includes a bore 236, a groove 238, a seat 240, and a protrusion 244. The profile member 214A engages with the groove 238 in a latching area 202. The remaining profile members 214B engage with the hose 230 in a sealing area 204. The hose 230 may be a general purpose rubber hose with or without any reinforcing features. The shape and size of the profile members 214A and 214B may be customized for use with the particular type of hose 230 and features of stem 234. For example, since the ferrule 200 is used primarily for a sealing interface with the hose 230, the profile members 214B may have a more rounded, contoured cross-sectional shape as opposed to the more triangular cross- sectional shape for the profile members 14 of ferrule 10.

[0043] Referring now to FIGS. 7-16, methods of manufacturing and applying a ferrule, including crimping a ferrule onto a hose, are shown and described. FIG. 7 illustrates an initial step of forming a profiled metal strip 50 from a length of stock material 70. The stock material 70 may have any desired cross-sectional shape such as, for example, the circular cross-sectional shape shown in FIG. 7. The stock material 70 typically is rolled upon a spool and is unrolled as it is drawn through one or more pairs of shaping rollers 72, 74. FIG. 7 illustrates a first shaping roller 72 that forms a plurality of profiles on one primary surface of the metal strip 50. A second shaping roller 74 is positioned opposite the first shaping roller 72 and forms an opposite primary surface of the metal strip 50. Typically, the second shaping roller 74 provides a relatively smooth surface opposite the profiled surface. The first shaping roller 72 may include a plurality of grooves and protrusions. The grooves and/or protrusions may have different shapes and/or sizes and different spacings across the width of the shaping roller 72 to provide the desired profiled shape on the resulting metal strip 50. In some embodiments, a plurality of first shaping rollers 72 and/or roller dies, a plurality of second shaping rollers 74 and/or roller dies, and other equipment are used to create the desired profiles for the metal strip 50.

[0044] In some embodiments, forming the profile metal strip 50 includes cold rolling the length of stock material 70. Cold rolling may be preferred in at least some examples as compared to other types of forming, such as forming methods that involve heat and the associated possibility of shrinkage and/or changed dimensions in the profile features resulting from the use of heat. In some examples, two or more sets of rollers are provided to form the profiled shapes in the metal strip 50. Each of these sets of rollers may define or further define certain features of the metal strip such as, for example, different shapes, sizes or the like of various profile members. [0045] In some manufacturing methods, the metal strip 50 is formed into a flat strip that is then further processed, such as being sheared into desired lengths for forming into the ferrule as described with reference to the FIGS. 7-12. In other examples, the metal strip 50 is collected upon a spool, such as being rolled up upon a large diameter spool (e.g., a spool having a core diameter in the range of about two feet to about six feet). Typically, the profiled metal strip 50 is collected in only a single layer on the spool so as to avoid damage to the profile members that may otherwise occur if multiple layers of the metal strip 50 are rolled upon the spool. The profiled metal strip 50 is collected on a spool typically for the purpose of storage, shipping, and/or further manufacturing steps.

[0046] FIG. 8 illustrates another example step in the manufacturing process wherein the metal strip 50 is straightened so as to have a flat overall profile. The steps shown in FIG.

8 may involve a plurality of first shaping rollers 72A and a plurality of second shaping rollers 74A arranged opposite each other and spaced apart along the length of the metal strip 50. In some embodiments, other equipment such as additional rollers and dies are used to create the desired shape for the metal strip 50.

[0047] The straightened metal strip 50 is then sheared to a desired length L2 as shown in FIG. 9. The length L2 may be determined based on a desired dimension of a resulting ferrule such as, for example, the inner diameter Di or outer diameter D2 as shown in FIG. 2. As described above, the sheared length of metal strip 50A include a plurality of first profile members 14A, a plurality of second profile members 14B, and opposite first and second side edges 16, 18.

[0048] An intermediate step in the manufacturing process may include coining the opposite edges 16, 18 of the length of metal strip 50 as described with reference to FIG. 10. Coining the edges 16, 18 to include a desired radius Ri, R2, respectively to form coined or otherwise shaped portions 52, 54 may be helpful in forming the metal strip 50 into a split ring as shown in FIG. 11. If the edges 16, 18 are not coined or otherwise shaped, the edges 16, 18 tend to be relatively flat or planer, which when mated to form a ferrule results in a flat portion around the circumference of the ferrule rather than a continuous round shape around the circumference of the ferrule. By providing coined or otherwise shaped portions 52, 54, as shown in FIG. 10, before forming the metal strip 50 into a split ring, the continuous radius around the circumference is provided without additional bending along the edges 16, 18.

[0049] Coining is known to be a form of precision forming in which a work piece is subjected to sufficiently high stress to induce plastic flow on one or more surfaces of the material. Coining is often used when high relief or very fine features are required, which makes it particularly useful when dealing with the profile members 14A and 14B of the profiled metal strip 50 shown in FIGS. 9 and 10. Coining is typically a cold forming process similar to forging, which takes place at high temperatures, but uses high force and no temperature to plastically deform the work piece so the work piece conforms to a desired shape. Coining is typically performed using a higher pressure than stamping in order to create the desired plastic deformation.

[0050] Whether or not the coining process is used to form coined or otherwise shaped portions 52, 54 as shown in FIG. 10, the metal strip 50 is eventually rolled up in another forming process to push the relatively flat shape of FIGS. 9 and 10 into the split ring shape shown in FIG. 11. The rolling process to form the split ring shown in FIG. 11 typically does not utilize a mandrel so as to avoid contact with the profile members 14A and 14B that might otherwise misshape the profile members 14A and 14B. In at least some examples, the rolling process used to form the split ring results in the first and second side edges, 16, 18 being moved into contact with each other. In some examples, the side edges 16, 18 remain spaced apart a small amount to provide a gap 62. Typically, the gap 62 is less than about 0.01 inches, and more particularly in the range of about 0.001 to about 0.1 inches. Typically, the smaller the gap 62, the less filler material is needed during the welding process, or the need for a filler may be completely eliminated if the gap is sufficiently small, depending on the type of welding performed to connect the side edges 16, 18.

[0051] In some arrangements, as shown in FIG. 10, a force F is applied to the split ring 60 during a welding process (e.g., using a welder 64) to close the gap 62 and/or press the edges 16, 18 together. In other arrangements, the force F is not required in order to close or minimize the gap 62 during the welding process. The force F may be applied to the split ring at any location. The welding process performed by welder 64 may be any of a variety of different available welding processes including, for example, tungsten inert gas (TIG) welding, plasma welding, laser welding, or brazing with or without filler material.

[0052] The welding process may weld together an entirety of the interface between the edges 16, 18, including the interface between the profile members 14A and 14B. In other examples, the weld is provided along an exterior portion of the ferrule such as along the outer surface 26 as shown in FIG. 13, but does not extend into the interface between the profile members 14A and 14B, leaving the ends of one or more profile members disconnected or with a gap. The structure and connecting effects of the welding may depend on the type of welding method as well as the time and temperature applied. Further, the shape of the split ring along the opposite first and second ends 20, 22, particularly at the interface between the ends 20, 22 and the outer surface 26, may influence the resulting weld 24 shown in FIG. 13. In at least some examples, the ends 20, 22 may include a radius, chamfer or other surface features that improves the quality or the characteristics of the weld 24.

[0053] The resulting weld 24 may extend above the outer surface 26 and/or have a shape, size or appearance that does not match that of the outer surface 26 or remaining portions of the ferrule 10. Although the shape or appearance of the weld 24 may not influence the overall functionality of the ferrule 10, for aesthetic purposes, it may be desirable to grind, sand, or otherwise smooth out the weld 24 along the outer surface 26.

[0054] Referring to FIG. 14, a further step of annealing the weld 24 and surrounding portions of the ferrule 10 may be desirable to improve the malleability of the weld 24 and/or ferrule 10 generally. The annealing process may soften the material of the weld 24 and the material of the ferrule 10 surrounding the weld. The annealing process may create a more even distribution of the material in the zone of the weld 24. Annealing may change the properties of weld material and surrounding material of the ferrule 10 sufficiently to permit later crimping of the ferrule 10 without failure of the ferrule. The annealing step may be optional depending on, for example, the materials of the ferrule 10, the amount of crimping necessary, the welding method used, and the like.

[0055] A further manufacturing step may include plating the ferrule 10. The plating step may occur at any point after the welding step described with reference to FIG. 13. The plating step may include adding a coating or surface treatment for the ferrule 10. The plating may provide improved corrosion resistance of the ferrule 10. Other surface treatments, such as passivation and waxing, may be used in place of or in addition to plating, depending on, for example, the type of material used for the ferrule.

[0056] Referring FIG. 15, a completed ferrule 10 (e.g., after welding, annealing, and the like) may be used with a stem 34 to create a coupling assembly. The coupling assembly may be used to secure the stem 34 to a hose or another elongate object. The stem 34 includes a hollow bore 36, a seat 40, a coupling feature 46, and other features as described above with reference to FIG. 4. The stem 34 may be particularly designed and configured for connection to a hose, such as the hose 30 shown in FIG. 16. The hose 30 is shown inserted over the seat 40 and into the pass-through bore 12 of the ferrule 10. Thereafter, the ferrule 10 is crimped as shown in FIG. 16 to secure the stem 34 to the hose 30. In at least some examples, the stem 34 provides a hydraulic connection feature to the hose 30. In other examples, stems may be used for other purposes alone or in combination with the ferrule 10 or other ferrule embodiments disclosed herein. As discussed above, the ferrule 10 and other ferrule embodiments disclosed herein may be used separate from a stem and may be crimped or otherwise attached directly to an elongate structure (e.g., cable, wire, rope or hose).

[0057] FIG. 17 is a flow diagram illustrating steps of an example method 300 in accordance with the present disclosure. The method 300 may be an example of any of the methods of manufacture and use associated with the ferrules disclosed herein, or portions thereof. The method 300 may include, at step 305, a step of providing a profiled metal strip. Block 310 includes forming the profiled metal strip into a split ring. At block 315, the method 300 includes welding the split ring to form a continuous ring-shaped ferrule.

[0058] The method 300 may also include providing a profiled metal strip with a flat surface on a first side, and in at least one profile member on a second side, wherein the at least one profile member is positioned on an interior of the continuous ring-shaped ferrule. The method 300 may also include providing the at least one profile member as a plurality of profile members. The plurality of profile members may include a plurality of ribs, and at least some of the plurality of ribs may have at least one of different sizes, different shapes, or different spacings between adjacent ribs. The method 300 may further include coining at least one end of the profiled metal strip before forming the profiled metal strip into the split ring. The method 300 may include contacting end surfaces of the split ring prior to and/or during welding the split ring. Welding the split ring may include at least one of tungsten inert gas (TIG) welding, plasma welding, laser welding, or brazing with or without filler material. The method 300 may include at least one of heat treating and plating the continuous ring- shaped ferrule. The heat treating may include annealing the material of the weld and/or the ferrule material generally. The split ring may include a gap between opposing ends of the profiled metal strip, and the method may further include applying a compression force to the split ring to reduce the gap during welding. Welding a split ring may include connecting opposite ends of the profiled metal strip along an exterior, radially outward facing surface of the split ring.

[0059] FIG. 18 illustrates another example method 400 in accordance with the present disclosure. The method 400 may be an example of one or more of the methods of manufacture and/or use described above with reference to the example ferrules described herein, or portions of such methods. At block 405, the method 400 includes providing a strip of metal, the strip of metal having a smooth first surface and a profiled second surface, the second surface being arranged opposite the first surface. At block 410, the method 400 includes coining opposite ends of the strip of metal. At block 415, the method includes forming the coined or otherwise shaped strip metal into a split ring with the opposite ends of the split ring arranged adjacent to each other. At block 420, the method 400 includes welding the opposite ends together. Block 425 includes annealing the weld to create a malleable ferrule that is capable of being crimped without the weld failing.

[0060] The method 400 may also include forming a profiled surface in a length of metal material and shearing the length of metal material to form the strip of metal. Providing the strip of metal may include cold rolling the strip of metal through a plurality of rollers to form a plurality of profile members. Forming the strip into a split ring may include rolling the strip of material to push the strip of material into the split ring shape. The method 400 may also include plating the ferrule after welding. The method 400 may include grinding, sanding, scraping or flattening the weld along an exterior surface of the ferrule. [0061] The welded ferrules and related methods of manufacture disclosed herein may provide one or more of the following improvements and/or advantages as compared to conventional solutions:

• Provide equivalent properties in a welded ferrule as that of a machined ferrule, but with a much less expensive and faster creation for the welded ferrule.

• By rolling and forming the welded ferrule, it is possible to avoid having to use bubble crimping or other post forming steps on a completed ferrule.

• By rolling and forming as a part of a welded ferrule method, it is possible to create complex geometries and profile shapes internal the pass-through bore of the ferrule.

• It is possible to use standard dies in the industry to create the profile shapes and form the strips into split rings as part of creating the welded ferrules disclosed herein.

• The time required to create the welded ferrules may be orders of magnitude less than the amount of time required for machining a ferrule. For example, the reduction in time may be as much as l/20th of the amount of time as compared to known machining methods to create ferrules. In one example, the disclosed welded ferrules can be manufactured in less than 10 seconds while traditional machined ferrules require 80-200 seconds.

• Significant reduction in scrap compared to machined ferrules, including zero scrap in some welded ferrule manufacturing methods disclosed herein.

• Reduced tooling wear because of reduced use and number of tools used.

• Reduced capital requirements because fewer tools and machining required.

[0062] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations can be made herein without departing from the scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods, and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. The invention disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein.

Claims

CLAIMS What is claimed is:

1. A method of manufacturing a ferrule, comprising: providing a profiled metal strip; forming the profiled metal strip into a split ring; and welding the split ring to form a continuous ring-shaped ferrule.

2. The method of claim 1, wherein the profiled metal strip includes a flat surface on a first side, and at least one profile member on a second side, the at least one profile member being positioned on an interior of the continuous ring-shaped ferrule.

3. The method of claim 2, wherein welding the split ring includes connecting opposite ends of the profiled metal strip along an exterior, radially outward facing surface of the split ring, and opposite ends of the at least one profile member are disconnected after welding the split ring.

4. The method of claim 2, wherein the at least one profile member includes a plurality of profile members.

5. The method of claim 4, wherein the plurality of profile members includes a plurality of ribs, at least some of the plurality of ribs having at least one of different sizes, different shapes, and different spacing between adjacent ribs.

6. The method of claim 1, further comprising coining at least one end of the profiled metal strip before forming the profiled metal strip into the split ring.

7. The method of claim 1, further comprising contacting end surfaces of the split ring prior to welding the split ring.

8. The method of claim 1, wherein welding the split ring includes at least one of tungsten inert gas (TIG) welding, plasma welding, laser welding, and brazing with or without filler material.

9. The method of claim 1, further comprising at least one of heat treating and plating the continuous ring-shaped ferrule.

10. The method of claim 1, wherein the split ring includes a gap between opposing ends of the profiled metal strip, the method further comprising applying a compression force to the split ring to reduce the gap during welding.

11. A metal ferrul e compri si ng : a smooth outer surface; a pass through bore; at least one profile member extending circumferentially along an interior surface of the pass-through bore; and a weld extending longitudinally along the outer surface to connect otherwise disconnected edges of the ferrule.

12. The ferrule of claim 11, wherein the at least one profile member includes a plurality of profile members.

13. The ferrule of claim 11, wherein the at least one profile member includes profile members having different sizes.

14. The ferrule of claim 11, wherein the weld includes filler material.

15. The ferrule of claim 11, wherein the otherwise disconnected edges include coined ends of a profiled metal strip that is formed into a split ring.

16. A method of fabricating a metal ferrule, comprising: providing a strip of metal, the strip of metal having a smooth first surface and a profiled second surface, the second surface being arranged opposite the first surface; shaping opposite ends of the strip of metal; forming the shaped strip of metal into a split ring with the opposite ends arranged adjacent to each other; and welding the opposite ends together to form the ferrule.

17. The method of claim 16, further comprising applying a compression force to the split ring to move the opposite ends toward each other prior to welding.

18. The method of claim 16, wherein welding includes at least one of tungsten inert gas (TIG) welding, plasma welding, laser welding, or brazing with or without filler material.

19. The method of claim 16, further comprising at least one of heat treating and plating the ferrule after welding.

20. The method of claim 16, wherein the ferrule includes a pass-through bore, and the profiled second surface includes a plurality of profile members arranged circumferentially and spaced apart along a longitudinal axis of the ferrule within the pass-through bore.

21. A method of fabricating a ferrule, comprising: providing a length of material; forming at least one profile member along a surface of the length of material; shearing the length of material into a strip having a length and the at least one profile member; forming the strip into a split ring with opposite ends arranged adjacent to each other and the at least one profile member positioned internal the split ring; and connecting the opposite ends together to form the ferrule.

22. The method of claim 21, wherein the length of material comprises a metal material and connecting the opposite ends includes welding the opposite ends together.

23. The method of claim 22, further comprising coining the opposite ends to include a radius before forming the strip into the split ring.

24. The method of claim 21, wherein forming the at least one profile member includes forming a plurality of profile members into a primary surface of the length of material.

25. The method of claim 21, wherein forming the at least one profile member includes cold rolling the length of material through a plurality of rollers to form a plurality of profile members.

26. The method of claim 21, wherein forming the strip into a split ring includes rolling the strip of material to push the strip of material into the split ring.

27. The method of claim 21, further comprising annealing at least a welded portion of the ferrule.

28. The method of claim 21, further comprising plating the ferrule after welding.

29. The method of claim 21, further comprising grinding, sanding, scraping, or flattening a welded portion of the ferrule along an exterior surface of the ferrule.

30. A method of fabricating a metal ferrule, comprising: providing a strip of metal, the strip of metal having a smooth first surface and a profiled second surface, the second surface being arranged opposite the first surface; shaping the strip of metal to form a radius in each of the opposite ends; forming the shaped strip of metal into a split ring with the opposite ends arranged adjacent to each other; welding the opposite ends together to form a weld portion along a length of the ferrule; and annealing at least the weld portion.

31. The method of claim 30, wherein providing the strip of metal includes forming the profiled second surface in a length of metal material, and shearing the length of metal material into the strip of metal.