CROSS REFERENCE TO RELATED APPLICATION

[0001] This PCT Patent Application claims the benefit of U.S. Provisional Patent

Application Serial No. 61/676,012 filed July 26, 2012, entitled "Pipe Connector Assembly," the entire disclosure of the application being considered part of the disclosure of this application, and hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention is related to connector assemblies for fluidly connecting pipes or tubes of different materials to one another.

2. Related Art

[0003] The plumbing systems of many buildings in the United States include one or more of copper, chlorinated polyvinyl chloride (CPVC) and/or cross-linked polyethylene (PEX) pipes or tubes. Many plumbers prefer to work with pipes formed of PEX over the other materials for a number of reasons including, for example, flexibility, cost

effectiveness, corrosion-resistance and resistance to bursting from freezing. Some pipe manufacturers produce copper or CPVC to PEX adapters for fluidly connecting PEX tubing with copper or CPVC piping. However, many of these adapter designs are costly, laborious to install (for example, some designs require adhesives or welding) or are otherwise unreliable. There remains a significant and continuing need for an improved connector assembly which overcomes any or all of the disadvantages associated with other known adapters. SUMMARY OF THE INVENTION

[0004] At least one aspect of the present invention provides for an improved quick connector assembly which can be used to more easily fluidly connect a first tube of a first material, such as copper or chlorinated polyvinyl chloride (CPVC), with a second tube of a different material, such as cross-linked polyethylene (PEX). The quick connector assembly includes a housing with an open bore which extends from an open first end to an open second end. The housing has a plurality of fingers which are deflectable in a radial direction. At least one of the fingers includes at least one radially inwardly extending tooth which extends into the open bore.

[0005] To connect the first tube to the housing, a user inserts the first tube through the first end. Then, once the first tube is in place, the user expands an end of the second tube and inserts it over the second end of the housing. Contraction of the second tube about the housing establishes a fluid-tight seal and also deflects the fingers inwardly so that the teeth on the fingers bite into the first tube to prevent removal of the first tube from the housing. With that, a very secure and fluid- tight connection is established between the first and second tubes without the use of welding, soldering, adhesives or any special equipment except for the expander which expands the end of the second tube. Additionally, all of the components of the quick connector assembly may be formed of materials other than brass, lead or other materials which could contaminate the fluid flowing between the first and second tubes. Even further, this design may be scaled to accommodate pipes and/or tubes of any desirable sizes.

[0006] According to another aspect of the present invention, the housing has a thickened portion which is aligned axially with the teeth. This is advantageous because it increases the biasing force of the teeth against the first tube to more securely retain the first tube within the open bore of the housing. [0007] According to yet another aspect of the present invention, the teeth are angled towards the second end of the housing. This feature allows for easier insertion of the first tube into the open bore of the housing while also more securely retaining the first tube within the open bore of the housing.

[0008] According to still another aspect of the present invention, the fingers of the housing are separated from one another by slots. As such, the housing (apart from the teeth) may be made as one integral piece of material.

[0009] According to a further aspect of the present invention, an O-ring seal is disposed in the open bore of the housing to establish a fluid-tight seal between the housing and the first tube.

[0010] According to yet a further aspect of the present invention, the housing has at least one window positioned axially between the O-ring and the second end of the housing to provide a visual indication that the seal between the housing and the first tube has been established.

[0011] According to still a further aspect of the present invention, the housing has a radially outwardly extending flange for establishing a fluid-tight seal between the housing and the second tube after the second tube contracts around the housing.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] These and other features and advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0013] Figure 1 is a perspective and elevation view of an exemplary quick connector assembly attached to a copper or CPVC pipe and a PEX tube; [0014] Figure 2 is a perspective and elevation view of the exemplary quick connector assembly of Figure 1;

[0015] Figure 3 is a side view of the exemplary quick connector assembly of Figure l ;

[0016] Figure 4 is a cross-sectional view of the exemplary quick connector assembly;

[0017] Figure 5 is a perspective and fragmentary view showing the end of the PEX tube as being expanded before inserting the quick connector therein; and

[0018] Figure 6 is a sectional view of the exemplary quick connector assembly of

Figure 1 and attached to the copper or CPVC pipe and the PEX tube.

DESCRIPTION OF THE ENABLING EMBODIMENT

[0019] Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, an exemplary quick connector assembly 20 is shown in engagement with and establishing fluid communication between a first tube 22 of a first material and a second tube 24 of a second material that is different than the first material. In the exemplary embodiment, the first tube 22 is a pipe of either copper or a chlorinated polyvinyl chloride (CPVC) material and is hereinafter referred to as the "copper or CPVC pipe". The second tube 24 of the exemplary embodiment is of a cross-lined polyethylene (PEX) material and is hereinafter referred to as the "PEX tube". As such, the exemplary quick connector assembly 20 may find uses in the plumbing systems of many residential, industrial or commercial buildings by serving as a bridge between an existing copper or CPVC pipe 22 in the building and a new PEX tube 24. However, it should be appreciated that the first and second tubes 22, 24 could be of a range of different materials, and the quick connector assembly 20 could also find uses in a range of applications other than the plumbing systems of buildings. [0020] Referring now to Figure 2, the exemplary quick connector assembly 20 includes a housing 26 which extends along an axis A from an open first end 28 to an open second end 30. As shown in Figure 4, the inner surface of the housing 26 includes a ring- groove, which supports and retains an O-ring 32 for establishing the fluid tight seal between the copper or CPVC pipe 22 and the housing 26 as discussed above. Referring now to Figure 4, the exemplary quick connector assembly 20 includes a plurality of teeth 34 which extend radially inwardly from the inner surface to engage or bite into the copper or CPVC pipe 22 and restrict pull-out of the copper or CPVC pipe 22 from the housing 26, as will be discussed in further detail below. The housing 26 is preferably overmolded around a portion of the teeth 34 to establish the connection between the teeth 34 and the housing 26. However, it should be appreciated that the teeth 34 could be attached to the housing 26 through any desirable process. The teeth 34 are preferably formed of a corrosion resistant metal such as stainless steel but may be formed of any suitable metal or any other suitable type of material. In the exemplary embodiment, the teeth 34 are angled towards the second end 30 of the housing 26 to further improve their effectiveness at resisting pull-out of the copper or CPVC pipe 22 from the housing 26. The housing 26 is preferably of a polymeric material and is preferably formed through an injection molding process. However, it should be appreciated that the housing 26 may be formed of a range of suitable materials and through a range of different forming processes.

[0021] Referring back to Figure 2, the exemplary housing 26 also includes a plurality of circumferentially spaced slits which extend in an axial direction from the first end 28 of the housing 26 to approximately an axial midpoint of the housing 26. Between adjacent ones of the slits, the housing 26 has fingers 36 which extend axially to the first end 28 of the housing 26. As shown, in the exemplary embodiment, each of the fingers 36 includes a pair of the above-discussed teeth 34 for biting into the copper or CPVC pipe 22. However, it should be appreciated that the fingers 36 may have any number of teeth 34. As shown in Figure 5, the housing 26 is made of a deflectable material, and thus, the fingers 36 are deflectable in a radially outward direction to allow insertion of the copper or CPVC pipe 22 into the housing 26 and past the teeth 34. In other words, the fingers 36 are bendable at their ends opposite of the first end 28 to allow the copper or CPVC pipe 22 to be inserted past the radially inwardly extending teeth 34 on the fingers 36. In the exemplary embodiment, the housing 26 includes six fingers 36. However, it should be appreciated that the housing 26 could alternately include any desirable number of fingers 36.

[0022] Referring back to Figure 4, the second end 30 of the housing 26 includes a pair of flanges 38, 40 with one of the flanges 38 being an inner flange 38 and extending radially inwardly from the inner surface and the other flange 40 being an outer flange 40 and extending radially outwardly from the outer surface. The inner flange 38 defines a stopping point for the insertion of the pipe 22 into the housing 26. For example, as shown in Figure 6, when the copper or CPVC pipe 22 is properly installed into the housing 26, its end abuts the inner flange 38 of the housing 26. The outer flange 40 extends

circumferentially continuously around the housing 26. As such, as shown in Figure 6 and discussed in further detail below, the outer flange 40 on the housing 26 allows for a fluid tight seal between the housing 26 and the end of the PEX tube 24 when the PEX tube 24 is contracted about the housing 26.

[0023] The housing 26 also includes a plurality of windows 44 which are circumferentially spaced from one another and are disposed axially between the O-ring 32 and the inner flange 38 to provide a visual indication to a user when the copper or CPVC pipe 22 is properly inserted into the housing 26, i.e. the end of the copper or CPVC pipe 22 will be visible through the windows 44 when if it has passed the O-ring 32. As such, these windows 44 provide a safety feature to ensure that the copper or PVC pipe 22 is properly inserted into and sealed with the housing 26.

[0024] Referring back to Figure 2, two of the fingers 36 include a tab 42 that extends radially outwardly at the first end 28 of the housing 26 to present a stopping point for the PEX tube 24 and a PEX expansion ring 48 when they are inserted over the housing 26. As such, the tabs 42 on the first end 28 of the housing 26 provide the stopping point for the PEX tube 24 and PEX expansion ring 48, and the inner flange 38 on the second end 30 of the housing 26 provides the stopping point for the copper or CPVP pipe 22.

[0025] Additionally, each of the fingers 36 includes a thickened portion 46 which is aligned axially with the teeth 34 and has a shoulder that faces towards the second end 30 of the housing 26. When the PEX tube 24 is in engagement with the outer surface of the housing 26, the end of the PEX tube 24 is contracted about the thickened portion 46 of the fingers 36 to urge the teeth 34 in a radially inward direction and against the copper or CPVC pipe 22. This provides a force to resist pull-out of the copper or CPVC pipe 22 from the housing 26. Additionally, the thickened portions 46 of the fingers 36 resist pull out of the housing 26 from the PEX tube 24 once the PEX tube 24 has contracted about the housing 26.

[0026] The process of fluidly connecting a copper or CPVC pipe 22 with a PEX tube 24 using the exemplary quick connector assembly 20 is described as follows. First, a user, such as a plumber, inserts the copper pipe 22 into the housing 26 through the open first end 28. The copper pipe 22 is inserted such that it seals with the O-ring 32 disposed in the housing 26 and abuts the inner flange 38. During this process, the fingers 36 will resiliently deflect outwardly as the end of the copper or CPVC pipe 22 passes the teeth 34. The user should then ensure that the copper or CPVC pipe 22 is properly inserted into and sealed with the housing 26 by checking to see if the end of the copper or CPVC pipe 22 is visible through the windows 44. Next, the user slides a PEX expansion ring 48 over one end of the PEX tube 24 and uses an expansion tool (not shown) to expand the end of the PEX tube 24 and the PEX expansion ring 48 to a predetermined width such that its inner diameter is greater than the outer diameter of the housing 26 at the thickened portions 46. For example, Figure 5 shows the PEX tube 22 and the PEX expansion ring 48 after expansion. The adjacent ends of the PEX tube 24 and PEX expansion ring 48 are then inserted over the second end 30 of the housing 26 until at least one of them abuts the tabs 42 at the ends of the fingers 36. The PEX tube 24 and PEX expansion ring 48 then are allowed to contract about the outer surface of the housing 26. As shown in Figure 6, contraction of the PEX tube 24 and the PEX expansion ring 48 about the thickened portions 46 of the fingers 36 biases the teeth 34 against the outer surface of the copper or CPVC pipe 22. This locks the housing 26 in engagement with the copper or CPVC pipe 22. Additionally, the PEX tube 24 contraction about the outer flange 40 at the second end 30 of the housing 26 establishes a fluid tight seal between the housing 26 and the PEX tube 24. Even further, the contraction of the PEX tube 24 about the thickened portion 46 of the fingers 36 causes the shoulders on the thickened portions 46 to cooperate with the PEX tube 24 and prevent the PEX tube 24 from being pulled off of the housing 26. This entire process is very quick and requires no adhesives, soldering or other specialty tools other than the PEX expander, which many plumbers who work with PEX tubing already will have. The resulting connection between the copper or CPVC pipe 22 and the PEX tube 24 is more secure and fluid-tight than the connections established by using other known adapters or connector assemblies. Even further, the connector assembly does not require any brass, lead or other metals which could contaminate the fluid flowing between the copper or PVC pipe 22 and the PEX tube 24.

[0027] Another aspect of the present invention provides for a method of establishing fluid communication between a first tube 22 of a first material, such as copper or CPVC, and a second tube 24 of a second material, such as PEX, that is different than the first material. The method of the exemplary embodiment includes the step of preparing a housing 26 that has an open bore which extends from an open first end 28 to an open second end 30 and a plurality of fingers 36 that are spaced from one another and a plurality of radially inwardly extending teeth 34 that extend from the fingers 36 into the open bore. In the exemplary embodiment, the method continues with the step of inserting the first tube 22 into the open bore of the housing 26 through the open first end 28 and establishing a fluid- tight seal between the first tube 22 and the housing 26 with an O-ring 32. Preferably, the teeth 34 are angled towards the second end 30 of the housing such that inserting the first tube 22 into the open bore causes the fingers 36 to deflect radially outwardly. The exemplary method proceeds with the step of expanding an open end of the second tube 24 and an expansion ring 48 of the second material. The exemplary method then continues with the step of contracting, or collapsing, the second tube 24 and the expansion ring 48 around the fingers 36 of the housing 26 to urge the teeth 34 into engagement with the first tube 22 in the open bore of the housing 26 to restrict removal of the first tube 22 from the open bore of the housing 26. The second tube 24 also contracts about a radially outwardly extending flange 40 on the housing 26 to establish a fluid-tight seal between the second tube 24 and the housing 26.

[0028] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims.