An upgradeable A/C maintenance system and methodology is provided including one or more modular manifolds for mounting and fluidly connecting several components. Embodiments include first and second manifolds, each for removably mounting a plurality of components, and each comprising an internal passage for fluidly connecting at least two of the plurality of components to each other, and a port for fluidly connecting the internal passage to an external surface of the first manifold. The first and second manifolds are removably attachable to each other such that their respective ports fluidly communicate with each other. The first manifold provides a first functionality for the system when the second manifold is not attached to the first manifold, and the second manifold provides a second functionality different from the first functionality when the second manifold is attached to the first manifold.

TECHNICAL FIELD

The present disclosure relates to pneumatic and hydraulic manifolds for fluidly connecting pluralities of components into circuits. The present disclosure has particular applicability to refrigerant handling systems and to systems for maintaining air conditioning (A/C) systems.

BACKGROUND ART

Conventional A/C maintenance systems, such as recharging/recycling systems for vehicle air conditioners, are either manual or automatic. One exemplary function performed by A/C maintenance systems is refrigerant charging. Such systems all include a device, such as a microprocessor, for monitoring a refrigerant charge going into the vehicle A/C system. The automatic systems shut off refrigerant flow to the vehicle automatically when the correct charge is achieved, typically by causing electric solenoid valve(s) to close. The manual systems typically display a notice on a display screen and/or a gauge indicating to the technician that the refrigerant flow valve(s) should be shut manually, usually via a handle on the front panel of the system's cabinet.

The above-described A/C maintenance systems are not upgradeable from manual to automatic. They are also not easily upgradeable to add additional functionality.

There exists a need for an apparatus and methodology for enabling A/C maintenance systems to be upgraded or customized as desired by the end user to add functions and/or to automate manual functions.

SUMMARY

An advantage of the present disclosure is an upgradeable pneumatic/hydraulic valve manifold that allows modules to be added to transform an A/C maintenance system from manual, to semiautomatic, to automatic operation.

According to the present disclosure, the foregoing and other advantages are achieved in part by a modular system comprising a first manifold for removably mounting a first plurality of components, the first manifold comprising an internal passage for fluidly connecting at least two of the first plurality of components to each other when they are mounted to the first manifold, and a port for fluidly connecting the internal passage to an external surface of the first manifold; and a second manifold for removably mounting a second plurality of components, the second manifold comprising an internal passage for fluidly connecting at least two of the second plurality of components to each other when they are mounted to the second manifold, and a port fluidly connecting the internal passage to an external surface of the second manifold. The first and second manifolds are removably attachable to each other such that their respective ports fluidly communicate with each other. The first manifold provides a first functionality for the system when the second manifold is not attached to the first manifold, and the second manifold provides a second functionality different from the first functionality when the second manifold is attached to the first manifold.

Another aspect of the disclosure is a method comprising providing a first manifold for removably mounting a first plurality of components, the first manifold comprising an internal passage for fluidly connecting at least two of the first plurality of components to each other when they are mounted to the first manifold, and a port for fluidly connecting the internal passage to an external surface of the first manifold; providing a second manifold for removably mounting a second plurality of components, the second manifold comprising an internal passage for fluidly connecting at least two of the second plurality of components to each other when they are mounted to the second manifold, and a port fluidly connecting the internal passage to an external surface of the second manifold; and attaching the first and second manifolds to each other such that their respective ports fluidly communicate with each other. The first manifold provides a first A/C maintenance functionality for the system when the second manifold is not attached to the first manifold, and the second manifold provides a second A/C maintenance functionality different from the first A/C maintenance functionality when the second manifold is attached to the first manifold.

DETAILED DESCRIPTION

Conventional A/C maintenance systems cannot be upgraded from manual operation to automatic operation, thereby reducing their flexibility and requiring the user to choose between a manual system or a more expensive automatic system at the time of purchase. The present disclosure addresses and solves this problem of conventional A/C maintenance systems.

According to the present disclosure, an upgradeable A/C maintenance system includes one or more modular manifolds for mounting and fluidly connecting several components. Each modular manifold has components for providing a different level of functionality to the system. The modular manifolds and their associated components are added, as needed, to the maintenance system by attaching them to the system's existing manifolds. Thus, by “stringing together” modular manifolds, parts can be added to easily convert the system from a less expensive unit, such as a manual unit, to a semi-automatic or automatic unit.

Conventional A/C maintenance systems typically employ a manifold, such as an aluminum block having internal passages, to mount certain components and fluidly connect them to each other to form a pneumatic circuit. A manifold of conventional design is shown inFIG. 1as reference numeral100. Mounted to manifold100via threaded fittings are electrical solenoids S1, S2, S3, and S6, a vacuum switch105, a low pressure switch110, a high pressure switch115, an oil separator120, and a pressure transducer125. Manifold100includes ports130,135, and140for attaching hoses and/or pipes, and further includes internal passages (not shown) for fluidly connecting the above-described solenoids and other components mounted on manifold100to each other and to ports130,135,140as appropriate to create the desired circuit(s) for A/C maintenance functionality.

An embodiment will now be described in detail with reference toFIGS. 2A-4A. Referring now toFIGS. 2A-2B, a first manifold200is for removably mounting a first plurality of components, including a first solenoid valve205, a temperature switch210, a high-pressure cutoff switch215, a check valve220, and manually operatable valves225, as by conventional screw mounting. First manifold200is a single piece, and has internal passages230; e.g., formed by drilling or casting. Passages230fluidly connect at least two of the first plurality of components205-225to each other when they are mounted to first manifold200.

First manifold200also has ports235,240for fluidly connecting the internal passages230to an external surface of first manifold200. Ports235,240have screw threads for facilitating connecting hoses, tubes, and components to them. Manifold200and components205-225provide at least one A/C maintenance function when certain of the ports235,240are connected to outside components of the A/C maintenance system (not shown) in a conventional manner. For example, port240is connectable to a compressor, port235adjacent check valve220is connectable to a condenser, and port235adjacent solenoid valve205is connectable to an accumulator. At least one side200aof first manifold200on which ports235are disposed is substantially flat, and has blind threaded holes245. Ports235have grooves235asurrounding them to accommodate conventional O-rings for sealing manifold200to another manifold, as will be explained hereinbelow.

Referring now toFIGS. 3A-3B, a second manifold300is for removably mounting a second plurality of components, including a second solenoid valve305, a third solenoid valve310, a low pressure switch315, and a vacuum switch320, as by conventional screw mounting. Second manifold300is a single piece, and has internal passages325; e.g., formed by drilling or casting. Passages325fluidly connect at least two of the first plurality of components305-320to each other when they are mounted to second manifold300.

Second manifold300also has ports330,335for fluidly connecting the internal passages325to an external surface of second manifold300. Ports330,335have screw threads for facilitating connecting hoses, tubes, and components to them. Second manifold300has through holes340that correspond to blind holes245in first manifold200. At least one side300aof second manifold300on which ports330are disposed is substantially flat, and ports330have grooves330asurrounding them to accommodate conventional O-rings for sealing manifold300to first manifold200, as will be explained hereinbelow.

Referring now toFIG. 4A, first manifold200and second manifold300are shown attached to each other such that their respective ports235,330fluidly communicate with each other. Note manually operatable valves225are removed from first manifold200prior to attaching first and second manifolds200,300to each other. Manually operatable valves225are effectively replaced by solenoid valves305,310of second manifold300. Second manifold300and components305-320provide at least one additional A/C maintenance function to that of first manifold200when it is connected to first manifold200, and certain of the ports335are connected to outside components of the A/C maintenance system (not shown) in a conventional manner. For example, the function of automatic operation is added via solenoid valves305,310. The components205-220mounted on first manifold200, and the components305-320mounted on second manifold300, are electrically connected via conventional wiring to a processor P, such as a conventional computer, for automatic control of at least solenoid valves205,305,310. Other conventional functions related to A/C maintenance can also be controlled by processor P.

In the embodiment shown inFIG. 4A, flat surfaces200a,300aon which ports235,330are disposed abut each other such that the ports fluidly communicate with each other. O-ring seals405fit in grooves235a,330a, between ports235,330, and fasteners410(such as conventional hex bolts) extend through holes340and screw into threaded holes245to provide a substantially leak-free seal between first and second manifolds200,300.

In the embodiment shown inFIG. 4B, flat surfaces200a,300aon which ports235,330are disposed abut each other such that the ports fluidly communicate with each other, with a gasket415between flat surfaces200a,300a. Fasteners410(such as conventional hex bolts) extend through holes340and screw into threaded holes245to provide a substantially leak-free seal between first and second manifolds200,300. If manifolds200and300are to be connected to each other using gasket415, grooves235a,330aare unnecessary. The apparatus ofFIGS. 4A and 4Bare otherwise substantially identical, although certain elements have not been duplicated inFIG. 4Bfor the sake of simplicity.

In the embodiment shown inFIG. 4C, ports235of first manifold200and ports330of second manifold300are fluidly connected in a substantially leak-free manner via conventional hoses or pipes420that screw into the threads in respective ports235,330. If manifolds200and300are to be connected via hoses or pipes420, then threaded holes245, through holes340, and grooves235a,330aare not necessary. The apparatus ofFIG. 4Cis otherwise substantially identical to that ofFIG. 4A, although certain elements have not been duplicated inFIG. 4Cfor the sake of simplicity.

Referring now toFIG. 5, a third manifold500is for removably mounting a third plurality of components, including a fourth solenoid valve510and a check valve505, as by conventional screw mounting. Third manifold500is a single piece, and has internal passages515; e.g., formed by drilling or casting. Passages515fluidly connect at least two of the third plurality of components505,510to each other when they are mounted to third manifold500.

Third manifold500also has ports520,530for fluidly connecting the internal passages515to an external surface of third manifold500. Ports520,530have screw threads for facilitating connecting hoses, tubes, and components to them. Third manifold500has through holes525that correspond to blind holes245in first manifold200. At least one side500aof third manifold500on which port520is disposed is substantially flat, and port520has a groove520asurrounding it to accommodate a conventional O-ring for sealing manifold500to first manifold200, as will be explained hereinbelow.

First manifold200and third manifold500are shown attached to each other inFIG. 5, such that their respective ports235,520fluidly communicate with each other. Third manifold500and components505,510provide at least one additional A/C maintenance function to that of first manifold200when it is connected to first manifold200, and certain of the ports530are connected to outside components of the A/C maintenance system (not shown) in a conventional manner. For example, an additional automatic function is added via solenoid valve510, which is electrically connected via conventional wiring to processor P.

Flat surfaces200b,500aon which ports235,520are disposed abut each other such that the ports fluidly communicate with each other. An O-ring seal405fits in grooves235a,520a, between ports235,520, and fasteners410(such as conventional hex bolts) extend through holes525and screw into threaded holes245to provide a substantially leak-free seal between first and third manifolds200,500. Instead of the O-ring seal arrangement shown inFIG. 5, those skilled in the art will appreciate that a gasket seal or a hose or pipe can be used to connect first and third manifolds200,500, analogous to the arrangements shown inFIGS. 4B and 4C.

The present disclosure can be practiced by employing conventional materials, methodology and equipment. Accordingly, the details of such materials, equipment and methodology are not set forth herein in detail. In the previous descriptions, numerous specific details are set forth, such as specific materials, structures, chemicals, processes, etc., in order to provide a thorough understanding of the disclosure. However, it should be recognized that the disclosure can be practiced without resorting to the details specifically set forth. In other instances, well known structures have not been described in detail, in order not to unnecessarily obscure the present disclosure.

Only exemplary embodiments of the present disclosure are shown and described herein. It is to be understood that the present disclosure is capable of use in various other combinations and environments and is capable of changes or modifications within the scope of the inventive concepts as expressed herein.