Note: Descriptions are shown in the official language in which they were submitted.
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HOSE CONNECTOR-TANK ASSEMBLY AND
ASSEMBLY METHOD
FIELD OF THE INVENTION
The present invention relates to a hose connector and tank assembly
and a method for assembling such an assembly, in particular, a hose connector
and
tank assembly and assembly method which limits improper insertion of the hose
connector into the tank.
BACKGROUND OF THE INVENTION
It is known in the heat exchanger art to use a pipe fitting attached to
a tank forming part of the heat exchanger to define either an inlet or an
outlet for the
tank. These pipe fittings may be referred to as hose connectors, for they
serve as the
attachment site between a hose and the tank.
Typically, a first end of the hose connector is disposed into an
opening in the tank. To prevent relative movement between the hose connector
and
the tank, the hose connector is secured to the tank with a tack weld, for
example.
The hose connector-tank assembly, which is conventionally made of aluminum,
then
undergoes a brazing process to form a sealed joint between the hose connector
and
the tank.
This process has its disadvantages. The hose connector may be
inserted too far or not far enough into the opening in the tank during the
assembly
process. If the hose connector is inserted too far into the opening, the hose
connector
may obstruct the flow of the coolant within the tank and/or between the tank
and the
open ends of the tubes in a header to which the tank is fitted. If the hose
connector
is not inserted far enough into the tank, the joint between the hose connector
and the
tank may be weakened and/or not fluid tight.
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SUMMARY OF THE INVENTION
According to an aspect of the present invention, a tank assembly for
a heat exchanger includes a tank having a wall with an opening therethrough
and
adapted to be fitted to the header of a heat exchanger, and a hose connector
having
a first end and a stop disposed a predetermined distance from the first end
greater
than the thickness of the wall. The stop abuts the wall with the first end of
the hose
connector disposed in the opening in the tank wall to prevent the hose
connector
from being disposed further into the opening. The first end of the hose
connector is
deformed against the wall of the tank oppositely of the stop to prevent
withdrawal
of the hose connector from the tank. Preferably, the hose connector body
includes
a wall, and the wall may have a plurality of slits therethrough starting at
the first end
of the hose connector and extending no further than the stop.
Most preferably, the slits may extend no further than a distance equal
to the predetermined distance from the first end of the hose connector less
the
thickness of the tank wall.
The hose connector may include a stepped wall defining a shoulder
at the predetermined distance from the first end, the shoulder defining the
stop.
Also, the hose connector may include a wall deformed to define a rib at the
predetermined distance from the first end, the rib defining the stop.
The stop and the first end may be brazed to the tank to form leak-tight
joints therebetween.
According to another aspect of the present invention, a tank assembly
for a heat exchanger includes a tank having a wall with an interior surface,
an
exterior surface, and an opening therethrough and adapted to be fitted to the
header
of a heat exchanger, and a hose connector having a first end and a stop
disposed a
predetermined distance from the first end greater than the thickness of the
wall. The
stop abuts the exterior surface of the wall of the tank to prevent the hose
connector
",..
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from being disposed further into the opening. The first end is disposed
through the
opening and is deformed against the interior surface of the wall of the tank
to prevent
the hose connector from being disposed further into the opening.
Braze alloy may be applied to the exterior and/or the interior surface
of the tank. Braze alloy may be applied to the hose connector. The stop may be
brazed to the exterior surface of the wall of the tank , and the first end may
be brazed
to the interior surface of the wall of the tank.
According to a further aspect of the invention, a method of
positioning a hose connector relative to a tank for a heat exchanger includes
providing a tank with a wall having an opening therethrough, and providing a
hose
connector with a first end and a stop disposed a predetermined distance
greater than
the thickness of the wall from the first end. The first end of the hose
connector is
disposed into the opening in the tank wall, and the stop is abutted against
the wall
to position the first end relative to the tank. The first end of the hose
connector is
deformed against the wall of the tank.
The method may include applying braze alloy to the tank and/or the
hose connector. The method may also include brazing the hose connector to the
tank.
The step of deforming may include the step of flaring out the first end
of the hose connector against the wall of the tank.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a side view of a heat exchanger with a connector/tank
assembly made according to the present invention attached thereto;
Fig. 2 is an end view of an embodiment of a hose connector made
according to the present invention;
Fig. 3 is a side view of the hose connector of Fig. 2;
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Fig. 4 is a partial cross-sectional view of the hose connector of Fig.
2 and a wall of a tank in a pre-insertion state;
Fig. 5 is a partial cross-sectional view of the connector-tank assembly
of Fig. 4 with a first end of the connector inserted into an opening in the
wall of the
tank;
Fig. 6 is a partial cross-sectional view of the connector-tank assembly
of Fig. 4 with the first end of the connector deformed against the wall of the
tank;
Fig. 7 is an end view of another embodiment of a hose connector
made according to the present invention;
Fig. 8 is a side view of the hose connector of Fig. 7;
Fig. 9 is an end view of still another embodiment of a hose connector
made according to the present invention;
Fig. 10 is a side view of the hose connector of Fig. 9; and
Fig. 11 is a bottom view of the hose connector of Fig. 9.
BRIEF DESCRIPTION OF THE DETAILED EMBODIMENTS
An embodiment of the present invention is explained first with
reference to Fig. 1. A heat exchanger 20 is shown, with first and second tank
assemblies 22, 24 and a plurality of tubes 26 extending therebetween and in
fluid
communication therewith. Fins 28 are disposed between the tubes 26. Each of
the
first and second tank assemblies 22, 24 includes a header 30, 32 to which the
tubes
26 are attached, and a tank 34, 36. An first port 38 is provided to the tank
34, while
a second port 40 is provided to the tank 36 to allow coolant to enter and exit
the heat
exchanger 20. Although the ports 38, 40 are shown in Fig. 1 in separate tanks
34,
36, such that the coolant flows in an odd number of passes through the tubes
26, the
ports 38, 40 may be in the same tank 34 or 36 so that the coolant flows
through tubes
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26 in an even number of passes. The presence or absence of conventional
baffles
W thin the tank 34 and/or tank 36 will define the number of passes.
Each of the ports 38, 40 is defined by a hose connector 42, which is
attached to the tanks 34, 36. Figs. 2-3 show a first embodiment of the hose
S connector 42 according to the present invention. The hose connector 42 has a
tubular body 44 with a first end 46 and a second end 48. The body 44 of the
hose
connector 42 is flattened in a section 50 adjacent to the first end 46 so that
the latter
is in the form of an oval. The second end 48 is circular to receive a hose,
and
includes a peripheral radially outwardly directed hose retaining rib 52. In
use, a hose
(not shown) is fitted about the second end 48, and over the rib 52. A hose
clamp
(not shown) is disposed about the hose between the end 46 and the rib 52 and
tightened to secure the hose in fluid tight relation to the hose connector 42.
The body 44 also has a wall 54 which defines a passage 56
therethrough. The body 44 also has a stepped region 58 adjacent to the first
end 46,
which may be formed by milling down the wall 54 adjacent to the first end 46.
The
stepped region 58 defines a shoulder or stop 60 which is disposed a distance
"d"
from the first end 46.
Figs. 4-6 show an assembly of the hose connector 42 with the tank 34,
for example. In Fig. 4, the hose connector 42 is shown in a pre-insertion
state
relative to a wall 62 of the tank 34. It will be recognized that an opening 64
is
provided in the wall 62 and is sized to receive the first end 46 of the hose
connector
42.
Because the tank 34 and hose connector 42 are preferably made of
aluminum, the tank 34 and hose connector 42, as assembled, will preferably be
brazed together to provide a leak-tight joint, although alternative means of
attachment, for example soldering, can be used when the tank 34 and/or hose
connector 42 are made of other materials. Assuming a brazed joint is to be
formed,
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braze alloy will be applied before assembly to the wall 62 of the tank and/or
the body
44 of the hose connector 42. As shown in Fig. 4, because the wall 54 of the
hose
connector 42 is milled down to define the shoulder 60, it is more advantageous
to
apply the braze clad to the wall 62 of the tank 34. This is the case because
the
milling process used to form the stepped region 58 will remove the braze alloy
from
the exterior surface of the wall 54 of the hose connector 42.
The cladding may be applied to both sides 66, 68 of the wall 62, or
alternatively only to one side 66 or 68. It is preferable, however, to use
cladding on
both sides 66, 68 of the wall 62, so that any gap between the wall 62 and the
body
44 of the hose connector 42 is filled and so that a brazed joint may be formed
both
on the internal and external sides 66, 68 of the wall 62. Overall, the clad
wall 62 has
a thickness "t" (inclusive of the thickness of the cladding material) which is
less than
the distance "d". Alternatively, braze alloy in the form of a powder may be
applied
to the joint to be formed.
As shown in Fig. 5, the hose connector 42 is moved in the direction
of an arrow 70, such that the first end 46 of the hose connector 42 enters the
opening
64 in the wall 62. With continued movement of the hose connector 42 in the
direction of the arrow 70, the shoulder 60 of the hose connector 42 abuts the
external
surface 66 of the wall 62. Abutment of the shoulder 60 with the external
surface 66
of the wall 62 prevents further movement of the hose connector 42 into the
opening
64. It will be recognized that the first end 46 of the hose connector 42
extends into
the tank 34 a distance equal to "d" (the predetermined distance from the first
end 46
to the shoulder 60) less "t" (the thickness of the wall 62 of the tank 34).
Fig. 6 shows the completed assembly 72 of the hose connector 42 and
the tank 34, wherein the first end 46 of the hose connector 42 has been
deformed to
form a flared out region 74 which abuts against the interior surface 68 of the
tank
wall 62. The abutment of the flared out region 74 and the interior surface 68
of the
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tank wall 62 prevents separation of the hose connector 42 from the tank wall
62, and,
in particular, the first end 46 from being withdrawn from the opening 64 in
the tank
wall 62. Moreover, the flaring out of the first end 46 urges to the shoulder
60 into
closer abutment with the external surface 68 of the wall 62.
It will be recognized that this method ensures that the first end 46 of
the connector 42 is disposed only to a predetermined depth through the opening
64
in the tank wall 62. In particular, the method achieves this result without
the
necessity of tack welding the hose connector 42 to the tank wall 62. The post
connector-tank assembly 72 can now be brazed, thereby providing a secure and
leak
tight joint between the hose connector 42 and the tank 34, in particular
between the
shoulder 60 of the hose connector 42 and the external surface 68 of the wall
62 and
the flared out region 74 of the hose connector 42 and the internal surface 66
of the
wall 62.
A modified embodiment of the invention is shown in Figs. 7-8. In the
interest of brevity, like components are given the same reference numerals as
in the
previous description of the embodiment of Figs. 1-6, and will not be
redescribed.
The embodiment of Figs. 7-8 omits the stepped region 58 adjacent the first end
46
in favor of oppositely directed ribs or beads 76, 78 which define a stop. The
ribs 76,
78 are located on opposite flat sides 80, 82 of the flattened section 50, and
have stop
surfaces 84, 86 most nearly adjacent the first end 46 spaced therefrom by the
distance
~~d~~,
The ribs 76, 78 may be formed, for example, by applying a force to
the interior surface of the wall 54 to deform the wall 54 radially outward
such that
a raised area is formed on the sides 80, 82 of the body 44 of the hose
connector 42.
Because, unlike the first embodiment, it is not necessary to remove material
from the
sides 80, 82 to form the ribs 76, 78, braze alloy may be applied to the sides
80, 82
instead of or in addition to the braze alloy applied to the wall 62 of the
tank 34, for
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example. By applying the braze alloy to the hose connector 42 instead of the
tank
34, less braze alloy may be used, resulting in a less expensive hose connector-
tank
assembly 72. However, by applying braze alloy to the tank 34 is believed that
there
is less of a chance that a leak-tight braze joint will not form between the
hose
connector 42 and the tank 34.
The stop surfaces 84, 86 of the ribs 76, 78 serve the same purpose as
the shoulder 60, i.e., to abut against the external surface 68 of the wall 62
of the tank
34, for example. With the stop surfaces 84, 86 abutting the external surface
68, the
first end 46 of the hose connector 42 extends into the tank 34 a predetermined
distance, depending on the values of the distance from the stop surfaces 84,
86 to the
first end 46, the thickness of the wall 62 of the tank 34, and the placement
of the
cladding material. If the cladding material is applied to the surfaces 84, 86
and the
exterior surface 68 of the wall, then the distance which the first end 46 of
the hose
connector 42 extends into the tank 34 will be reduced in accordance with the
thickness of the cladding material applied.
A still further embodiment of the hose connector according to the
present invention is shown in Figs. 9-11, again with like components numbered
similarly. In addition to the ribs 76, 78, the hose connector 42 has four
slits 88, 90,
92, 94. As best seen in Fig. 9, the wall is nominally rectangular with rounded
corners; and the slots 88, 90, 92, 94 are located in such corners. The slits
88, 90, 92,
94 are provided to mininuze the chance of metal tearing during the deformation
process of the first end 46 of the hose connector 42. The slits 88, 90, 92, 94
also
decrease the force required during the deformation process to deform the end
46 of
the hose connector 42, and may increase the extent to which the end 46 may be
flared out to maintain the hose connector 42 fixed to the wall 62 of the tank
34, for
example. Preferably, the depth of the slit (shown ~s "s" in Fig. 11) is less
than the
distance "d" - "t" (the distance from the surfaces 84, 86 to the first end 46
less the
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thickness of the wall 62 of the tank 34), taking into account the placement
and
thickness of the cladding material.
It will be recognized that any of the embodiments of the hose
connector 42 according to the present invention described above may be used to
assure proper insertion of the hose connector 42 into the opening 64 in the
tank wall
62. By preventing the hose connector 42 from being inserted too far into the
tank 34,
for example, the risk of flow obstruction due to the extension of the hose
connector
42 into the tank 34 is limited. This is especially true as the end 46 of the
hose
connector 42 disposed in the tank 34 is flared out against the interior
surface 74 of
the tank 34 to secure the hose connector 42 and tank 34 together, thereby
limiting the
extent to which the hose connector 42 extends into the tank 34. Further, the
risk of
weak or leaky joints formed by not inserting the hose connector 42 far enough
into
the tank 34 may be avoided through the abutment of the body 44 of the hose
connector 42 and the exterior surface 68 of the tank 34. The flaring out of
the end
46 of the hose connector 42 against the interior surface 74 of the wall 62
also assists
in encouraging a snug abutment of the body 44 of the hose connector 42 with
the
exterior surface 68 of the tank 34.
Still other aspects, objects, and advantages of the present invention
can be obtained from a study of the specification, the drawings, and the
appended
claims.
