TITLE: TUBE MOUNTING ASSEMBLY WITH RADIAL STAKING, METHOD OF ASSEMBLY

FIELD OF THE INVENTION:

This invention pertains to solderless and lead-sealed mechanical connections between fluid transfer lines, particularly those encountered with respect to heat transfer systems and internal combustion engines, and other mechanical components such as engine or transmission blocks.

BACKGROUND:

In high speed mechanical component assembly it is often critically important that complex components be positioned, aligned and held in place from the time of first assembly and thereafter until a finished component or finished machine assembly is fabricated and shipped. This is particularly so in respect of solderless fluid line connections where speed, space and compactness work against sealed-in fluid flow and dictate that the fluid lines have highly complex shapes designed to fit in tight spaces. The interconnections must be adaptable to the manufacturing environment and become permanent over the production cycle while maintaining axial alignment between the lines and the connecting assemblies.

This is particularly so with solderless connections sealed with an O-ring entrapped in an annular recess(s) on an inserted fluid line and a receiving bore-hole. Such a seal must remain stable in alignment throughout the assembly process and throughout a long and difficult engine duty cycle. In most cases O-ring seals provide just the seal while mechanical elements, such as bolts, provide the positioning. Leakage pathways must be kept to a minimum . It is even more so where multiple units of fluid lines such as inlet and outlet lines are pre-formed and paired into a line-assembly prior to the 1 ^st assembly of the lines to the receiving machine components.

In most modern solderless connections a fluid line is fitted with or formed into a 0- ring-receiving groove at a pilot (open) end and installation involves axial alignment of the line with a receiving bore hole which captures and compresses the O-ring between the fluid line and the bore for a sealing connection. In another the O- ring and receiving groove are in the receiving component and insertion of the fluid line captures and compresses the O-ring. These lines are also fitted with or formed into a radially extending annular collar-bead adjacent the O-ring groove which acts as an alignment element, a clamping ledge and an insertion stop.

In the many modern situations, the O-ring groove and the annular-bead is formed into the wall of the fluid line tube in a continuous manner. The annular collar- bead is formed by severe bending of the tube wall back upon itself about a transverse plane so that previously adjacent sections of cylindrical wall abut one another in an annular area outside of the nominal interior diameter of the fluid line. Further bending in the order of a right angle to the transverse plane before (wall curving outward) and after (wall curing back in to axial alignment) the adjacent sections provides a tube with a cylindrical cross-section and an upstanding collar-bead.

PRIOR ART:

Typically highly bent fluid lines are 1 st secured to a hold-down clamp or yoke and then inserted into sealing engagement with a receiving body. Sealing is by a male/female O-ring combination. Fixation is by the hold-down clamp or yoke. The clamp is provided with a circular recess of slightly larger diameter than the outer overall diameter of the fluid line tube collar-bead. Interior to the recess are an array of axial teeth arranged in a radial pattern whose internal diameter is slightly smaller than the outer diameter of the fluid line tube collar-bead. Careful insertion of the fluid line tube into the recess engages the teeth into the material, typically aluminum, of the fluid line tube for fixation against rotation and axial displacement during further assembly operations. The component is known to the applicant as expensive to produce and difficult to use efficiently in an manufacturing environment.

An example is shown in US patent 9,469,177 issued to Eberspacher Climate on October 18, 2016. USP'177 describes a complex tubing assembly of two fluid lines and a hold-down clamp 16 in Figure 1. A pre-assembled state is established by a press fitted male/female conical fitment or a positive locking mesh. The tubular connecting branches are fixed to the exchanger body by a specific hold-down clamp which is tightened to complete the fixation. USP'177 provides a 2-part fixation, the first including an amount of flexibility and the 2nd a more permanent and secure matched set of internal and external meshing formations. Upon insertion of the significantly bent fluid line the parts are aligned and then meshed together as a unit for further assembly on to an exchanger body. This disclosure requires a highly complex tubing arrangements and a mating hold down clamp which is expensive to manufacture and appears prone to part failure or non- uniform production.

Another example is shown in US patent 7,425,021 issued to Denso Corporation on September 16, 2008. Basically in USP'021 a fluid line is received into a connector block through a hole. A bulged portion of the fluid line is press fitted into a recess in the connector. The fluid line is held in place on the connector by a separate retainer on the opposite side of the connector from the recess. Anti-rotation is assisted, as in Figure 2A, by a polygonal configuration of the recess and by holding projections as shown in Figures 2B and 3. Despite the press fit and the holding projections a retaining agent is required on the opposite side of the connector to maintain position and resist part separation. These mechanisms are prone to failure and interfere with the highly stressed and highly bent fluid lines which are common, increasing the likelihood of mis-assembly, mis-alignment and potential part failure.

An embodiment of USP'021 includes a circular crenulated recess as an alternative. In all cases, the projections are designed to deform the outer surface of the fluid line collar-bead at a vulnerable point for a primary purpose of an interim hold. Such deformations are to be avoided as they must be carefully controlled and handled.

Such structures are problematic in situations where fluid line bending becomes more extreme, exposing the line to much higher curvatures, stresses and deformations as the clamp hold is by further deformation of the already highly deformed tubing and requires a difficult-to-achieve circular cross-section in the fluid line at its most vulnerable point.

The Invention

The invention provides a machine assembly, a staking tool and a assembly procedure wherein a clamping yoke of deformable material securing the pilot end of one or more tubular fluid transfer lines to a receiver including a receiver mating surface including at least one fluid transfer line with a main fluid flow axis including an annular collar adjacent its pilot end with a collar axial width extending radially outward to an overall diameter, and the clamping yoke includes a clamping surface adjacent said receiver mating surface, an axial through-hole for each of said fluid transfer lines adapted to permit assembly of the yoke to the fluid transfer lines radially, including a through-hole diameter at least as large as the diameter of said fluid transfer line and less than the said overall diameter of the collar, and a through-hole extension passage extending radially of said transfer line with a width at least as large as the diameter of said fluid transfer line and less than the diameter of the collar. T connecting yoke further includes a cylindrical clamping recess on said connecting surface co-axial with said fluid transfer line having a cylindrical outer clamping surface, an annular land clamping surface extending radially of the fluid transfer line interior to the yoke, a diameter greater than the said overall diameter of said collar, and a depth greater than the said axial width of the said collar, at least one inwardly directed staked deformation restraining said collar within said clamping recess, each extending both radially inwardly and axially away from said pilot end to abut the collar and drive the collar against said land surface.

The invention further provides a assembly wherein the spacings between the fluid transfer line at one or more of the line to passage, the collar to recess or the collar and the land to recess and the yoke are a tight sliding fit before or after assembly. Further, the annular collar extends radially outward to a curved outer surface including a maximum diameter within the overall diameter and the annular collar includes an operative axial width less than the said collar axial width , wherein the annular land clamping surface extends from the fluid transfer line to the maximum diameter.

Further, the clamping recess depth is less than the axial with of the said collar and greater than the operative axial width and the clamping yoke transmits clamping force to the said collar and from the said collar to the receiver at the receiver mating surface through the said collar by a spacing between the collar clamping surface and the receiver mating surface.

Even further, the invention provides an assembly wherein the inwardly directed staked deformation is circular and may form an incomplete circle on the clamping surface co-axial with the fluid transfer line formed by a gap smaller in width than the with of either or both of the diameter of the fluid transfer line or width of the passageway.

The incomplete circle may be formed in two or more continuous circular portions.

Still further, the inwardly directed staked deformation restrainingly abuts the surface of the collar without penetration and drives against the collar as a surface to surface contact which includes that part of the collar beyond the maximum diameter in the direction of the pilot end and/or the bulk of that part of the collar between the maximum diameter and the fluid transfer line in the direction opposite to the direction of the pilot end.

OBJECTS OF THE INVENTION

It is an object of the invention to provide an improved and more secure means of assembly of fluid lines to a receiving body which is quick and efficient to produce in a high speed manufacture setting and which does not rely upon deformations of or penetrations into the vulnerable fluid lines or the receiving body (flatness); for its hold on the parts. DRAWINGS

Figures 1 a, 1 b, 1 c and 1 d depict a top plan view, a bottom plan view, a B-B cross- section (from Fig. 1 a) and a A-A cross-section (from Fig. 1 a) of the clamping yoke 1 of the assembly of the invention.

Figure 2 depicts a highly bent fluid line in partial cross-section C-C as shown in Figure 2a.

Figure 3 is a large scale pictorial view of the fluid tube mounting assembly including the clamping yoke and a pair of differently sized fluid lines.

Figure 4 is a small scale view showing the radial staking of the mounting assembly of Figure 3.

Figure 5 is a small scale diagrammatic view of the collar and radial staking in cross-section.

Figure 6 includes a progressive series of diagrammatic drawings, Figs 6a, 6b, 6c and 6d depicting the progress of a radial staking tool in accordance with the preferred embodiment.

Figure 7 is a diagrammatic view of the collar shown in Figure 5 in an alternative embodiment.

PREFERRED EMBODIMENTS

Clamping block or yoke 1 is preferably a machined rectangular solid with opposing parallel clamping surface 2 and surface 3. Surface 2 is preferably machined to a higher tolerance so as to mate with a machine assembly or component.

In the preferred case of a clamping block or yoke 1 adapted for use with highly bent fluid lines, the clamping block 1 is formed as by drilling along axes 4 and 5 perpendicular to the clamping surface 2, Figure 1 a. Drilling or other forming produces a small cylindrical tube passage 6 and a larger cylindrical tube passage 7 passing from clamping surface 2 towards surface 3. In the preferred cases cylindrical through-holes 6 and 7 may be extended, as at 9 and 10, which extensions may be perpendicular through-hole or at an angle such as is shown in Figures 1 as a cant angle of 10 degrees clockwise about the perpendicular through- hole axes 4 and 5 respectively. Extension passages 9 and 10 are preferably adapted to accommodate highly bent (deformed) fluid lines which curve, particularly in the small space between the end of the tubing and the width of the block 1 which would otherwise interfere with the clamping block 1 , as by a tight sliding fit to the tube-line.

Figures 1 b and 1c depict the preferred form of the surface 3 showing a preferably symmetrical arranged and centrally located pair of bolt holes 12 and 13 and a cross-section B-B. Engagement of clamping bolts (not shown) through holes 12 and 13 and with a machine assembly or component surface 11 under tension parallel to the axes 4 and 5 and perpendicular to clamping surface 2 draws clamping block 1 towards a clamping engagement with machine assembly surface 11 in a parallel mating arrangement.

Cylindrical through-holes 6 and 7 are dimensioned with a diameter (small tube) 16 and 17 (large tube) respectively as shown in Figure 1d. Diameters 16 and 17 are at least just sufficient to accommodate the outside diameter of the cylindrical fluid lines being joined to the machine assembly 11 . In one alternative embodiment, diameters 16 and 17 are provided to form a tight sliding fit with cylindrical fluid lines in order to support the clamping along their circumferences 18 and 19.

In the preferred embodiment passageways 9 and 10 include side walls 20 which are flat and perpendicular to the clamping surface 2. Side walls 20 are preferably parallel and spaced apart a distance 21 (small line) and 22 (large line) respectively. Distances 21 and 22 are most preferably the same as respective through-hole diameters 16 and 17 and at least as wide as the outside diameter of the fluid lines. In one embodiment, spacing distances 21 and 22 form a tight fit with cylindrical fluid lines in combination with diameters 16 and 17. As show in Figures 1a and 1 d clamping face 2 is relieved by a pair of annular and cylindrical clamping recesses 30 and 31 , each centered upon respective through- hole axes 4 and 5 with a clamping diameter 30a and 31a. Each recess 30 and 31 includes an axially aligned outer cylindrical clamping surface 32 and 33, at a clamping diameter of 30a and 31a, respectively, which each relieve clamping surface 2 to an X-depth 34. Each recess 30 and 31 also includes a clamping land surface as at 35 and 36 respectively which are each parallel to the clamping surface 2 and further relieve clamping surface 2 to a Y-depth 37.

Most preferably each recess 30 and 31 also includes an annular curved retaining surface 38 (small) and 39 (large) respectively extending between outer cylindrical clamping surfaces 32 and 33 and land clamping surfaces 35 and 36 which further relieves the clamping surface 2 by a Z-depth 40. In one embodiment the clamping surfaces 30 and 31 have rectangular profiles resulting in X-depth 34 being the same as Z-depth 37. In the preferred embodiment clamping recesses 30 and 31 have an identical clamping depth of X+Z=Y total depth.

In another preferred embodiment each of recess 30 and 31 includes a reverse curve retaining surface 37 (small) and 38 (large) to avoid the corner of the block damaging tubes between the respective land clamping surfaces 35 and 36 and the cylindrical passageway circumferences 18 and 19.

Most preferably bolt axes 14 and 15 are offset from block center line 45 by an bolt- offset distance 46. Passageway axes 4 and 5 are offset a line-offset distance 47. The offset distances 46 and 47 are preferably determined so as to provide a clamping force perpendicular to both clamping surface 2 and machine assembly 11 when fluid lines are engaged or as determined by the parts mating geometry.

In Figure 2 fluid line 50 is highly bent as at a typical right angle severe bend 51 so as to sealingly and solderlessly mate with a machine assembly 60 having the mating surface 11 . The pilot or open end of the fluid line 50 is provided with a male O-ring sealing assembly 52 including an O-ring seal 53 captured in a line recess 54. For assembly, clamping and bore hole axis 55 of machine assembly 60 is aligned with fluid line axis 56 (at the pilot end). Fluid line 50 is inserted into bore hole 65 for sealing engagement with fluid line axis 56 at a severe angle, such as a right angle, to the fluid line main axis 57.

Fluid line 50 is formed with a annular clamping collar 58 adapted to provide an outer annular, preferably flat, abutment surface 59 adjacent its pilot or open end, which is transverse to the fluid line axis 56 and the clamping bore axis 55, and, thus, adapted to be parallel to and mate with machine assembly surface 11 in an annular clamping ring surface as at 64 in Figure 2.

Upon assembly as depicted in Figure 2 fluid flow 61 in the connected line travels unimpeded around severe bend 51 as at 62 for a free-flow sealed connection with machine assembly 60 along flow direction 63.

As can be seen in Figure 2 the mating surface 2 of clamping block or yoke 1 is adapted to be lie adjacent to, and preferably parallel with, machine assembly surface 11. In the preferred embodiment the assembly provides a small but uniform spacing 70 between the yoke mating surface 2 and the machine surface 11 .

Annular collar 58 is also adapted to provide a 2 ^nd , preferably flat, inner abutment surface 76 transverse to and spaced along the fluid line 50 which is adapted to be parallel to and mate with an annular and transverse yoke receiving surface 75 upon application of closing clamping force along axes 55 and 56 between yoke 1 and machine assembly 60.

In one embodiment, annular collar 58 is adapted to sit within a cylindrical recess 77 (generally rectangular cross-section as shown in Figure 2) extending from the yoke mating surface 2 in to the material of the yoke 1 . In the preferred embodiment the recess 76 Is contoured, at least in part, to match the outer contour of the annular collar 58 as shown in Fig 4 and 5.

In Figure 3 the preferred embodiment of the invention includes a pair of highly bent fluid lines 50a (smaller) and 50b (larger) engaged with clamping yoke 1 respectively. Recesses 76a and 76b respectively include extended passageways 9 and 10 to accommodate fluid line bends. Recesses 76a and 76b are shaped to conform to annular collars 58 and 58b.

In Figure 4 the preferred embodiment of Figure 3 is shown in small scale for the larger fluid line 50b, wherein the sub-b labeled components are similarly numbered from the prior drawings. The inner abutment surface 76is shown as an annular curved surface preferably with a flat bottom adapted to mate with the external surface of collar 58 along circumference where not interrupted by passageway 10. Most preferably, recess 77 is closely machined so as to closely mate with collar 58 inner abutment surface 76.

As at radial stake 80, yoke 1 clamping surface 2 is radially staked in an annular staking ring 81 to deform the material of yoke 1 radially inward and over the remaining surfaces of collar 58 into a close mating abutment with collar 58. Most preferably, radial stake 80 combines with the inner abutment surface 76 and collar 58 for a continuous abutting contact as shown in Figure 4.

In Figure 5 a diagrammatic cross-section of the preferred embodiment assembled and fully clamped in place Is shown with compression forces between yoke 1 , line 50 and assembly 60 applied along axis 55 as by a pair of tightened bolts in bolt holes 12 and 13 (Fig4). Collar 58 is clamped between annular surface 64 (a portion of surface 11 ) and surface 75 so as to, preferably, provide complete mating and reduce spacings 82 and 87 to or close to 0, (with spacing 91 at or close to 0) collar 58 remaining in a near-closed or fully closed condition about transverse plane 88 for a tight and secure mechanical connection. Prior to clamping, yoke 1 is radially staked in direction 83 in an annular pattern adapted to penetrate the yoke material at ring 81 and deform the free edge, at 80, inwards and downwards towards collar 58 along line 50 as at directions 84 and 85. Preferably, the annular pattern is circular and continuous. In another embodiment shown in Figure 7 the annular pattern remains circular but is discontinuous where design limitations require a gap without the staking component. The deformation along directions 84 and 85 drives the yoke material radially into a mating relationship with collar 58 so as to close or nearly close gaps 86 and 87 securely mating the collar 58 to the yoke 1 and thence to machine assembly 60 when the assembly 60 and the yoke, are driven together along bolt axes 14 and 15 for a permanent sealed result.

Most preferably, the depth of yoke recess 71 is somewhat less than the axial thickness 94 of collar 58 so as to provide and accommodate a spacing 70 when clamped and spacing 82 is at or close to 0. Further preferably stake 80 (fig 5) occupies less space 90 than ½ 92 of the recess depth being the sum total of spacings 92 and 93. Most preferably collar 58 includes an annular axial portion 95 of its outer mating surface which extends a distance 96 axially and equally spacing on either side of transverse plane 88 or extension 90. In this preferred embodiment spacing 92 is greater than ½ of spacing 96 and is adapted so that stake 80 may be deformed fully inboard of surface 95 to mate with curved surfaces of collar 58 as at 97

Figures 6a through 6d depict the operation of a circular radial staking tool in accordance with the preferred method and apparatus of the invention. Tool body 100 may be a complete annular shape or incomplete as including a relieved section. Tool body is driven downward in direction 83 with its circular point 103 into initial contact with yoke surface 2, preferably along a circular line, and then in to the body of yoke 1 immediately adjacent and outboard of annular recess 77. Further motion of tool body 100 downward into yoke 1 forcibly deforms (stakes) the material of yoke 1 into a stake 105 directed radially inward towards collar 58. Tool body 100 includes staking surfaces 101a (inside) and 101 b (outside) staking surfaces each at an angel to direction 83. As staking surface 101a is driven downwards in direction 83, as at Figures 6b and 6c, an annular radial stake 105 is forming as yoke material is deformed both inward along direction 84 and downward along direction 85. The completed radial stake is shown as element 80 in Figures 4 and 5. Deformations outwardly from collar 58 caused by staking surface 101 b may be accommodated within spacing 74 so as not to interfere with clamping, and to meet the 0.15 flatness requirement.

The staking surfaces 101 a and b may be symmetrical about direction 83 as shown in Figures 6 or asymmetrical such as 101 b being aligned parallel to direction 83.

In the case of a rectangular recess 77 as shown in Figures 6 the staking may leave a residual cavity 104 not present with mating contact as shown in Figures 4 and 5.

As shown in Figure 6d motion of tool body 100 may be stopped before the tool body itself strikes the yoke 1 or severs the stake 105.

A radial staking tool adapted for use in machine assembly of fluid transfer lines to a receiving body as shown in Figures 6 including a blow end, a strike end, a generally cylindrical body co-axial with the direction of a strike extending from the blow end and a body to be struck towards the strike end, the body may include an axial gap adapted to accommodate a part upstanding from said body to be struck, the blow end including a circular penetration abutment adapted to deform struck material in larger part inwards of the cylindrical body and and in smaller part in the direction of the strike.

The blow end further includes an annular portion transverse to the direction of the strike interior to the penetration abutment and/or a portion exterior to the penetration abutment.

A procedure is provided as shown in the description and drawings herein for the assembly of fluid transfer lines to a receiving body including assembling at least one fluid transfer line to a transverse connecting yoke as described Figure 1 through 7 through the respective through-hole by means of a passageway with a tight sliding fit between between the fluid transfer line and the yoke, and orienting the fluid transfer line about is main fluid-flow axis to a finished angular position, radially staking the yoke on its clamping surface with a staking tool as described in Figures 7 and deforming a circular portion of the yoke into the recess and clamping the collar in abutment against the recess, securing the assembly to the receiving surface.

By the procedure, the securing drives the receiver mating surface against the collar of the fluid transfer line and the collar against the yoke. Fluid tight sealing is maintained by an O-ring seal between the fluid transfer line and the receiver as in Figure 2.

The scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations, and/or additions to the present subject matter as would be readily apparent to the person skilled in the art.

List of elements

1 yoke - clamping block

2 mating surface

3 surface

4 through-hole axis

5 through-hole axis

6 through-hole / small

7 through-hole / large

8

9 passageway

10 passageway

11 machine assembly - mating surface - machine assembly surface- point of surface

12 bolt hole

13 bolt hole

14 bolt axis

15 bolt axis

16 through-hole diameter

17 through-hole diameter

18 circumference

19 circumference

20 side wall

21 spacing distance (small line)

22 spacing distance (large line)

30 annular clamping recess 31 annular clamping recess

30a clamping diameter

31 a clamping diameter

32 clamping distance

33 clamping distance

34 X-depth

35 location (as at)

36 location (as at)

37 Y-depth

38 surface (small)

39 surface (large)

40 Z-depth

45 center line

46 bolt-offset distance

47 line-offset distance

50 fluid line

50a highly bent fluid lines (small) 50b highly bent fluid lines (large)

51 right angle severe bend

52 O-ring sealing assembly

53 O-ring seal

54 line recess

55 bore hole axis

56 fluid line axis (at the pilot end)

57 main axis

58 annular collar

58a

58b annular collar

59 abutment surface

60 machine assembly

61 fluid flow

61 a 61 b

62 location (as at)

63 direction

63b

64 ring surface - annular surface

65 bore hole

70 uniform spacing

71 yoke recess

72

73

74 spacing

75 surface

75b

76 recess - inner abutment surface

76a recess

76b recess

77 cylindrical recess - annular recess

80 radial stake

81 ring

82 spacing

83 direction

84 direction

85 direction

86 gap

87 spacing- gap

88 transverse plane

90 space - extension

91 spacing

92 embodiment spacing

93 spacing

94

95 axial portion - surface 96 distance - spacing

97 location (as at)

100 tool body

101 a staking surfaces (inside) 101 b staking surfaces (outside) 102

103 circular point

104 cavity

105 radial stake

106

A

B C

D