Abstract:
A quick connector assembly incorporating a substantially non-circular, compressible sealing element in a connector housing. Upon insertion of a male adaptor, the male adaptor directly or indirectly applies an axial compressive force, thereby causing the sealing element to compress and/or reshape upon continued insertion until final assembly is complete.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This non-provisional application claims the benefit of, and priority from, copending U.S. Provisional Application 62/082,436 having a filing date of Nov. 20, 2014. The contents of such earlier application and all other documents referenced herein are hereby incorporated by reference as if set forth in their entirety 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates generally to fluid line systems which include quick connector couplings. In particular, the present disclosure relates to quick connectors adapted for use in transportation vehicles such as automobiles, aircraft and the like to establish and maintain reliable connections in various fluid line systems such as coolant systems, hydraulic systems and the like. 
       BACKGROUND 
       [0003]    In automotive and other fields, quick connector assemblies are often used to provide a fluid connection between two components or conduits. Such quick connector assemblies typically include a male adaptor which is received and sealingly retained in a plastic or metal female connector housing. Within the connector housing, an O-ring sealing element is typically seated within a groove bordered by a sealing ring which is fixed in place by welding or the like so as to block the O-ring sealing element against undesired axial movement. A spring clamp of metal or the like is positioned rearward of the sealing ring between the sealing ring and the housing entrance. As the male adaptor (over which a hose or other structure is mounted) is inserted into the connector housing entrance, the spring clamp is first engaged and caused to deform radially. As the male adaptor is advanced further into the connector housing a distal end of the male adaptor is forced through the O-ring sealing element, thereby causing the O-ring sealing element to expand radially. Upon full insertion of the male adaptor into the housing, the spring clamp falls into a radial groove on the male adaptor, thereby blocking both axial and rotational displacement of the male adaptor. At the same time, the O-ring sealing element is captured between the distal end of the male adaptor and the connector housing to provide a fluid tight seal. 
         [0004]    While prior quick connector configurations have provided excellent performance, they may require the application of substantial force in order to establish the initial connection. In particular, a significant amount of force may be required to push the distal end of the male adaptor through the O-ring sealing element so as to cause the required radial expansion of the O-ring sealing element. Some users may lack the physical strength necessary to carry out this function. Accordingly, a quick connector which reduces the insertion force necessary to establish a sealed connection between the connector housing and the male adaptor would be desirable. 
       SUMMARY OF THE DISCLOSURE 
       [0005]    The present disclosure provides advantages and alternatives over the prior art by providing a quick connector assembly incorporating a compressible sealing element adapted to reduce initial insertion force of a male adaptor. Upon insertion of a male adaptor into the connector housing, the compressible sealing element is caused to compress and/or reshape upon continued insertion until final assembly is complete. Initial resistance is substantially reduced as the sealing surface of the male adaptor moves past the sealing element. Overall assembly is thereby simplified and made easier. 
         [0006]    In accordance with one exemplary aspect, the present disclosure provides a quick connector assembly including a connector housing defining an axial through bore having a housing entrance. A male adaptor is provided for insertion into the connector housing through the housing entrance in substantially coaxial relation with the axial through bore. The male adaptor comprises a flared distal end having a nose portion. A compressible sealing element having a substantially non-circular, cross-sectional profile is disposed at a position within the connector housing. Upon initial insertion of the male adaptor into the connector housing, the nose portion of the male adaptor passes the compressible sealing element, and upon continued insertion of the male adaptor into the connector housing, the compressible sealing element is deformed by folding or reoriented to form a fluid-tight seal between the male adaptor and an opposing surface of the connector housing. 
         [0007]    Other features and advantages of the disclosure will become apparent to those of skill in the art upon review of the following detailed description, claims and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a schematic, exploded perspective view illustrating an exemplary quick connector assembly incorporating a fixed retainer ring and O-ring sealing element in accordance with the prior art; 
           [0009]      FIG. 2  is a schematic cut-away view illustrating an exemplary quick connector assembly incorporating a compressible sealing element in accordance with the present disclosure; 
           [0010]      FIG. 3  is a schematic cross-sectional view illustrating the relation among the male adaptor and compressible sealing element in the quick connector assembly of  FIG. 2 ; 
           [0011]      FIGS. 4 and 5  illustrate alternative exemplary constructions for a compressible sealing element in a quick connector assembly in accordance with the present disclosure; 
           [0012]      FIGS. 6 and 7  are schematic illustrations of an exemplary alternative construction quick connector assembly incorporating a compressible sealing element in accordance with the present disclosure; and 
           [0013]      FIG. 8  is a schematic exploded view of the exemplary quick connector assembly of  FIGS. 6 and 7 . 
       
    
    
       [0014]    Before the exemplary embodiments of the invention are explained in detail, it is to be understood that the invention is in no way limited in its application or construction to the details and the arrangements of the components set forth in the following description or illustrated in the drawings. Rather, the invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for purposes of description only and should not be regarded as limiting. The use herein of terms such as “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. 
       DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0015]    Reference will now be made to the drawings, wherein to the extent possible, like elements are designated by like reference numerals in the various views. In  FIG. 1 , an exemplary prior art quick connector assembly  10  is illustrated. Such quick connector assemblies typically include a male adaptor  12  which is received and sealingly retained in a plastic or metal female connector housing  14  defining a through bore. Within the connector housing  14 , an O-ring sealing element  16  is typically seated within an O-ring groove  18  defined on one side by a sealing ring  20 . In the prior art construction, the sealing ring  20  is fixed in place by welding or the like so as to contain the O-ring sealing element  16  within the O-ring groove  18 . In this configuration, the O-ring sealing element  16  is substantially blocked against axial movement. 
         [0016]    As illustrated, in the exemplary prior art construction, a spring clamp  30  of metal or the like is positioned rearward of the sealing ring  20 . As shown, the spring clamp  30  may be of a generally ring-shaped configuration with a substantially elliptical or other non-circular geometry. The male adaptor  12  may include a proximal end  32  which matedly engages a hose or other structure (not shown). The male adaptor  12  also includes a distal end  34  which is adapted for insertion into the connector housing  14  in substantially coaxial relation to the housing through bore. An enhanced diameter intermediate collar  36  is disposed between the proximal end  32  and the distal end  34 . A radial groove  40  is disposed within the intermediate collar  36 . As the male adaptor  12  is inserted into the connector housing  14 , the spring clamp  30  is first engaged and caused to deform radially outwardly by outward force from the distal end  34 . As the male adaptor  12  is advanced further into the connector housing  14 , the distal end  34  is forced through the O-ring sealing element  16 , thereby causing the O-ring sealing element  16  to expand radially outwardly to fill the O-ring groove  18 . Upon full insertion of the male adaptor  12  into the connector housing, the spring clamp  30  falls into the radial groove  40  at the intermediate collar  36 . With the spring clamp  30  captured in the radial groove  40 , the male adaptor  12  is blocked against axial displacement. The radial expansion of the O-ring sealing element  16  provides a fluid tight seal between the male adaptor  12  and the surrounding connector housing  14 . In this configuration a sealed fluid passageway is established across the connector housing  14 . 
         [0017]    Referring now to  FIGS. 2 and 3 , an improved quick connector assembly  110  consistent with the present disclosure will now be described wherein elements corresponding to those previously described will be designated by like reference numerals within a  100  series. As illustrated, the quick connector assembly  110  includes a male adaptor  112  and a connector housing  114  defining an axial through bore. The male adaptor  112  and the connector housing  114  are adapted for mated engagement as illustrated by the force arrows in the various views. 
         [0018]    As shown, the male adaptor  112  may have a configuration generally as described in reference to the prior art. In this regard, the male adaptor  112  may include a proximal end  132  which matedly engages a hose or other structure (not shown). The male adaptor  112  may also include a flared distal end  134  having a rounded nose  135  as best seen in  FIG. 3  which is adapted for insertion into the connector housing  114 . In the illustrated exemplary construction, an enhanced diameter intermediate collar  136  is disposed between the proximal end  132  and the distal end  134 . A radial groove  140  may be disposed within the intermediate collar  136 . 
         [0019]    Referring jointly to  FIGS. 2 and 3 , it may be seen that the illustrated, exemplary quick connector assembly  110  includes a compressible sealing element  150  in combination with a floating retainer ring  160 . This combination facilitates the insertion of the male adaptor  112  by reducing the force required during the initial stage of insertion. In particular, the use of the floating retainer ring  160  which may slide axially relative to the adjacent surface of the connector housing  114  permits early stage insertion forces to be minimized, while nonetheless permitting compression and reshaping of the compressible sealing element  150  to establish a fluid tight seal. 
         [0020]    As best illustrated in  FIG. 3 , the floating retainer ring  160  may have a generally wedge-shaped cross-section construction incorporating a rear forward sloped face  162  projecting in a direction generally opposing the direction of male adaptor insertion. The floating retainer ring  160  may also include a forward face  164  which is adapted to engage and compress the compressible sealing element  150  as will be described further hereinafter. 
         [0021]    Prior to insertion of the male adaptor  112  into the connector housing  114 , the compressible sealing element  150  may be disposed in resting relation within the interior of the connector housing  114  adjacent to a supporting radial shoulder surface  168 . In this regard, it will be understood that the compressible sealing element  150  may be a generally ring-shaped structure with a cross-section adapted for folding deformation upon the application of compression in the axial direction. In this regard, the cross-section of the compressible sealing element  150  may define one or more leg segments intersecting to form living hinges to facilitate such folding deformation. The compressible sealing element  150  may be formed from an elastomer with sufficient dimensional stability such that the sealing element  150  maintains a general ring structure within the connector housing  114  prior to use and does not fall out. 
         [0022]    Prior to insertion of the male adaptor  112  into the connector housing  114 , the floating retainer ring  160  may be disposed in floating relation between the compressible sealing element  150  and a sealing ring (not shown) as previously described in relation to  FIG. 1 . Thus, the floating retainer ring  160  is initially permitted to slide axially relative to the opposing surface of the connector housing  114  within a zone bordered by the compressible sealing element  150  and the sealing ring. Of course, other arrangements may likewise be used if desired. 
         [0023]    As best seen in  FIG. 3 , in the exemplary construction, the male adaptor  112  may include a forward projecting sloped shoulder surface  170  defining a portion of flared distal end  134  in spaced apart relation to the rounded nose  135 . The sloped shoulder surface  170  of the male adaptor  112  is adapted to contact and bear against the rear sloped face  162  of the floating retainer ring in the final assemble condition. In this final condition, the compressible sealing element  150  may be deformably compressed between the forward face  164  of the floating retainer ring  160  and the opposing radial shoulder surface  168 . The compressible sealing element  150  is also compressed between flared distal end  134  and the opposing surface of the connector housing  114  thereby providing a fluid-tight seal. At the same time, axial withdrawal of the male adaptor  112  may be blocked by engagement between in the same manner as described in relation to  FIG. 1 . 
         [0024]    As noted previously, a significant benefit of the quick connector assembly  110  is the reduction in the force required to achieve full insertion of the male adaptor  112 . In this regard, upon initial insertion of the male adaptor  112 , the male adaptor  112  will first contact the floating retainer ring  160  and will cause the floating retainer ring  160  to move axially forward generally into the position illustrated in  FIG. 3  as the male adaptor  112  itself moves inwardly. As will be appreciated, during this initial stage of insertion, the male adaptor  112  encounters minimal resistance as the surface of the male adaptor moves over the compressible sealing element  150 . 
         [0025]    At the final stage of insertion, as axial force is applied to the male adaptor  112 , the sloped shoulder surface  170  urges the floating retainer ring  160  progressively forward against the compressible sealing element  150  until the final locked relation is achieved. However, this final distance of movement by the floating retainer ring  160  may be quite short such that the overall insertion effort is still relatively minimal. In the final assembled condition, the compressible sealing element is compressed to a deformed shape thereby forming the desired sealed relationship. 
         [0026]    As indicated previously, the compressible sealing element  150  may be a generally ring-shaped structure with a substantially non-circular cross-section adapted for folding deformation or reorientation upon the application of compression in the axial direction. In this regard, the compressible sealing element may have one or more leg segments with a length to thickness ratio greater than about 1.2 and more preferably a length to thickness ratio greater than about 2.0 and more preferably a length to thickness ratio greater than about 3.0. As illustrated in  FIGS. 2 and 3 , one possible configuration for the compressible sealing element  150  is an elastomer ring structure with a generally “V” shaped cross-section. As will be readily understood, as axial forces are applied, such a “V” configuration may undergo folding deformation at the living hinge formed at the intersection of the leg segments forming the “V”. Thus, the structure may fold in a hinging manner as the compressible sealing element  150  is pressed between the floating retainer ring  160  and the radial shoulder surface  168 . As this folding takes place, the compressible sealing element  150  will be urged to adopt an increased height within its zone of confinement thereby pressing against the opposing surfaces of the male adaptor  112  and the connector housing  114  and establishing the desired sealed condition. 
         [0027]    It is also contemplated that any number of other cross-sectional configurations may be used for a compressible sealing element within a quick connector assembly consistent with the present disclosure. By way of example only, and not limitation,  FIG. 4  illustrates one exemplary configuration for a compressible sealing element  250  for use in a quick connection assembly  210  consistent with the present disclosure. In the embodiment illustrated in  FIG. 4 , a compressible sealing element  250  may be an elastomeric ring having a generally “M” shape or “W” shape cross section. Such a sealing element may be disposed in a compression zone bordered by the male adaptor  212 , the connector housing  214  and the floating retainer ring  260  as previously described. Such a configuration may undergo folding deformation as axial forces are applied. More particularly, the structure may fold in a hinging manner as the compressible sealing element  250  is pressed between the floating retainer ring  260  and the radial shoulder surface  268 . As this folding takes place, the compressible sealing element  250  will also be urged to adopt an increased height within its zone of confinement thereby pressing against the opposing surfaces of the male adaptor  212  and the connector housing  214  and establishing the desired sealed condition. 
         [0028]      FIG. 5  illustrates yet another exemplary configuration for a compressible sealing element  350  for use in a quick connection assembly  310  consistent with the present disclosure. In the embodiment illustrated in  FIG. 5 , a compressible sealing element  350  may be an elastomeric ring having a generally tilted, elliptical cross section for disposition in a compression zone bordered by the male adaptor  312 , the connector housing  314  and the floating retainer ring  360  as previously described. Such a configuration may undergo folding deformation and/or reorientation to a more vertical orientation as axial forces are applied and the compressible sealing element  350  is pressed between the floating retainer ring  360  and the radial shoulder surface  368 . As this folding and/or reorientation takes place, the compressible sealing element  350  will also be urged to press against the opposing surfaces of the male adaptor  312  and the connector housing  314  and establish the desired sealed condition. 
         [0029]    It is also contemplated that the use of a floating retainer ring may be eliminated if desired. By way of example only, and not limitation,  FIGS. 6-8  illustrate one exemplary construction for a quick connector assembly  410  consistent with the present disclosure and wherein no floating retainer ring is used. In  FIGS. 6-8 , elements corresponding to those previously described will be designated by like reference numerals within a  400  series. As illustrated, the quick connector assembly  410  includes a male adaptor  412  and a connector housing  414  defining an axial through bore. The male adaptor  412  and the connector housing  414  are adapted for mated engagement as best illustrated in  FIGS. 7 and 8 . 
         [0030]    As shown, the male adaptor  412  may include a proximal end  432  which matedly engages a hose or other structure (not shown). The male adaptor  412  may also include a flared distal end  434  having a rounded nose  435  which is adapted for insertion into the connector housing  414 . In the illustrated exemplary construction, an enhanced diameter intermediate collar  436  is disposed between the proximal end  432  and the distal end  434 . A radial groove  440  may be disposed within the intermediate collar  436  for engagement with the spring clamp  430 . 
         [0031]    Referring jointly to  FIGS. 6-8 , it may be seen that the illustrated, exemplary quick connector assembly  410  includes a compressible sealing element  450  adapted for disposition in sealing relation between the distal end  434  of the male adaptor and an interir surface of the connector housing  414 . As can be best seen through joint reference to  FIGS. 6 and 7 , the compressible sealing element  450  may be a generally ring-shaped structure with a cross-section adapted for folding deformation upon the application of compression in the axial direction. In this regard, the cross-section of the compressible sealing element  450  may define one or more leg segments intersecting to form living hinges to facilitate such folding deformation. Such leg segments may be characterized by a length to thickness ratio greater than about 1.2 and more preferably a length to thickness ratio greater than about 2.0 and more preferably a length to thickness ratio greater than about 3.0. 
         [0032]    Prior to insertion of the male adaptor  412  into the connector housing  414 , the compressible sealing element  450  may be disposed in resting relation within the interior of the connector housing  414  adjacent to a supporting radial shoulder surface. The compressible sealing element  450  may be formed from an elastomer with sufficient dimensional stability such that the sealing element  450  maintains a general ring structure within the connector housing  414  prior to use and does not fall out. 
         [0033]    As illustrated, in the exemplary construction, the male adaptor  412  may include a forward projecting sloped shoulder surface  470  defining a portion of the flared distal end  434  in spaced apart relation to the rounded nose  435 . The sloped shoulder surface  470  of the male adaptor  412  is adapted to contact and bear against the rear face  452  of the compressible sealing element  450  in the final assembled condition. As shown, the sloped shoulder surface  470  and the rear face  452  of the compressible sealing element  450  may have generally complementary angles such that they may slide over one another as the male adaptor is being inserted into the final sealed condition illustrated in  FIG. 8 . In this final condition, the compressible sealing element  450  may be deformably compressed between the sloped shoulder surface  470  of the male adaptor and and an opposing radial shoulder surface  468  in the connector housing, thereby providing a fluid-tight seal. At the same time, axial withdrawal of the adaptor  412  may be blocked by engagement between the spring clamp  430  and the radial groove  440  in the same manner as described in relation to  FIG. 1 . 
         [0034]    Of course, variations and modifications of the foregoing are within the scope of the present disclosure. The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
         [0035]    Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.