Hydraulic port fittings

Abstract: The present invention relates to an improved hydraulic coupling which forms contact seals to fluidly connect a tapered port (201) with a tube (203) having a threaded connecting portion (202). The contact seals may be metal-to-metal seals, or alternatively may include a resin polymer element. For connecting a tube (203) directly in the port (201), one embodiment of the invention includes an outwardly extending lip (206) on an expanded portion of the tube (203) and a tube nut rim (211) wherein the tube nut engages the expanded portion and by tightening the tube nut (204), the tube lip (206) deforms on the tapered port (215) and the tube nut rim (211) deforms on both the tapered port (215) and the tube (203). Another embodiment of the invention provides a fluid coupling for a tube (338) which is transverse to the port, allowing for flow redirection in the coupling similar to the flow redirection in prior art "banjo" couplings. The body of the transverse coupling includes a lip (353) which deforms on the tapered surface of the port (303), and the body also includes a tapered surface (360) on which a rim (359) of the bolt (350) contacts, thereby providing a contact seal at both potential leak points. Optionally, o-rings (323, 322) may be added to provide additional seals. Both embodiments may be designed not to seal without the application of tool generated torques.

Description: The present invention relates to hydraulic couplings. More specifically, the field of the invention is that of hydraulic port fittings such as used in automobiles, aircraft, and the like. There are many port fittings on the marketplace currently which are designed to connect tubing or hydraulic hose to power equipment such as brake calipers etc. The most frequently used methods of attachment are the tube-to-port and the 'banjo' type fittings. The former is used in brake and air conditioning systems, and the latter predominantly in brake systems. The problem with both technologies is that they are prone to leaks which are both expensive and dangerous. Warranty and in-house costs of fixing such leaks may become quite large, and the environmental consideration of the effects of such loss of contaminating fluids cannot be ignored. Traditionally, the hydraulics supply industry has recommended better surface finishes and tighter tolerances in manufacture in order to minimise the potential for leaks. This has, however, failed adequately to answer the problem. To adequately address this problem, the causes of the leaks in two prior art port fittings must be examined. Descriptions of tube-to-port and "banjo" port fittings are presented below which include an examination of their inherent inadequacies. "Banjo" fittings are so termed because of their shape, which usually comprises of a tube brazed onto a round component, giving rise to a substantially banjo shaped assembly. Referring to Figures 1 and 2, which show a prior art " banjo" fitting, a typical banjo fitting is comprised of body 102 through which bolt 103 is assembled. The combination of body 102 and bolt 103 is then assembled to port 101. Sealing of the body/bolt assembly is accomplished with washers 104 and 105 (typically copper) which are placed either side of body 102. Large torques, applied in the direction of the arrow T in Figure 1 are required to attain a seal, which in turn, requires a high tensile strength bolt, and an internally recessed body. These are expensive requirements for the manufacture of the " banjo" fitting. An additional problem involves the lack of any secondary seal in the port interface. Should one of the four metal to metal interfaces develop a leak, the only way of overcoming it is to impart greater torque to the assembly. This regularly leads to tensile failures of bolts or stripped threads on bolts or in ports. Specifications USA 3 219 366 and GB 2 172 357 also disclose banjo-type hydraulic connectors which use metal-to-metal seals for the components thereof, but in each case the seals incorporate a taper on one component and a rounded surface on another, so that the seals are formed by line contact only. Such seals are notoriously difficult to make and maintain because of their susceptability to minor imperfections and creep off the metal of the mating surfaces under the high surface loadings necessary to obtain effective seals initially. Further problems involve shape, size and alignment of the prior art " banjo" fittings. Flow characteristics within the fitting are primarily derived from consideration of tensile strengths rather than from system demand. This often leads to flow restrictions which are not desirable. Also, the face-to-face association of components requires close control in order to form an adequate seal. Concentricity and squareness of through bores on bodies must be carefully maintained in production, and aligned accurately during assembly, if a seal is to be obtained. Specification US 2 400 658 discloses a specialised form of banjo-type hydraulic coupling which is required to be free to rotate after assembly. The hydraulic seal is made solely by o-rings. What is needed is an improved hydraulic coupling which utilises the elastic properties of the materials. Also needed is an improved hydraulic coupling which does not excessively deform o-rings in the coupling. A further need is for an improved hydraulic coupling which includes secondary seals. An additional need exists for an improved hydraulic coupling for refrigerant systems which includes metal-to-metal seals. A still further need exists for an improved hydraulic coupling which minimises the number of potential leak paths. Yet another need exists for an improved hydraulic coupling which requires less torque for assembly. The problems highlighted above, though seeming very different, are in many ways linked. Primarily both systems have single sealing methods, one being elastomeric only, and the other being only the metal-to-metal plastic deformation. Another common feature is that there is little invocation of elastic memory in either design, as plastic deformation of components occurs in both designs as a result of their face-to-face associations. The elastic deformation of mating components is preferred because the elastic memory of the material (either metal or rubber and the like) imparts a continuous sealing force. In comparison, plastic deformation of the material, which permanently deforms the fitting components, imparts no additional sealing force. Both metals and rubber type materials are subject to both forms of deformation, as metal material may be plastically deformed by high torque when assembled while elastic materials may be plastically deformed by setting over time. Embodiments of the present invention impart multiple seals to the port interface, and use elastic memory of metallic components in the interface where possible. This is attained by the use of elastic components in those instances where such is possible or desirable in conjunction with abutting tapered metallic surfaces which allow for the generation of an interface the integrity of which is enhanced by elastic memory. With ports made of softer materials, a metallic component having a complementary taper or a resin polymer component may be used to create a contact seal of similar integrity. The acute tapered metallic surfaces provides a high unit loading which ameliorates the need for the expensive materials needed for receiving the high torques required with prior art fitting components. According to the present invention there is provided a hydraulic coupling comprising a port having a fluid passage terminating in an internally threaded portion and an outwardly tapering seating surface, a conduit means having a first axial fluid passage and a second fluid passage positioned tranversely of the first fluid passage and communicating therewith, a connector means for securing the conduit means to the port, the connector means having an externally threaded portion adapted to engage the threaded portion of the port, an axial bore and a radial hole communicating with the axial bore, a first seal constituted by a lip on the conduit means adapted to engage the seating surface of the port and a second seal constituted by an outwardly tapering portion of the fluid passage in the conduit means and a rim forming part of the distal end of the connector means in which the lip on the conduit means and the rim forming part of the distal end of the connector means are complementary in form to the respective seating surfaces and of the port and the connector means and are adapted to deform elastically on the tightening of the connector means to provide areas of sealing contact beneath tapered seating surfaces of the port and the conduit means respectively, the first fluid passage in the conduit means is constituted by a bore of substantially constant diameter with no recesses therein and at least a major portion of the connecting means having a diameter smaller than that of the bore in the conduit means so as to define an internal cavity within the conduit means which is in fluid communication with the fluid passage and the port regardless of the angular position of the connector means. The present invention lowers the number of leak paths associated with "banjo" fittings from four to two, and, with the tapered surface of the port and forces the rim into sealing contact with both the taper of the port and the conduit. One object of the present invention is to provide an improved hydraulic coupling which utilises the elastic properties of the materials. Also an object is to provide an improved hydraulic coupling which does not excessively deform o-rings in the coupling. A further object is to provide an improved hydraulic coupling which includes secondary seals. An additional object is to provide an improved hydraulic coupling for refrigerant systems which includes metal-to-metal seals. A still further object is to provide an improved hydraulic coupling which minimises the number of potential leak paths. Yet another object is to provide an improved hydraulic coupling which requires less torque for assembly. The above mentioned and other features and objects of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein: Figure 1 is a side view, in partial cross-section, of a prior art "banjo" coupling prior to assembly; Figure 2 is a side view, in partial cross-section,of the coupling of Figure 1 when assembled; Figure 3 is a side view, in partial cross-section, of a transverse hydraulic coupling embodying the invention, prior to assembly; Figure 4 is a side view, in partial cross-section, of the coupling of Figure 3 assembled, but without o-rings; Figure 5 is a side view, in partial cross-section, of the coupling of Figure 3 assembled with o-rings; of a transverse hydraulic coupling embodying the invention, prior to assembly; Figure 4 is a side view, in partial cross-section, of the coupling of Figure 3 assembled, but without o-rings; Figure 5 is a side view, in partial cross-section, of the coupling of Figure 3 assembled with o-rings; Figure 6 is a side view, in partial cross-section, of the coupling of Figure 3 showing a transverse passageway; Figure 7 is a side view, in partial cross-section, of a second transverse hydraulic coupling embodying the invention; Figure 8 is a side view, in partial cross-section, of the coupling of Figure 7 after initial assembly; Figure 9 is a side view, in partial cross-section, of the coupling of Figure 8 after final assembly; Figure 10 is a side view, in partial cross-section, of a hydraulic coupling embodying the invention and including a socket head; Figure 11 is an end view of the socket head of the embodiment of Figure 10; Figure 12 is a side view, in partial cross-section, of a fourth embodiment of the invention. Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate a preferred embodiment of the invention, in one form thereof, and such exemplifications are not to be construed as limiting the scope of the invention in any manner. A transverse hydraulic embodying the invention is shown in Figures 3 to 6. The transverse coupling comprises port 301, body 304 and bolt 309. Port 301 has internal threads 302 and a tapered surface 303 into which fits external taper 305 of body 304. Body 304 defines axial passageway 306 which is in fluid communication with port 301, and includes annular surface 308 facing port 301. At the distal end of body 304 is an internal taper 307 which mates with external taper 319 on the bolt 309. Bolt 309 has surfaces 311 and 317 which may support optional o-rings 322 and 323 in pockets 327 and 328, respectively. Pocket 327 is defined between surface 311, tapered surface 303, and annular surfaces 312 and 308 of bolt 309 and body 304, respectively. Pocket 328 is defined between extension 316, surface 317, annular surface 318, and tapered surface 307. During assembly, if o-rings are desired then o-ring 323 is first placed on surface 317. Bolt 309 is then assembled into body 304 and o-ring 322 is placed on surface 311. In the situation where o-rings 322 and 323 are used, which will be in the majority of cases, the fitting formed by bolt 309 and body 304 is held together by o-ring 323, which is an advantage during final attachment to port 301. Once bolt 309 is assembled through body 304, the bolt/body combination is then assembled to port 301 by engagement of threads 310 of bolt 309 with threads 302 of port 301. As torque is applied to hex head 320 of bolt 309, the mating tapers of bolt-to-body and of body-to-port create very high unit loading and invoke elastic memory between mating parts. The net result of the mating tapers is a coupling which seals at relatively low torques and, due to the elasticity in the interface, remains sealed over considerable time. Referring to Figure 9, seals are formed at locations 324 and 325 which provide such an elastic interface. When o-rings 322 and 323 are used (see Figure 5), the reliability of the system is enhanced considerably. The internal fluid conduit provided by body 304 is defined by internal cylindrical wall 306 and bolt 309. Specifically, the conduit includes chamber 326, aperture 315, and bore 321. Chamber 326 is defined by wall 306 and outer surface 314 of bolt 309, and also may be further defined by extensions 313 and 316 of bolt 309. Bore 321 is in fluid communication with chamber 326 by virtue of aperture 315 which is located on outer surface 314. Referring to Figure 11, another passageway 332, which is transverse to bore 321, is defined by arm 331 of body 304. Passageway 332 is in fluid communication with chamber 326 to thereby provide a fluid conduit for flow from a tube, or other device which may be attached to arm 331, to port 301. An alternative embodiment of the transverse coupling is shown in Figures 7-9. This embodiment is similar to the embodiment of Figures 3-6 except for bolt 309' which has a different structure and arrangement between outer surface 314 and annular surface 318 which allows for easily detecting a coupling that is only manually tightened. Extension 316' of bolt 309' has an outer diameter which is greater than the diameter of internal cylindrical wall 306 so that when bolt 309' is manually tightened to port 301, extension 316' contacts tapered surface 307 and creates gap 333 which prevents o-ring 323 from forming a seal with tapered surface 307 (see Figure 8). Thus, when bolt 309' is hand tightened to port 301, a leak will be apparent when pressurised fluid is directed through the coupling. Upon subsequent tightening of bolt 309' with a tool bolt 309'' is sealingly connected to port 301. The tool tightening of bolt 309'' forces extension 316'' (see Figure 9) into internal surface 306 and deform extension 316' into sealing contact 330 with wall 306. Raised portion 329 prevents o-ring 323 from being trapped by deformed extension 316'', with raised portion 329 separating o-ring seating surface 317' from extension 316". Also, o-ring 323 is placed into sealing contact with tapered surface 307. These two seals are in addition to seal 325 formed between external taper 319 and tapered surface 307. Thus, tightening of bolt 309' by a tool creates deformed bolt 309" having three seals with body 304. Figures 10 and 11 show a third embodiment of the transverse coupling including bolt 309''' having socket head 334. Generally circular socket head 334 includes flat face 335 and hexagonal recess 336 for receiving an allen wrench. With prior art hydraulic couplings, a great amount of torque is applied to the bolt in order to achieve proper sealing. If a socket head would be provided on a prior art design, then the internal sides of the socket would be stripped by the application of the required high tightening torque. Therefore, prior art couplings are constrained to using an exterior hex head design in order to receive the tightening torque. However, with the coupling of the present invention, lower tightening torques are required and socket head 334 may replace hex head 320 on the bolt and provide a more streamlined joinder with body 304 which also may be an easier method of tightening the bolt, ie, with an allen wrench. In the preferred embodiment of the present invention, the connector portion of the hydraulic coupling ie, the bolt 309 of the transverse coupling is made of a material such as mild steel, stainless steel, monel, titanium, aluminium, brass, and various machinable alloys as well as certain plastics. The conduit portions of the hydraulic coupling are made of a material such as copper, brass, mild steel, stainless steel, titanium, aluminium, and various malleable/machinable alloys as well as certain plastics. The angle of the tapered surfaces of the coupling interfaces is in the range of 5° to 45°, more particularly in the range of 10° to 30°, and preferably about 15°. Figure 12 shows a fourth embodiment of the transverse coupling of the present invention. In this embodiment, both the connector and the conduit elements are formed from two elements. The conduit element includes body 337' and tube 338, which is preferably connected to body 337' by brazing or the like. The connector element includes top engaging portion 350 and body engaging portion 351. Body 337' includes through chamber 352 which is in fluid communication with tube 338. Lip portion 353 is located at the bottom end of body 337' and defines an opening facing port 301. Lip portion 353 may have an external tapered surface which is complementary to tapered surface 303 of port 301. Engaging portion 351 has an internal bore in communication with a passageway of port 301, and aperture 354 provides fluid communication between the bore of engaging portion 351 and chamber 352. Engaging portion 351 also has threaded portion 355 which engages threads 302 of body 301, and top portion 356 with hex socket 357 and annular groove 358. Top engaging portion 350 comprises a collar which is located in a relatively fixed position relative to port engaging portion 351 between annular groove 358 of top portion 356 and body 337'; and collar 350 may be formed by locating a suitable ring of metal around port engaging portion 351 and striking the ring with a tapered die or the like to deform the material into collar 350 that fits between top portions 356 and body 337' and provides rim portion 359 with an external tapered surface matingly engaging tapered surface 360. The fourth embodiment attaches to port 301 by first threadedly engaging threads 355 of port engaging portion 351 with internal threads 302 of port 301. Port engaging portion 351 may then be tightened to create an interference fit with collar 350, with external tapered surface 359 sealingly engaging tapered surface 360 of body 337'. O-ring 323 may optionally be disposed around port engaging portion 351 between aperture 354 and collar 350 to enhance the reliability of the seal. Port engaging portion 351 includes hex socket 357 which allows for an allen wrench of the like to be used to turn and tighten the engagement threads 355 with threads 302. Tightening port engaging portion 351 also causes lip portion 353 to be forced into sealing contact with tapered surface 303 of port 301. O-ring 322 may optionally be disposed around port engaging portion 351 between tapered portion 353 and threads 355 to enhance the reliability of the seal. Further, a passageway is created through the bore of port engaging portion 351 and aperture 354 providing for fluid communication between port 301 and tube 338. In the embodiment of Figure 12, the connection of port engaging portion 351 to port 301 may alternatively be accomplished previous to securing body 337' to top portion 356. In this alternative method, body 337' is placed over the previously connected port engaging portion 351 and a ring for forming collar 350 is positioned on body 337'. The ring may then be struck with a die or the like to form collar 350 having external tapered 359. Port engaging portion 351 may be further tightened to enhance the interference fit of collar 350. This allows the preassembly of port engaging portion 351 to port 301, which may be advantageous in some manufacturing processes. While this invention has been described as having a preferred design, the present invention can be further modified within the scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims.

Claims: A hydraulic coupling comprising a port (301) having a fluid passage terminating in an internally threaded portion (302) and an outwardly tapering seating surface (303), a conduit means (304) having a first axial fluid passage (306) and a second fluid passage (332) positioned tranversely of the first fluid passage (306) and communicating therewith, a connector means (309) for securing the conduit means (304) to the port (301), the connector means (309) having an externally threaded portion (310) adapted to engage the threaded portion (302) of the port (301), an axial bore (321) and a radial hole (315) communicating with the axial bore (321), a first seal constituted by a lip (305) on the conduit means (304) adapted to engage the seating surface (303) of the port (301) and a second seal constituted by an outwardly tapering portion (307) of the fluid passage (306) in the conduit means (304) and a rim (319) forming part of the distal end of the connector means (309) in which the lip (305) on the conduit means (304) and the rim (319) forming part of the distal end of the connector means (309) are complementary in form to the respective seating surfaces (303) and (307) of the port (301) and the connector means (309) and are adapted to deform elastically on the tightening of the connector means (309) to provide areas of sealing contact beneath tapered seating surfaces (303, 307) of the port (301) and the conduit means (304) respectively, the first fluid passage (306) in the conduit means (304) is constituted by a bore of substantially constant diameter with no recesses therein and at least a major portion of the connecting means (309) having a diameter smaller than that of the bore (306) in the conduit means (304) so as to define an internal cavity (326) within the conduit means (304) which is in fluid communication with the fluid passage (306) and the port (301) regardless of the angular position of the connector means (309). An hydraulic coupling according to Claim 1, characterised in that the first seal is constituted by the conjunction of the seating surface (303) of the port (301), tapered lip (305) projecting from the surface of the conduit means (304) adjacent to the port (301) and adapted to conform to the tapered seating surface (303) of the port (301) and an O-ring seal (322) positioned in the space between the end of the lip (305) on the conduit means (304) and the tapered surface (303) of the port (301), the lip (305) of the conduit means (304) being adapted to deform elastically on tightening of the connector means (302, 309, 310) to establish a contact seal in addition to the seal provided by the O-ring (322). An hydraulic coupling according to Claim 2, characterised in that the connector means (309, 310) passes axially through the conduit means (304) and there is provided a second combined taper contact and o-ring seal (307, 317, 319, 323) at the junction between the distal end of the connector means (309, 310) and the conduit means (304). An hydraulic coupling according to Claim 2 or Claim 3, characterised in that the connector means (309) includes two annular projections (313, 316), the internal surface of the bore (306) in the conduit means (304) and the space between the radial projections (313, 316) constituting the internal cavity (326) whereby a fluid flow path is provided from the second fluid passage (338) in the conduit means (304) to the internal cavity (326) and thence through the hole (315) and the bore (321) in the connector means (309, 310) to the passageway of the port (301). An hydraulic coupling according to Claim 4, characterised in that when the coupling is assembled a first edge (312) of one of the radial projections (313) is approximately aligned with the edge (308) of the lip (305) on the conduit means (304) and there is provided an O-ring seat adjacent the edge (312) of the radial projection (313) and a second O-ring seat between the other of the radial projections (316) and an annular surface (318) of a taper seat (319) formed on the distal end of the connector means (309, 310). An hydraulic coupling according to Claim 5, characterised in that the one of said radial projections (316) has an outer diameter greater than that of the chamber (326) in the conduit means (304) so that on initial tightening of the connector means (309) contact is made between the radial projection (316) and the surface of the cavity (326) of the conduit means (304) before the O-ring seal (323) contacts the surface (307) of the second taper contact seal and further tightening of the connector means (309) causes a deformation of the radial projection (316) so as to allow the O-ring seal (323) to become effective. An hydraulic coupling according to Claim 1, characterised in that the connector (350) means comprises a port engaging portion (355) having an axial bore and a transverse hole (345) which communicates with an internal cavity (352) in conduit means (337) and terminates in a tapered section and flange (356) and there is provided a tapered collar (350) which is deformed to conform both with the tapered end of the port engaging portion, (355) and a tapered seat (360) at a distal end of a bore (352) in the conduit means (337) thereby to affect a fluid-tight seal at the distal end of the port engaging portion (355) of the connector means (350). An hydraulic coupling according to any preceding claim, characterised in that the angle of taper of the tapered surface seals lies in the range of 10-30°. An hydraulic coupling according to Claim 8, characterised in that the angle of taper of the tapered surface seals is approximately 15°.

Inventors: WILLIAMSON NIGEL D, WILLIAMSON, NIGEL D.
Applicants: NWD INT INC, NWD INTERNATIONAL, INC.
Application year: 1992
Main classification: F16L19
IPC codes: F16L41, F16L19, F16L27