Abstract:
A low profile heater core connector is disclosed which facilitates installation in a plurality of positions, wherein a size, a weight, and a cost of production of the heater core connector is minimized.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates generally to a heater core connector and more particularly to a low profile heater core connector which facilitates installation in a plurality of positions. 
       BACKGROUND OF THE INVENTION 
       [0002]    Heater core connectors are typically used to connect heat exchanger tanks to other components in a vehicle. Ideally, the connectors have low profiles to comply with packaging requirements and facilitate a fluid tight seal between the heat exchanger tank and the other components. 
         [0003]    Prior art heater core connectors are typically comprised of stamped pieces that are brazed together with the heat exchanger to form a fluid-tight connection therebetween. However, the brazing employed on multiple-piece connectors often leaves the connection susceptible to leaking, and limits the available options for connection to extension tubes. Typical stamped, single-piece connectors only allow for use of circular cross-section inlet or outlet configurations, which limit the fluid circuit and the efficiency of the heat exchanger device. 
         [0004]    To overcome this problem, heater core connectors have been formed from a single piece of material that is bent to form a desired angle, wherein the brazing step is eliminated. However, typical design guides recommend that a minimum centerline bend radius of a tube section is one and one half times a diameter of the section. Such a bend radius yields connectors having lengths that are undesirable due to packaging limitations which require the connector to have smaller profiles. 
         [0005]    It would be desirable to produce a heater core connector having a low profile, wherein a size, a weight, and a cost of production thereof are minimized and wherein the heater core connector can be installed in a plurality of positions. 
       SUMMARY OF THE INVENTION 
       [0006]    Harmonious with the present invention, a heater core connector having a low profile, wherein a size, a weight, and a cost of production thereof are minimized and wherein the heater core connector can be installed in a plurality of positions, has surprisingly been discovered. 
         [0007]    In one embodiment, a heater core connector comprises: a first section having a first end and a spaced apart second end; and a second section having a first end and a spaced apart second end, wherein the first end of the second section receives the second end of the first section, and wherein the first section is selectively positionable with respect to the second section. 
         [0008]    In another embodiment, a heater core connector comprises: a first section connected to an extension tube and having a first end and a spaced apart second end; and a second section having a first end and a spaced apart second end, wherein the first end of the second section receives the second end of the first section, and wherein a longitudinal axis of the first section is selectively positionable with respect to a longitudinal axis of the second section. 
         [0009]    In another embodiment, a heater core connector comprises: a first section connected to an extension tube and having a first end and a spaced apart second end; and a second section disposed on a heat exchanger tank and having a first end and a spaced apart second end, wherein the first end of the second section receives the second end of the first section, and wherein a longitudinal axis of the first section is selectively positionable with respect to a longitudinal axis of the heat exchanger tank. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above, as well as other objects and advantages of the invention, will become readily apparent to those skilled in the art from reading the following detailed description of a preferred embodiment of the invention when considered in the light of the accompanying drawings in which: 
           [0011]      FIG. 1  is a perspective view of a heater core having an inlet heater core connector and an outlet heater core connector in accordance with an embodiment of the invention; 
           [0012]      FIG. 2  is an enlarged fragmentary perspective view of the inlet heater core connector illustrated in  FIG. 1  showing the inlet heater core in section; 
           [0013]      FIG. 3  is a perspective view of a heater core having an inlet heater core connector and an outlet heater core connector in accordance with another embodiment of the invention; and 
           [0014]      FIG. 4  is an enlarged fragmentary side elevational view of the inlet heater core connector illustrated in  FIG. 3  showing the inlet heater core in section. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0015]    The following detailed description and appended drawings describe and illustrate various exemplary embodiments of the invention. The description and drawings serve to enable one skilled in the art to make and use the invention, and are not intended to limit the scope of the invention in any manner. 
         [0016]      FIG. 1  shows a heater core  10  including a hollow inlet heater core connector  12  and a hollow outlet heater core connector  14  in accordance with an embodiment of the invention. In the embodiment shown, the heater core connectors  12 ,  14  are formed from aluminum. However, other materials can be used to form the heater core connectors  12 ,  14  as desired. The heater core  10  includes a first heat exchanger tank  16  having a longitudinal axis LT and disposed at a first end  18  thereof. In the embodiment shown, the heater core  10  is a U-flow type heater core. However, other types of heater cores can be used as desired. 
         [0017]    For exemplary purposes, only the inlet heater core connector  12  will now be described. It is understood that the outlet heater core connector  14  is substantially identical in structure to the inlet heater core connector  12 . As more clearly shown in  FIG. 2 , the inlet heater core connector  12  includes a first section  20  and a second section  21 . 
         [0018]    The first section  20  of the inlet heater core connector  12  includes a first end  22 , a spaced apart second end  24 , an intermediate portion  26 , and a longitudinal axis L 1 . The first end  22  of the first section  20  is substantially circular in cross section. A first flared portion  28  is formed on the first end  22 . The first flared portion  28  is flared substantially radially outwardly from the first end  22 . A distal end  30  of the first flared portion  28  is adapted to abut a radially outwardly extending protuberance  32  formed on a first extension tube  34 . 
         [0019]    A clamp  36  is disposed around the first flared portion  28  of the inlet heater core connector  12  and the protuberance  32  of the first extension tube  34 , such as is disclosed in commonly owned U.S. patent application Ser. No. 11/594,548, hereby incorporated herein by reference in its entirety. In the embodiment shown, the clamp  36  includes a pair of opposed, radially inwardly extending lips  38  that engage the first flared portion  28  of the inlet heater core connector  12  and the protuberance  32  of the first extension tube  34 . It is understood that clamps having other shapes and configurations can be used as desired without departing from the scope and spirit of the invention. The second end  24  of the first section  20  is substantially circular in cross section. The intermediate portion  26  of the first section  20  has an inner surface  40  having a transition in diameter  42  that is adapted to abut a distal end  43  of the first extension tube  34 . The inner surface  40  is adapted to engage an O-ring  44  that is optionally disposed in a channel  46  formed in the extension tube  34 . While a single O-ring  44  is shown in the drawings, additional O-rings (not shown) may be disposed in the channel  46  or in additional channels (not shown) as desired. The intermediate portion  26  has an outer surface  48  including a radially outwardly extending annular bend  50  formed adjacent to the second end  24 . 
         [0020]    In the embodiment illustrated, the second section  21  of the inlet heater core connector  12  is formed separately from and secured to an inlet cover portion  51  of the heat exchanger tank  16 . It is understood that the second section  21  can be formed integrally with the inlet cover portion  51  as desired without departing from the scope and spirit of the invention. 
         [0021]    The second section  21  of the inlet heater core connector  12  includes a first end  52 , a spaced apart second end  54 , an intermediate portion  56 , and a longitudinal axis L 2 . The first end  52  includes a substantially circular shaped aperture  58  formed therein adapted to receive the second end  24  of the first section  20  of the inlet heater core connector  12 . A radially inwardly extending annular lip  60  formed on the first end  52  is adapted to abut the bend  50  formed on the intermediate portion  26  of the first section  20 . The second end  54  of the second section  21  is disposed on the first end  18  of the heater core  10 . 
         [0022]    To assemble the heater core  10 , the first end  22  of the first section  20  of the inlet heater core connector  12  receives the first extension tube  34 . The distal end  43  of the first extension tube  34  abuts the transition in diameter  42  of the intermediate portion  26  of the first section  20  of the inlet heater core connector  12 . The O-ring  44  disposed between the first extension tube  34  and the inner surface  40  of the first section  20  of the inlet heater core connector  12  forms a substantially fluid tight seal therebetween. The clamp  36  is secured to the first flared portion  28  of the first section  20  of the inlet heater core connector  12  and the first extension tube  34  to militate against relative axial movement therebetween. It is understood that other means of securing the first section  20  of the inlet heater core connector  12  to the first extension tube  34  can be used as desired such as by brazing, for example. 
         [0023]    The second end  24  of the first section  20  of the inlet heater core connector  12  is disposed in the aperture  58  formed in the second section  21  of the inlet heater core connector  12 , so that the longitudinal axis L 1  of the first section  20  is disposed at an angle of approximately 135 degrees with respect to the longitudinal axis L 2  of the second section  21 . The bend  50  formed on the first section  20  of the inlet heater core connector  12  is then brazed, press fit, or otherwise connected to the lip  60  formed on the second section  21  of the inlet connector  12 . 
         [0024]    A second extension tube  64  is connected to the outlet heater core connector  14  and the outlet heater core connector  14  is connected to an outlet cover portion  66  of the heat exchanger tank  16  in substantially the same manner as described for the inlet heater core connector  12 . The heat exchanger tank  16  is then press fitted or otherwise disposed onto the heater core  10 . 
         [0025]    In use, a fluid (not shown) is caused to flow through the first extension tube  34  into the inlet heater core connector  12 . The fluid flows through the inlet heater core connector  12 , into the inlet cover portion  51  of the heat exchanger tank  16 , and into the first end  18  of the heater core  10 . The fluid then flows through tubes  67  in the heater core  10  to the second end thereof. The tubes  67  extend within the heater core  10  in a generally U-shaped pattern, and guide the fluid to the outlet cover portion  66  of the heat exchanger tank  16 . The fluid flows through the outlet cover portion  66  of the heat exchanger tank  16  and into the outlet heater core connector  14 . Thereafter, the fluid flows through the outlet heater core connector  14  and into the second extension tube  64 . 
         [0026]      FIG. 3  shows a heater core  110  including a hollow inlet heater core connector  112  and a hollow outlet heater core connector  114 . In the embodiment shown, the heater core connectors  112 ,  114  are formed from aluminum. However, other materials can be used to form the heater core connectors  112 ,  114  as desired. The heater core  110  includes a first heat exchanger tank  116  having a longitudinal axis LT 2  and disposed at a first end  118  thereof. In the embodiment shown, the heater core  110  is a U-flow type heater core. However, other types of heater cores can be used as desired. 
         [0027]    For exemplary purposes, only the inlet heater core connector  112  will now be described. It is understood that the outlet heater core connector  114  is substantially identical in structure to the inlet heater core connector  112 . As more clearly shown in  FIG. 4 , the inlet heater core connector  112  includes a first section  120  and a second section  121 . 
         [0028]    The first section  120  of the inlet heater core connector  112  includes a first end  122 , a spaced apart second end  124 , an intermediate portion  126 , and a longitudinal axis L 11 . The first end  122  of the first section  120  is substantially circular in cross section. A first flared portion  128  is formed on the first end  122 . The first flared portion  128  is flared substantially radially outwardly from the first end  122 . A distal end  130  of the first flared portion  128  is adapted to abut a radially outwardly extending protuberance  132  formed on a first extension tube  134 . A clamp  136  is disposed around the first flared portion  128  of the inlet heater core connector  112  and the protuberance  132  of the first extension tube  134 . In the embodiment shown, the clamp  136  includes a pair of opposed, radially inwardly extending lips  138  that engage the first flared portion  128  of the inlet heater core connector  112  and the protuberance  132  of the first extension tube  134 . It is understood that clamps having other shapes and configurations can be used as desired without departing from the scope and spirit of the invention. The second end  124  of the first section  120  is substantially circular in cross section. The intermediate portion  126  of the first section  120  has an inner surface  140  having a transition in diameter  142  that is adapted to abut a distal end  143  of the first extension tube  134 . The inner surface  140  is adapted to engage an O-ring  144  that is optionally disposed in a channel  146  formed in the extension tube  134 . While a single O-ring  144  is shown in the drawings, additional O-rings (not shown) may be disposed in the channel  146  or in additional channels (not shown) as desired. The intermediate portion  126  has an outer surface  148  including a radially outwardly extending annular bend  150  formed adjacent to the second end  124 . 
         [0029]    In the embodiment illustrated, the second section  121  of the inlet heater core connector  112  is formed separately from and secured to an inlet cover portion  151  of the heat exchanger tank  116 . It is understood that the second section  121  can be formed integrally with the inlet cover portion  151  as desired without departing from the scope and spirit of the invention. 
         [0030]    The second section  121  of the inlet heater core connector  112  includes a first end  152 , a spaced apart second end  154 , and an intermediate portion  156 , and a longitudinal axis L 12 . The first end  152  includes a substantially circular shaped aperture  158  formed therein adapted to receive the second end  124  of the first section  120  of the inlet heater core connector  112 . A radially inwardly extending annular lip  160  formed on the first end  152  is adapted to abut the bend  150  formed on the intermediate portion  126  of the first section  120 . The second end  154  of the second section  121  is disposed on the first end  118  of the heater core  110 . 
         [0031]    To assemble the heater core  110 , the first end  122  of the first section  120  of the inlet heater core connector  112  receives the first extension tube  134 . The distal end  143  of the first extension tube  134  abuts the transition in diameter  142  of the intermediate portion  126  of the first section  120  of the inlet heater core connector  112 . The O-ring  144  disposed between the first extension tube  134  and the inner surface  140  of the first section  120  of the inlet heater core connector  112  forms a substantially fluid tight seal therebetween. The clamp  136  is secured to the first flared portion  128  of the first section  120  of the inlet heater core connector  112  and the first extension tube  134  to militate against relative axial movement therebetween. It is understood that other means of securing the first section  120  of the inlet heater core connector  112  to the first extension tube  134  can be used as desired, such as by brazing, for example. 
         [0032]    The second end  124  of the first section  120  of the inlet heater core connector  112  is disposed in the aperture  158  formed in the second section  121  of the inlet heater core connector  112  so that the longitudinal axis L 11  of the first section  120  is disposed at an angle of approximately 225 degrees with respect to the longitudinal axis L 12  of the second section  121 . The bend  150  formed on the first section  120  of the inlet heater core connector  112  is then brazed, press fit, or otherwise connected to the lip  160  formed on the second section  121  of the inlet connector  112 . 
         [0033]    A second extension tube  164  is connected to the outlet heater core connector  114  and the outlet heater core connector  114  is connected to an outlet cover portion  166  of the heat exchanger tank  116  in substantially the same manner as described for the inlet heater core connector  112 . The heat exchanger tank  116  is then press fitted onto the heater core  110 . 
         [0034]    In use, a fluid (not shown) is caused to flow through the first extension tube  134  into the inlet heater core connector  112 . The fluid flows through the inlet heater core connector  112 , into the inlet cover portion  151  of the heat exchanger tank  116 , and into the first end  118  of the heater core  110 . The fluid then flows through tubes  167  in the heater core  110  to the second end thereof. The tubes  167  extend within the heater core  110  in a generally U-shaped pattern, and guide the fluid to the outlet cover portion  166  of the heat exchanger tank  116 . The fluid flows through the outlet section  166  of the heat exchanger tank  116  and into the outlet heater core connector  114 . Thereafter, the fluid flows through the outlet heater core connector  114  and into the second extension tube  164 . 
         [0035]    The heater core connectors  12 ,  14 ,  112 ,  114  can be arranged as shown in  FIGS. 1 and 2  or as shown in  FIGS. 3 and 4  to facilitate use in a plurality of heater core compartments (not shown), such as in a vehicle (not shown), for example. Further, a size of a package (not shown) required to house the heater core connectors  12 ,  14 ,  112 ,  114  and the costs associated with the shipment thereof are minimized. Further, since the connectors  12 ,  14 ,  112 ,  114  can be connected directly to the heat exchanger tanks  16 ,  116  the need for additional tubes or conduits disposed therebetween is eliminated. Accordingly, the cost required for producing the heater cores  10 ,  110  and the time and effort required for assembly thereof are minimized. 
         [0036]    From the foregoing description, one ordinarily skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications to the invention to adapt it to various usages and conditions.