Patent Application
20120199318
1. Field of the Invention
The subject invention relates to an assembly for fastening a fitting to a hole in a manifold.
2. Description of Related Art
Heat exchangers with manifolds and a fitting secured thereto are widely used in commercial, residential and vehicle applications. Generally, the fitting is oriented in the same direction as the refrigerant tubes where space is the greatest, as shown by U.S. Pat. No. 7,213,640 issued to Fuller et al. on May 8, 2007. However, this type of connection can be undesirable because it adds significantly to the overall length of the heat exchanger. Therefore, it is desirable to attach the fitting in a transverse direction to the refrigerant tubes. The problem with attaching fittings in a transverse direction to the refrigerant tubes is the close proximity of the refrigerant tubes to the side of the manifold and the amount of manifold space left to provide the fitting. Furnace brazing is a desirable method of connecting fittings to manifolds for mass production and to ensure that the fitting is sealed to the manifold. One known method of securing fittings prior to furnace brazing is to tack weld the fitting in place. However, welding requires a great skill set, can be expensive due to time and labor costs, and leaves the fitting at risk of tilting or drooping during the brazing process which is especially undesirable due to the limited amount of space in the manifold. A known alternative to welding for securing a fitting prior to furnace brazing is to use a bracket assembly. An example of a bracket configuration is shown in European Patent Application EP 1,496,329 to Maciej et al. published on Dec. 1, 2005. EP 1,496,329 discloses a manifold with a bracket presenting a leg for engaging a slot on a fitting block. The fitting block is oriented in the same direction as the refrigerant tubes.
There is a significant and continuing need for a fitting connected to the manifold in a transverse direction to the refrigerant tubes that provides adequate clearance for the refrigerant tubes and is sufficiently held in place during furnace brazing.
The invention provides an assembly for fastening a fitting to a hole in a manifold that receives refrigerant tubes that extend into the manifold transverse the hole in the manifold. The assembly includes a fitting that extends along an axis and presents a pair of slots spaced from one another. In addition, the fitting has a lower section that defines an opening to provide clearance for the refrigerant tubes extending into the manifold. The assembly further includes a bracket that presents a pair of legs that extend in spaced relationship with one another. The legs engage the slots of the fitting to limit rotary movement of the fitting about the axis relative to the bracket before and during brazing of the fitting to the manifold for maintaining clearance between the lower section of the fitting and the refrigerant tubes.
The subject invention also provides a method of fastening a fitting to a hole in a manifold that receives refrigerant tubes that extend into the manifold transverse the hole in the manifold. The method includes the step of providing a fitting that defines an axis, and presents a pair of slots in spaced and parallel relationship with one another. The fitting has a lower section with an opening to provide clearance for the refrigerant tubes. The method also includes the step of providing a bracket that includes a pair of legs spaced from one another. The method further includes the step of locating the fitting in the hole of the manifold. In addition, the method includes the step of brazing the fitting to the manifold. Furthermore, the method includes the step of connecting the bracket and the fitting with the legs of the bracket disposed in the slots of the fitting to limit rotary movement of the fitting about the axis relative to the bracket before and during brazing of the fitting to the manifold for maintaining clearance between the lower section of the fitting and the refrigerant tubes.
Thus several advantages of one or more aspects of the invention are the elimination of a tack weld prior to furnace brazing, a compact design due to the fact that the fitting extends in a transverse direction to the refrigerant tubes, the reduction of the risk of tilting or drooping of the fitting during furnace brazing, error proofing due to the ease of assembly of the fitting and bracket, and increased process control due to the fact that the lower part of the fitting can be common regardless of connection requirements, allowing the use of only one sized manifold hole, bracket and braze ring.
Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description and the accompanying drawings that set forth an exemplary embodiment wherein:
Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, an assembly 20, 120 for fastening a fitting 22, 122 to a hole in a manifold 26, 126 having a tubular shape and receiving refrigerant tubes 28 extending into the manifold 26, 126 transverse the hole in the manifold 26, 126 is generally shown.
The assembly 20, 120 includes a fitting 22, 122 extending along an axis A. The fitting 22, 122 has an upper section 32, 132, an intermediate section 34, 134 and a lower section 36, 136. A passage 38, 138 for conveying a fluid extends along the axis A through the upper 32, 132, intermediate 34, 134 and lower sections 36, 136. The lower section 36, 136 has a semi-cylindrical shape that defines an opening 40, 140 into the passage 38, 138. The opening 40, 140 provides clearance for the refrigerant tubes 28 extending into the manifold 26, 126, ensuring adequate flow of fluid through the manifold 26, 126, refrigerant tubes 28 and fitting 22, 122. The upper section 32, 132 of the fitting 22, 122 presents a pair of slots 42, 142 in spaced and parallel relationship with one another. It should be appreciated that more than a pair of slots 42, 142 could be used and the slots 42, 142 don't have to be parallel with one another. In addition, it should be appreciated that the upper section 32, 132 of the fitting 22, 122 could have various shapes and sizes to suit different connection requirements as best shown in
The assembly 20, 120 further includes a semi-cylindrical shaped mounting plate 52, 152. The mounting plate 52, 152 has a semi-cylindrical shape for concentric mating with the manifold 26, 126. The mounting plate 52, 152 includes a rear face 54, 154 and a pair of side faces 56, 156. Furthermore, the mounting plate 52, 152 includes a plurality of apertures 58, 158, each having a peripheral portion 60, 160. One of the apertures 58, 158 is disposed adjacent to each of the side faces 56, 156 and an additional pair of apertures 58, 158 is disposed on the opposing side of the mounting bracket 62, 162. The apertures 58, 158 are used for skiving the mounting plate 52, 152 to the manifold 26, 126. During skiving, material from the manifold 26, 126 is displaced against the peripheral portion 60, 160 of the apertures 58, 158 to secure the mounting plate 52, 152 to the manifold 26, 126. It should be appreciated that any number of apertures 58, 158 could be used, and the apertures 58, 158 could be located at different locations across the mounting plate 52, 152, so long as the mounting plate 52, 152 is capable of being skived to the manifold 26, 126. Furthermore, the mounting plate 52, 152 includes a bracket 62, 162. The bracket 62, 162 presents a pair of legs 64, 164 which extend in spaced and parallel relationship with one another. The legs 64, 164 engage the slots 42, 142 of the fitting 22, 122 to limit rotary movement of the fitting 22, 122 about the axis A relative to the bracket 62, 162 before and during brazing of the fitting 22, 122 to the manifold 26, 126 for maintaining clearance between the lower section 36, 136 and the refrigerant tubes 28 as best shown in
In a first enabling embodiment shown in
In a second enabling embodiment, shown in
A method for fastening a fitting 22, 122 to a hole in a manifold 26, 126 having a tubular shape and an outer surface 76, 176 and receiving refrigerant tubes 28 extending into the manifold 26, 126 transverse the hole in the manifold 26, 126 is also included.
The method starts with the step of providing a fitting 22, 122 defining an axis A and having an upper section 32, 132, an intermediate section 34, 134 and a lower section 36, 136. The upper section 32, 132 includes a pair of slots 42, 142 in spaced and parallel relationship to one another. The intermediate section 34, 134 includes a braze ring 50, 150 disposed thereabout. The lower section 36, 136 has an opening 40, 140 for providing clearance for the refrigerant tubes 28. The next step is to provide a mounting plate 52, 152 having a semi-cylindrical shape. The mounting plate 52, 152 includes an inner surface 78, 178 and presents a plurality of apertures 58, 158. Each of the apertures 58, 158 has a peripheral portion 60, 160. Furthermore, the mounting plate 52, 152 presents a bracket 62, 162 having a pair of legs 64, 164 extending in spaced and parallel relationship with one another. The next step is to locate the fitting 22, 122 into the hole of the manifold 26, 126 with the braze ring 50, 150 of the fitting 22, 122 in contact with the manifold 26, 126 outer surface 76, 176. The next step is to locate the mounting plate 52, 152 on the manifold 26, 126 outer surface 76, 176. While locating the mounting plate 52, 152 on the manifold 26, 126 outer surface 76, 176, the bracket 62, 162 and the fitting 22, 122 are connected with the legs 64, 164 of the bracket 62, 162 disposed in the slots 42, 142 of the fitting 22, 122. This connection limits rotary movement of the fitting 22, 122 about the axis A relative to the bracket 62, 162 before and during brazing of the fitting 22, 122 to the manifold 26, 126 for maintaining clearance between the lower section 36, 136 of the fitting 22, 122 and the refrigerant tubes 28. The next step is to skive the inner surface 78, 178 of the mounting plate 52, 152 to the outer surface 76, 176 of the manifold 26, 126 by displacing material from the manifold 26, 126 outer surface 76, 176 and deforming it against the edge of the peripheral portions 60, 160 of the apertures 58, 158. The next step is to braze the fitting 22, 122 to the manifold 26, 126 in a brazing furnace.
For the second enabling embodiment of
While the invention has been described with reference to an exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
