Abstract:
A duct assembly comprises a collar that defines a bore and has a first plurality of slots and a second plurality of slots formed therethrough. The collar includes an annular wall formed within the bore and an end groove formed at one end thereof. A duct has an end fitted within the end groove. A ring is disposed within the collar and abuts the annular wall. A ring retainer is disposed within the collar and abuts the ring. The ring retainer has a plurality of tabs formed thereon that fit within the first plurality of slots. An end of a port extends into the collar. The port has an annular groove formed along its circumference. A clip that has a plurality of arcs formed along its length extends around the collar. The arcs extend through the second plurality of slots into the annular groove of the port.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to a duct assembly and more particularly to a sealed connection for a duct assembly.  
       BACKGROUND OF THE INVENTION  
       [0002]     The transfer of gasses and fluids within the modern combustion engine is integral to its efficient operation. For example, a charged air cooler that operates to increase the output power of a typical motor vehicle engine compresses air flow to improve engine performance. This charged air cooler system has numerous air flow requirements. Air flow must be routed through various components such as the air filter, heat exchanger, the charger compressor, and through the engine.  
         [0003]     Air flow is routed using tubular duct assemblies. These duct assemblies must be able to withstand the environment in which they are employed. For example, the duct assemblies in a charged air cooler system must resist a continuous temperature upwards of 250 degrees Fahrenheit with pressures upwards of 30 pounds per square inch. In order to withstand these pressures and temperatures, the typical duct assembly has a steel tube body with silicone and rubber end connectors. The end connectors are assembled with up to 4 band clamps and 2 silicone hoses. These end connectors prevent the fluid from bleeding out of the assembly along leak paths.  
         [0004]     While previous duct assembly designs have been satisfactory, there remains room in the art for improvement. Accordingly, it is an object of the present invention to provide the art with a duct assembly having a reduced cost of construction, reduced weight, fewer leak paths, a simple installation, aesthetically pleasing, and easily recyclable.  
       SUMMARY OF THE INVENTION  
       [0005]     A duct assembly is provided having a collar that defines a bore and has a first plurality of slots and a second plurality of slots formed therethrough. The collar includes an annular wall formed within the bore and an end groove formed at one end thereof. The collar is secured to a duct by fitting an end of the duct within the end groove. A ring is disposed within the collar and abuts the annular wall. A ring retainer is also disposed within the collar and abuts the ring. The ring retainer has a plurality of tabs formed thereon that fit within the first plurality of slots, thereby securing the ring retainer to the collar. An end of a port extends into the collar. The port has an annular groove formed along its circumference. A clip that has a plurality of arcs formed along its length extends around the collar. The arcs extend through the second plurality of slots into the annular groove of the port thereby securing the port to the collar.  
         [0006]     Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]     The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:  
         [0008]      FIG. 1  is a perspective view of a powertrain with a supercharger air cooler system having duct assemblies constructed in accordance with the present invention;  
         [0009]      FIG. 2  is a perspective view of an exemplary duct assembly constructed in accordance with the present invention;  
         [0010]      FIG. 3  is an exploded perspective view of an end connection for use with the duct assembly;  
         [0011]      FIG. 4  is a side plan view of a collar for use with the duct assembly;  
         [0012]      FIG. 5  is a side sectional view of the collar;  
         [0013]      FIG. 6  is a front plan view of a clip for use with the duct assembly;  
         [0014]      FIG. 7  is a side plan view of a ring retainer for use with the duct assembly;  
         [0015]      FIG. 8  is a perspective view of a connector port designed to couple with the duct assembly;  
         [0016]      FIG. 9  is a side plan view of the connector port;  
         [0017]      FIG. 10  is a perspective view of the connector port coupled to the duct assembly; and  
         [0018]      FIG. 11  is a side sectional view of the connector port coupled to the duct assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]     With reference to  FIG. 1  of the drawings, an exemplary powertrain of a motor vehicle having a supercharger air cooler system using duct assemblies that are constructed in accordance with the teachings of the present invention is generally indicated by reference numeral  10 . The powertrain  10  includes an engine  12  whose output is transmitted to a transmission  14 . The supercharger air cooler system is used to increase the rate of air flow to the engine  12   
         [0020]     Atmospheric or dirty air flow is drawn into a dirty air intake duct  16  to an air filter  18  mounted within the motor vehicle. The air filter  18  removes particulate matter from the atmospheric air flow, typically using finely meshed screens. A clean air duct  20  then channels the air flow to a supercharger air compressor  22  mounted proximate to the engine  12 . The supercharger air compressor  22  compresses the air, thereby increasing the rate of air flow through the engine  12  and increasing performance. Compression of the air typically increases the temperature of the air flow. A charged air duct  24  then transports the compressed air flow to a heat exchanger  26 , typically mounted forward of the engine  12 . The heat exchanger  26  cools the charged air flow to a more desirable temperature. The air is then moved through a cooled charge air duct  28  to the engine  12  where it is used in the combustion process. Finally, air flow moves through a crankcase venting duct  30  back to the air filter  18  where it is recirculated to the engine  12 .  
         [0021]     The air ducts  16 ,  20 ,  24 ,  28 , and  30  are illustrated as having various tube shapes and lengths, however, all are constructed in a fashion according to the teachings of the present invention, as will be described in greater detail below. Moreover, various other applications for the duct assemblies may be employed, for example in oil cooler systems, transmission lines, oil fill tubing, or coolant tubing assemblies.  
         [0022]     Referring now to  FIG. 2 , an exemplary duct assembly constructed according to the principles of the present invention is generally indicated by reference numeral  50 . The duct assembly  50  includes a tubular duct  52  having opposing open ends  54 . Connectors  56  are mounted on each opposing end  54  in a manner to be described in greater detail below. A pair of flexible bellows  58  are mounted near the opposing ends  54  of the duct  52 . The flexible bellows  58  include convolutions  60  that are formed with a degree of flexibility. This flexibility in turn permits the opposing ends  54  to have some limited range of movement relative to the rest of the duct  52 . In this regard, the convolutions  60  deflect (e.g., fold or unfold) in response to the movement of the opposing ends  54 . Likewise, flexible bellow portions may be included throughout the length of the duct  52 .  
         [0023]     In the particular example provided, the duct  52  is a cylindrical tube with multiple bends throughout its length and made from a single wall unitary thermoplastic. However, it should be appreciated that the duct  52  may be of any shape and size with any amount of bends or turns along its length, and be of various other materials, its configuration defined only by the environment of its intended use.  
         [0024]     With reference to  FIG. 3 , the connector  56  includes a collar  62 , a clip  64 , a ring retainer  66 , and an o-ring  68 . The collar  62  is mounted to one or both ends  54  of the duct assembly  50  and essentially holds the remaining components of the connector  56  in place. The clip  64  is mounted externally around the collar  62  and the ring retainer  66  is mounted to the interior of the collar  62 . The ring retainer  66  aids in securing the o-ring  68  within the connector  56 . A more detailed description of the assembly of the connector  56  will be provided below.  
         [0025]     With reference to  FIGS. 4 and 5 , the collar  62  has a hollow and generally cylindrical body  70  with a receiver end  72  for receiving a connector port, as will be described below, and a fixed end  74  adapted to receive the ends  54  of the duct  52 . The collar  62  defines an inner cavity  76 . The body  70  has an enlarged portion  78  proximate to the receiver end  72  and a reduced portion  80  proximate to the fixed end  74 . The enlarged portion  78  is defined by an increased outer radius relative to the body  72 , and the reduced portion  80  is defined by a decreased outer radius relative to the body  72 .  
         [0026]     A clip groove  82  is formed in the enlarged portion  78  along the circumference of the collar  62 . A plurality of clip slots  84  are formed in the collar  62  and extend into the inner cavity  76 . The clip slots  84  are spaced at equal intervals along the circumference of the enlarged portion  78  and are located within the clip groove  82 . The clip slots  84  are sized to receive portions of the clip  64 , as will be described below.  
         [0027]     A plurality of ring slots  86  are formed in the body  70  of the collar  62  and extend into the inner cavity  76 . The ring slots  86  are spaced at equal intervals along the circumference of the body  70  and are sized to receive portions of the ring retainer  60 , as will be described below.  
         [0028]     As best seen in  FIG. 5 , the inner cavity  76  includes an annular wall  88  formed in the reduced portion  80 . The annular wall  88  extends along the circumference of the inner cavity  76 . The plane of the annular wall  88  faces the receiver end  72 .  
         [0029]     The reduced portion  80  defines an end groove  90 . The end groove  90  extends from the fixed end  74  into the reduced portion  80  and is sized to receive the ends  54  of the duct  52 .  
         [0030]     With reference to  FIG. 6 , the clip  64  is approximately circular in shape with free ends  92  proximate to each other. Preferably the clip  64  is formed from a heavy gauge wire of stainless steel or some other suitably strong material. The clip  64  includes a series of alternating protrusions  94  and valleys  96  formed along its length. The spacing of the valleys  96  along the length of the clip  64  matches the spacing of the clip slots  84  formed in the collar  62 . Moreover, the radius of the protrusions  94  matches that of the outer radius of the groove  82  formed in the collar  62 .  
         [0031]     With reference to  FIG. 7 , the ring retainer  66  is annular with a plurality of tabs  98  formed along its outer circumference. The tabs  98  each have sloped front faces  100  that aid in the mounting of the ring retainer  66  to the collar  62 . The tabs  98  are spaced to match the spacing of the ring slots  86  formed in the collar  62 .  
         [0032]     Referring now to  FIGS. 8 and 9 , a connector port, generally indicated by reference numeral  110 , is sized to fit within the connector  56 . The connector port  110  is generally cylindrical in shape and has an insert end  112  and a extending end  114 . The insert end  112  has a taper  116  to aid in installation of the insert end  116  into the connector  56 .  
         [0033]     An annular hub  118  with an increased outer radius is formed along the circumference of the connector port  110  proximate to the insert end  112 . The annular hub  118  includes a tapered face  120  facing towards the insert end  112 . Moreover, the annular hub  118  defines an annular detent  122  along the circumference of the connector port  110  which is sized to receive the valleys  96  of the clip  64 . The connector port  110  is preferably constructed from stainless steel, however, various other materials may be employed.  
         [0034]     With reference to  FIGS. 10 and 11 , the assembly of the connector  56  and the connector port  110  will now be described in greater detail. The end  54  of the duct  52  is inserted into the annular groove  90  of the collar  62  and secured using a spin weld. Alternative methods of securing the duct  52  to the collar  62  may be employed, such as adhesives or clamps.  
         [0035]     The o-ring  68  has a diameter approximately equal to the diameter of the inner cavity  76  of the collar  62 . The o-ring  68  is inserted into the inner cavity  76  until it abuts the annular wall  88  of the collar  62 . The ring retainer  66  may then be inserted into the inner cavity  76 . The ring retainer  66  slightly deforms until such time as the tabs  98  align with the ring slots  86 . The tabs  98  extend through the ring slots  98  and create an interference fit between the ring retainer  66  and the collar  62 . The o-ring  68  is confined by the ring retainer  66  and the annular wall  88  of the collar  62 .  
         [0036]     The clip  64  fits around the collar  62  such that the protrusions  94  align and fit within the clip grooves  82  formed on the collar  62  while the valleys  96  extend through the clip slots  84 .  
         [0037]     To sealingly lock the port connector  110  to the duct assembly  50 , the insert end  112  of the connector port  110  is inserted into the collar  62 . The outer diameter of the port connector  110  matches the inner diameter of the ring retainer  66  and the o-ring  68 . The tapered face  120  of the port connector  110  engages the valleys  96  of the clip  64 , urging the valleys  96  to move in a radial direction. The valleys  96  then snap into the annular detent  122  and secure the port connector  110  to the duct assembly  50 . The o-ring is sealed to the port connector  110  and prevents leakage through the connector  56  and port connector  110  assembly.  
         [0038]     The duct  52 , the collar  62 , and the ring retainer  66  are all constructed from a thermoplastic material, for example non-filled Nylon  6 , using a process known as suction blow molding. During the suction blow molding process, a molten thermoplastic material is sucked into a closed mold by a vacuum created by a suction fan. Once the molten thermoplastic material has reached its final position, air is blown into the mold, forcing the thermoplastic material against the sides of the mold. After cooling, the part is removed. It is to be understood, however, that the duct  52 , the collar  62 , and the ring retainer  66  may alternatively be constructed from various other materials using a variety of different processes.  
         [0039]     The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.