Patent Application
20080092975
The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings in which:
The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. In respect of the methods disclosed and illustrated, the steps presented are exemplary in nature, and thus, the order of the steps is not necessary or critical.
The first end 12 is substantially rectangular in cross section and is adapted to be connected to an inlet or outlet of a heat exchanger tank (not shown). It is understood that the first end 12 may have other cross sectional shapes and can be connected to other components as desired without departing from the scope and spirit of the invention. A flange 18 is formed on the conduit 10 adjacent the first end 12. The flange 18 is adapted to facilitate connection with the inlet or outlet of the heat exchanger tank.
The second end 14 is substantially circular in cross section and is adapted to be connected to an extension tube (not shown). It is understood that the second end 14 may have other cross sectional shapes and can be connected to other components as desired without departing from the scope and spirit of the invention. The second end 14 of the conduit 10 includes a flange 22 extending radially outwardly from the conduit 10 at an angle. An inner wall 20 of the conduit 10 adjacent to the second end 14 includes a sloped ridge 24. The sloped second ridge 24 is adapted to abut a distal end of the connector tube. Optionally, an O-ring (not shown) can be disposed between an outer wall of the extension tube and the inner wall 20 of the conduit 10 adjacent the flange 22.
The intermediate portion 16 includes a bend 26 formed therein. The bend 26 is approximately ninety degrees and includes a bend radius r. In the embodiment shown, the bend radius r is less than the diameter d of the conduit 10. A length L2 of a first leg of the conduit 10 adjacent the first end 12 thereof is also less than the diameter d of the conduit 10.
In use, the first end 12 of the conduit 10 is received by the inlet or outlet of the heat exchanger tank, so the inlet or outlet abuts the flange 18. The second end 14 of the conduit 10 receives the connector tube. When assembled, the sloped second ridge 24 of the conduit 10 abuts a distal end of the connector tube. The O-ring disposed between the outer wall of the connector tube and the inner wall 20 of the conduit 10 adjacent the flange 22 forms a substantially fluid tight seal therebetween. A fluid (not shown) is caused to flow through the connector tube into the conduit 10 and into the inlet of the heat exchanger tank. It is understood that the flow pattern is reversed if the conduit 10 is connected to an outlet of a heat exchanger tank.
Since the bend radius r of the conduit 10 is smaller than the diameter d of the conduit, the size of the package required to house the conduit 10 and the costs associated with the shipment thereof are minimized. Further, since the first end 12 of the conduit 10 has a rectangular cross section, the conduit 10 can be connected directly to the inlet or outlet of the heat exchanger tank, which are typically rectangular in cross section, without the use of additional tubes or conduits. Additionally, since the second end 14 of the conduit 10 has a circular cross section, the conduit 10 can be connected directly to the connector tube, which is typically circular in cross section, without the use of additional tubes or conduits. Accordingly, the cost required for producing the heater core and the time and effort required for the assembly thereof are minimized.
A method of forming the conduit 10 illustrated in
The conduit 110 is then placed in a die (not shown) and formed into a substantially Z-shape by crushing the conduit 110 where a bend 126 is to be formed, as shown in
Thereafter, the conduit 110 is placed in a second die (not shown). The second die is used to complete the bend 126 in the conduit 110 and to shape the second end 114 of the conduit 110 in a process similar to hydroforming. The first end 112 of the conduit 110 is plugged to form a substantially fluid tight seal. A fluid (not shown) capable of transmitting hydraulic force, such as water, for example, is disposed in the conduit 110. A ram is introduced into the second end 114 of the conduit 110 to hydraulically expand the conduit 110 and form the bend 126 into the desired shape, as shown in
Finally, a punch (not shown) is introduced into the second end 114 of the conduit 110. The punch is used to expand the conduit 110 at the second end 114 to form the flange 122 as shown in
From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.
