Obviousness

Obviousness Analysis under 35 U.S.C. § 103 for US Patent 11009162

This analysis will evaluate the obviousness of independent claims 1 and 9 of US Patent 11009162 under 35 U.S.C. § 103, considering combinations of prior art references cited within the patent. The core of the invention lies in the use of a flexible hose with a "first diameter" (specifically, a 5-inch hose) connected to an electric-powered hydraulic fracturing pump via a fitting that transitions to a "second diameter" (specifically, a 6-inch connection) which is larger than the first. The patent itself highlights that this configuration aims to overcome issues with standard 4-inch supply hoses (insufficient volume, cavitation, premature wear) and the problems associated with 6-inch hoses (proppant drop-out due to low fluid velocities) while maintaining compatibility with existing 6-inch pump fittings.

A person having ordinary skill in the art (PHOSITA) in hydraulic fracturing systems would possess knowledge of pump systems, fluid dynamics, hose and piping connections, and the operational challenges of fracturing, including proppant transport and pump longevity.

Obviousness of Claim 1

Claim 1 describes a hydraulic fracturing system comprising:

1. An electric powered, multi-plunger hydraulic fracturing pump with an inlet and an outlet coupled to a well, powered by at least one electric motor.
2. A fluid source coupled to the pump inlet, providing a slurry.
3. A flexible hose extending between the fluid source and the pump, having a first diameter.
4. A fitting between the hose and the pump, with a first end for receiving the hose at the first diameter and a second end for coupling to the pump at a second diameter, where the second diameter is larger than the first diameter.
5. A distribution system collecting the slurry from electric powered pumps for injection.

Combination of Prior Art References:

• Primary Reference: US20140174717A1 (Us Well Services Llc): This patent, titled "System for pumping hydraulic fracturing fluid using electric pumps," issued to the same original assignee as US11009162, serves as an excellent primary reference. It would teach a hydraulic fracturing system incorporating electric-powered pumps (element 1), a fluid source providing slurry (element 2), and a distribution system for collecting slurry (element 5). Such a system inherently requires fluid supply lines (hoses, element 3) to connect the fluid source to the pumps. [cite: US20140174717A1]
• Secondary Reference 1: US3055682A (Aeroquip Corp) or US8091928B2 (Eaton Corporation): These references disclose "Adjustment fitting for reinforced hose" and "Coupling assembly for connection to a hose," respectively. These patents teach the general concept and construction of fittings for hoses (element 4). [cite: US3055682A, US8091928B2]
• Secondary Reference 2: General Knowledge in the Art (and implied by patent's background): The patent itself acknowledges that "Many flow lines utilized in the industry have a 4 inch diameter" and that "merely increasing hose sizes is not practical because of component fittings on the pump." It also mentions "standard 6″ (0.1524 m) components, such as but not limited to hammer unions." This explicitly indicates that a PHOSITA would be aware of different connection sizes (e.g., 4-inch hoses and 6-inch pump inlets) and the need for transitional fittings to bridge these diameters. The classification F16L25/14 ("Joints for pipes of different diameters or cross-section") further supports the widespread knowledge of connecting pipes of varying diameters. [cite: US11009162B1]

Motivation to Combine:

A PHOSITA, seeking to optimize the performance and extend the life of electric hydraulic fracturing pumps (as taught in US20140174717A1), would be keenly aware of the problems identified in the background of US11009162. These problems include:

• Insufficient flow from standard 4-inch supply hoses: leading to cavitation and premature pump wear. [cite: US11009162B1, Description - SUMMARY, Description - FIG. 2]
• Proppant drop-out in larger (e.g., 6-inch) hoses: if flow velocities are too low to keep particulates in suspension. [cite: US11009162B1, Description - SUMMARY, Description - FIG. 2, Description - FIG. 3]

Faced with these known problems and the existing infrastructure of 6-inch pump connections, a PHOSITA would be motivated to select an intermediate hose diameter (e.g., 5 inches, as suggested in the '162 patent to balance flow and prevent drop-out) [cite: US11009162B1, Description - SUMMARY, Description - FIG. 2, Description - FIG. 3]. It would be obvious to then use a known fitting or coupling assembly (as taught by US3055682A or US8091928B2) to adapt this selected hose diameter (first diameter) to the standard, larger inlet connection of the pump (second diameter). This combination directly addresses known issues in the field using known components and engineering principles to achieve predictable results in fluid flow management.

Obviousness of Claim 9

Claim 9 similarly describes a hydraulic fracturing system, but provides more specific structural details for the fitting:

1. An electric powered, multi-plunger hydraulic fracturing pump, fluid source, hose (flexible, first diameter), and distribution system (as in Claim 1).
2. A fitting between the hose and the pump, where the fitting comprises:
   • A union arranged at a first end, having a second diameter (larger than the first diameter) and configured to couple to the pump.
   • A shank end configured to receive at least a portion of the hose, securable to the hose, and including an opening to receive the shank end.
   • A reducer positioned between the union and the shank end, welded to the respective union and shank end at each end, the reducer having an increasing diameter along its axial length, and extending at least partially into the union.

Combination of Prior Art References:

• Primary Reference: US20140174717A1 (Us Well Services Llc): As with Claim 1, this patent provides the foundational electric fracturing system. [cite: US20140174717A1]
• Secondary Reference 1: US8091928B2 (Eaton Corporation): This reference, "Coupling assembly for connection to a hose," would teach a hose coupling assembly. While not explicitly detailing every specific feature of the reducer, it would teach the concept of a coupling with a hose-receiving end (shank end) and a connection end (union) for integration into a system. [cite: US8091928B2]
• Secondary Reference 2: US3055682A (Aeroquip Corp) or General Mechanical Engineering Knowledge: This reference, "Adjustment fitting for reinforced hose," or general knowledge of mechanical design for fluid systems, would teach various forms of fittings, including those with unions and reducers to connect different sized components. The use of a "union" for connecting to piping is explicitly stated in the '162 patent as a standard 6-inch component, indicating it's well-known. [cite: US11009162B1] The features of the reducer (increasing diameter along axial length) are inherent to its function, and common engineering design to ensure smooth flow transitions. The patent also states that "various rigid couplings 214 are included along the fitting 200, for example, as welds utilizing to secure one or more components together," indicating that welding to secure fitting components is a known practice. [cite: US11009162B1, Description - FIG. 2] The design choice of a reducer extending "at least partially into the union" would be an obvious way to create a robust and streamlined connection for fluid flow, reducing turbulence and potential leak points.

Motivation to Combine:

Building upon the motivations for Claim 1 (i.e., optimizing pump performance and addressing known flow issues by selecting an optimal hose diameter, like a 5-inch hose, for 6-inch pump inlets), a PHOSITA would then turn to standard mechanical engineering practices for designing the connecting fitting. The specific structural elements detailed in Claim 9 for the fitting – a union, a shank end, and a welded reducer with an increasing diameter that extends into the union – represent conventional and predictable design choices for creating a robust, leak-proof, and flow-efficient connection between a flexible hose and a rigid pump inlet, especially in high-pressure applications like hydraulic fracturing. The explicit mention of "hammer unions" as standard 6-inch components and welding as a method for rigid coupling within the patent itself indicates these are well-established elements and techniques in the relevant art. [cite: US11009162B1, Description - SUMMARY, Description - FIG. 2] Thus, combining these known fitting components and manufacturing techniques to create a fitting for the chosen hose and pump diameters would be obvious to a PHOSITA.