Abstract:
The production of a quick connection device including a metal journal that fits in a complementary manner into a connector is performed by a process including the following steps: a metal tube is extruded to form a blank of the journal extending longitudinally from a large end to a small end along a first cylindrical portion; from the first cylindrical portion, the blank narrows along a conical portion to a second cylindrical portion. The wall of the tubular blank has a thickness that is substantially constant in all three portions.

Description:
TECHNICAL FIELD 
       [0001]    The invention relates to a process for manufacturing a quick connection between two tubular components. 
       TECHNICAL BACKGROUND OF THE INVENTION 
       [0002]    Devices for the quick connection of two tubular components comprising a male endpiece, or journal, fixed to one of the components, and a female endpiece, or connector, fixed to the other component, already exist. Assembling the journal into the connector in complementary fashion seals the connection. The assembly is held in place by an elastic clip secured to the connector which, upon assembly, moves aside to allow the journal to engage then becomes lodged in a transverse groove provided in the journal. In addition, the journal is provided with two tabs and the connector with two complementary grooves forming a means for preventing the components from turning. The connector and the journal are made of molded plastic and a complex mold is needed. Notably inserts are provided for forming the grooves for positioning the clip. In addition, the imposed shape does not make for easy manufacture of metal journals. 
       SUMMARY OF THE INVENTION 
       [0003]    The present invention addresses these problems by proposing a simple method for producing a quick connection device comprising a metal journal, for example made of aluminum alloy, copper, brass or even steel, that fits in a complementary manner into a connector. The process comprises the step of, by extrusion of a metal tube made of aluminum alloy or the like, forming a blank of the journal extending longitudinally from a large end to a small end along a first cylindrical portion, then narrowing along a conical portion then along a second cylindrical portion, the wall of the tubular blank being of a thickness that is substantially constant in all three portions. The extrusion step further comprises the formation of two longitudinal tabs produced on the exterior surface of the first portion, the tabs being diametrically opposite and part of a device that prevents the device from turning. 
         [0004]    The process additionally comprises the step of making, in the first portion, two transverse cuts through the wall of the first portion, the cuts forming open apertures separated by the two tabs. These cuts can be made in a number of ways, notably by transverse sawing. Using straight or circular saws, the apertures can be made one after another or alternatively simultaneously. The apertures may also be produced by radial stamping after a mandrel has been inserted up inside the journal to prevent deformation. 
         [0005]    The invention also relates to a process for producing a quick connection by push-fitting in a complementary manner a journal, secured to a first tubular component, into a connector secured to a second tubular component, the process of producing the connection comprising the step of providing a journal produced according to the previous paragraph, the first portion of the journal having an inside diameter matched to the outside diameter of the first component and an outside diameter matched to the inside diameter of the connector. The process also comprises the step of inserting the first component into the first portion so that the journal butts against the end of the first tubular component. The apertures are then closed by the first component. The process also comprises the step of fixing the journal on the end of the first component. 
         [0006]    The fixing may comprise a step of temporary fixing which is achieved by local deformation of the first component by producing radial protrusions that become lodged in the apertures. Temporary fixing comes prior to a step of permanent fixing which may be performed using brazing. It is then advantageous to provide a braze washer of which the outside and inside diameters are substantially those of the first tubular component, then to arrange the braze washer in the journal before the first component is inserted into the first portion of the journal, so that once the first component has been inserted, the braze washer finds itself trapped between the journal and the first component. 
         [0007]    The invention further relates to a quick connection device comprising a journal that fits in a complementary manner into a connector, the device being produced according to the preceding paragraphs. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    One embodiment of the invention is now described via the following figures. 
           [0009]      FIG. 1  is an isometric view of a quick connection device comprising a journal and a connector, the device not being assembled. 
           [0010]      FIG. 2  depicts the device of  FIG. 1 , assembled. 
           [0011]      FIG. 3  is a blank of the journal of  FIG. 1 . 
           [0012]      FIG. 4  is a view of the completed journal. 
           [0013]      FIG. 5  is a cross section of the assembly of the journal of  FIG. 4  on the end of a tubular component. 
           [0014]      FIG. 6  is an isometric view of the final assembly. 
       
    
    
       [0015]    The figures are provided for purely illustrative purposes and are not intended to limit the scope of the present invention. 
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0016]    According to  FIGS. 1 and 2 , a first and a second tubular component  2 ,  4  are connected using a quick-assembly device  10 . The device  10  comprises a metal journal  12 , for example made of aluminum, of copper, of brass or even of steel, secured to the endpiece of the first component  2  and a female connector  14  secured to the endpiece of the second tubular component  4 . The journal  12  is tubular and extends along the longitudinal axis A from a large end  16  engaged over the first tubular component  2  to a small end  18  which is free. Between its two ends  16 ,  18 , the journal  12  comprises a first cylindrical portion  20 , then a conical portion  22 , then a second cylindrical portion  24 , of a diameter smaller than that of the first portion  20 . The first portion  20  is provided with two longitudinal tabs  26 ,  28  which are diametrically opposite and designed to engage in complementary grooves of the connector  14  and thus prevent the journal  12  from turning relative to the connector  14 . The first portion  20  is additionally provided with two transverse openings  30 ,  32 , forming two apertures facing one another, each extending between the tabs  26 ,  28 . 
         [0017]    The connector  14  comprises a tubular cylindrical portion  34  of which the inside diameter allows the first portion  20  of the journal  12  to be inserted as a just-sliding fit. This portion  34  is provided with a U-shaped elastic clip  36 , the branches of which pass through transverse openings  38 ,  40  of the connector  14 . The U-shape of the clip is just one illustrative example and numerous alternatives may exist. 
         [0018]    As the journal  12  is engaged in the connector  14 , the free small end  18  and the second cylindrical portion  24  of the journal pass between the branches of the U. Next, the conical portion  22  parts the branches of the U elastically in order to allow the first cylindrical portion  20  to pass. When the journal  12  is fully engaged in the connector  14 , the transverse apertures  30 ,  32  of the journal  12  are positioned facing the transverse openings  38 ,  40  of the connector  14 , and the clip  36  returns to its original U-shape, the branches of the clip  36  engaging in the apertures  30 ,  32  of the journal  12 . The device  10  is thus held axially in position and can be disconnected only by parting the branches of the clip  36  and then pulling on the first component  2  in order to disengage the journal  12 . 
         [0019]    According to  FIG. 3 , during a first step El of manufacture, a blank  40  of the journal  12  is produced by extruding a metal tube, made of aluminum or some other metal. At the end of this first step E 1 , the blank  40  comprises the first cylindrical portion  20 , the conical portion  22  and the second cylindrical portion  24  as well as the longitudinal tabs  26 ,  28 . The extrusion process is accurate enough that the dimensions obtained do not have to be reworked subsequently using other means. 
         [0020]    According to  FIG. 4 , during a second step E 2  of manufacture, the apertures  30 ,  32  are created by transverse cutting or alternatively by stamping after having inserted a mandrel up inside the blank  40 . Other alternatives exist and the choice of alternative is notably dependent on the quantity of components to be produced. 
         [0021]    At the end of the second step E 2 , the metal journal  21  is complete. 
         [0022]    According to  FIG. 5 , during a third step E 3 , the completed journal  12  is mounted on the end of the first tubular component  2  by engaging said first component  2  into the first cylindrical portion  20  until it has passed the transverse apertures  30 ,  32  and come into abutment in the conical portion  22 . A braze washer  42  has been interposed between the end of the first tubular component  2  and the journal  12 , this washer being intended to melt during a subsequent brazing operation and thus permanently join the journal  12  and the first component  2  together. The composition of the braze washer is dependent on the metal chosen from which to produce the journal  12 . For example, in the case of a journal  12  made of aluminum alloy, the braze washer  42  is made of an alloy of aluminum and silicon, the melting point of which is below that of aluminum. As can be seen in the cross section of  FIG. 5  and in  FIG. 6 , because the first tubular component  22  is engaged beyond the transverse apertures  30 ,  32 , this first component  2  closes off said apertures  30 ,  32 . Alternatively, the journal could be covered with brazing flux, something which makes it possible not to fit a braze washer. 
         [0023]    At the end of the third step E 3 , the journal  12  is placed on the end of the first tubular component  2 . 
         [0024]    According to  FIG. 6 , during a fourth step E 4 , the journal  12  is fixed temporarily to the first component  2  by radially deforming the first component  2  so as to produce protuberances  44  which enter the transverse apertures  30 ,  32 . In order to produce these deformations, a tool, not depicted, is inserted inside the journal  12  via the small end  18  until it is positioned in line with the apertures  30 ,  32 . The tool is then expanded so as to deform the material of the first component  2  and produce the protrusions  44 . 
         [0025]    A fifth operation E 5 , not depicted, involves brazing the whole so as to assemble the journal  12  permanently on the end of the first component  2 . During brazing, the washer  42  melts, joining the journal  12  and the first tubular component  2 . 
         [0026]    Different sized connection devices  10  may thus be produced to fit the components that are to be connected. Connections of this type may for example be used within a vehicle heat exchange circuit, notably the engine cooling circuit, to connect a radiator to the pipes through which the coolant flows. 
         [0027]    The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.