Abstract:
A quick-connect connector for connecting ends of first and second ducts, the connector including a sleeve having opposite ends to be received over the ducts, wherein the sleeve has quick-connect couplings disposed at each to engage corresponding couplings on the duct ends.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a quick-connect connector for ducts. For example, the present invention relates to a connector for connecting ducts such as blow moulded or injection moulded ducts for use in automobile air intake systems. 
       BACKGROUND OF THE INVENTION 
       [0002]    Duct systems are commonly assembled on assembly lines, making it desirable for connectors to provide positive engagement quickly and easily. Hose clamps have been previously proposed though can be difficult and time consuming to install and their use requires a rigid duct end for clamping to and a smooth surface for sealing. Ducts are commonly blow moulded and due to the relatively soft material used can require a rigid ring to be located in the end of the duct to support the clamping force. Such ducts may also require internal machining to provide a surface suitable to match the rigid ring. 
         [0003]    Previously proposed quick-fit duct connectors can be expensive to manufacture and may not consistently provide positive engagement with ducts, in particular blow moulded ducts which can be dimensionally unstable. Some previously proposed duct connectors also require a permanent connection to be formed with a duct before they can assembled into a duct system, the permanent connection being complicated and requiring the use of special tooling. 
         [0004]    What is needed is a duct connector which addresses the above difficulties. 
       SUMMARY OF THE INVENTION 
       [0005]    According to the present invention, there is provided a quick-connect connector for connecting ends of first and second ducts, the connector including a sleeve having opposite ends to be received over the ducts, wherein the sleeve has quick-connect couplings disposed at each to engage corresponding couplings on the duct ends. 
         [0006]    At least one of the quick-connect couplings can have a resilient clip configured to engage corresponding lugs on the first duct end. Both of the quick-connect couplings can have resilient clips configured to engage corresponding lugs on the duct ends. 
         [0007]    A second quick-connect coupling can form part of a twist-lock bayonet coupling. The second quick-connect coupling can form a socket part of the twist-lock bayonet coupling. 
         [0008]    The at least one resilient clip can have a plurality of engaging portions configured to engage the lugs. 
         [0009]    The sleeve can be configured to maintain alignment of the engaging portions as the connector is being received over an end of the duct and configured to allow at least one of the engaging portions to be further advanced along the sleeve after the connector has been received to engage a respective corresponding lug which have been axially offset along the duct. 
         [0010]    The connector can be configured so that retraction of the connector causes any of the engaging portions which have not engaged corresponding lugs when the connector has been received to become engaged with those lugs. 
         [0011]    The engaging portions can be axially aligned around the connector as it is received by the duct. The at least one resilient clip can be generally semi-circular and have two lateral duct engaging portions, each being disposed near an end of the clip. The clip can further include a central duct engaging portion disposed between the lateral duct engaging portions. 
         [0012]    The lateral engaging members can be biased radially inward and configured so as to be disengaged from their corresponding lugs when the central engaging portion is disengaged from its corresponding lug. 
         [0013]    The at least one resilient clip can extend around an external surface of the connector. 
         [0014]    The duct connector can further include a seal disposed within the tubular body to engage an outer surface of each duct end to fluidly seal the connection. 
         [0015]    The seal can have a pair of lips in the form of inwardly turned flanges, each lip configured to engage an end of the duct so that pressure of a fluid flowing in the duct urges the lip against the duct. The seal can have a pair of inwardly projecting ribs adjacent each end of the connector. 
         [0016]    The connector can, adjacent the bayonet coupling, further include a resilient locking tab configured to engage a corresponding lug configured to engage a corresponding lug on the second duct when locked to prevent rotation of the connector relative to the second duct. 
         [0017]    The bayonet coupling can include three slots, one of which is offset around the circumference of the connector so that the connector can only be connected to the first duct in a single orientation. 
         [0018]    According to the present invention, there is also provided a duct system, including a connector of the above described type and first and second ducts fixed thereto. 
         [0019]    Lugs can be formed on the first duct to engage the first quick-connect coupling, the lugs being in the form of ramps extending radially outward, at least one of which is axially offset along the duct. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    The invention will be further described by way of example only with reference to the accompanying drawings, in which: 
           [0021]      FIG. 1  is a perspective view of a duct connector of one embodiment of the invention, the duct connector connecting two ducts; and 
           [0022]      FIG. 2  is a partial sectioned view of the assembly of  FIG. 1 ; 
           [0023]      FIG. 3  is a plan view of a body of the connector; 
           [0024]      FIG. 4  is a sectioned view of the connector; 
           [0025]      FIG. 5  is perspective view of the assembly of  FIG. 1  in a partially disassembled condition of use; 
           [0026]      FIG. 6  is perspective view of the assembly of  FIG. 1  in another partially disassembled condition of use; 
           [0027]      FIG. 7  is a perspective end view of one of the ducts of the assembly of  FIG. 1 ; 
           [0028]      FIG. 8  is an end view of the duct of  FIG. 7 ; 
           [0029]      FIG. 9  is a perspective end view of another duct of the assembly of  FIG. 1 ; 
           [0030]      FIG. 10  is a plan view of the duct of  FIG. 9 ; 
           [0031]      FIG. 11  is an end view of the duct of  FIG. 9 ; 
           [0032]      FIG. 12  is a cutaway view of a seal for use with the connector; and 
           [0033]      FIG. 13  is a perspective view of the duct connector connecting two ducts, the duct connector having a differently configured seal. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]      FIG. 1  illustrates a duct connector  10  connecting first and second ducts  12  and  14  respectively. The connector  10  includes a body  16  and a resilient clip  18  which extends around an end of the connector  10 . The ducts shown are formed from a suitable process, such as blow moulded from a plastic parison or injection moulding, and are configured for use in an air intake system of an automobile. 
         [0035]    Referring to  FIG. 2 , a partial sectioned view of the connection can be seen. The connector  10  is received over ends of the first and second ducts  12 ,  14  and provides snap-fitting engagement with the duct ends. In the example shown, the connector  10  is fixed to first duct  12 . Resilient clip  18  extends around the body  16  of the connector  10  and is configured to engage lugs  50  formed on the second duct  14  to releasably fix the connector thereto. Connector  10  includes an annular seal  20  to fluidly seal the connection between the ducts  12 ,  14 . 
         [0036]      FIG. 3  illustrates the body  16  of the connector  10 . The clip  18  (not shown) is received in grooves  24   a  and  24   b  and slot  22 . The shape of slot  22  allows the clip to be maintained in axial alignment as the connector  10  is being received by the duct though allows a part of the clip which is received in the slot  22  to be advanced along the connector once received. 
         [0037]    As can be seen in  FIG. 4 , the clip  18  is generally semi-circular in shape, though it may be shaped alternatively, and has a central section  26  disposed between lateral sections  28   a ,  28   b.  An engaging member  30  is disposed within each of the central ( 30   c ) and lateral sections ( 30   a,    30   b ) for engaging corresponding lugs on the second duct  14 . Although not depicted, in some embodiments the clip  18  may only include two lateral engaging members  30   a,    30   b  without a central engaging member  30   c.  The clip  18  is configured so that the engaging members  30   a,    30   b  in the lateral sections  28   a,    28   b  are biased radially inwards 
         [0038]    The clip  18  is also configured so that the engaging members in the lateral sections  28   a,    28   b  are disengaged from their corresponding lugs on the second duct  14  when the central engaging member  30   e  is disengaged. When the central engaging member  30   c  is moved radially outwards to a disengaged position, sloping portions  32   a,    32   b  of clip  18  contact body  16  and are urged radially outwards away from their corresponding lugs, thereby moving them also to a disengaged position so that the connector  10  cannot be fixed to the second duct  14  unless the central engaging member  30   c  has engaged its corresponding lug  50 . 
         [0039]    The central engaging member is shown in a central position of the clip  18 , though it will be appreciated that it may be offset to either side of the centre of the clip  18 . 
         [0040]      FIGS. 5 and 6  illustrate the connector  10  in partially assembled conditions of use. In  FIG. 5  it can be seen that the connector  10  is not locked to the first duct  12 . In  FIG. 6 , it can be seen that the central engaging member  30   c  of the clip  18  is in a disengaged position so that the connector  10  is not fixed to the second duct  14 . 
         [0041]      FIGS. 7 and 8  illustrate an end of first duct  12 . The end of first duct  12  is formed with pins  34  disposed around its circumference. Pins  34  are configured to align with corresponding L-shaped slots  36  formed in the connector  10  to form a bayonet socket to allow the connector  10  to be easily fixed to the duct  12  and twist-locked. In the example shown, the pins are not evenly disposed around the duct  12 . This creates a single orientation in which the connector  10  can be received by the duct  12  to prevent incorrect installation. In this regard, one of the pins and its corresponding slot has been rotated around the body  16  of the connector by five degrees. 
         [0042]    Use of a bayonet socket allows the connector  10  to be positively connected to a duct as part of a sub-assembly process before the duct is fitted to a vehicle. This avoids costly joining operations, such as mechanical joining operations, welding, clamping or bonding, and does not require any special tooling, though provides a positive connection to allow the assembled duct and connector to be quickly and easily fitted to a vehicle on an assembly line. 
         [0043]    Connection of the duct  12  and connector  10  is effected by axially introducing the connector over an end of the duct until the pins  34  can move no further in the slots  36 . The connector  10  is then rotated so that the pins  34  move further along the slots  36 . The duct  12  also includes a lug  38  which is configured to engage with a corresponding resilient tab  40  ( FIGS. 5 and 6 ) to lock the duct  12  and the connector  10  together. The lug  38  and tab  40  are configured to be brought into engagement during rotation of the connector  10  and duct  12 . Tab  40  can be lifted to disengage the lug  38  to release engagement. 
         [0044]    The connector  10  is inserted over an end of the first duct  12  and rotated to lock the duct and the connector together prior to the first duct being fitted to the vehicle. The connected duct  12  and connector  10  are then fitted to the vehicle, and the second duct  14  may then be received by the connector  10  to complete the installation. 
         [0045]      FIGS. 9 ,  10  and  11  illustrate an end of the second duct  14 . The second duct  14  includes three lugs  50   a,    50   b,    50   c  disposed around an outer surface for engagement with engaging members  30   a,    30   b,    30   c.  The lugs  50   a,    50   b,    50   c  are formed by forming a continuous groove around the end of duct  14  in a region of increasing diameter. 
         [0046]    During connection of the connector  10  to the second duct  14 , the engaging members are forced radially outwards as they travel over ramps  52   a,    52   b,    52   c  formed on respective lugs  50   a,    50   b,    50   c.  As the engaging members pass over the ramps, the resilient nature of clip  18  urges them radially inwards to engage the lug and lock the connector  10  to the duct  14 . A locating lug  54  may be provided to guide placement of the duct  14  to ensure correct orientation of the duct  14 . 
         [0047]    With reference to  FIGS. 7 to 11 , it can be seen that the features used for engagement between the ducts  12 ,  14  and the connector  10  have been formed in the external surface of the ducts  12 ,  14 , thus avoiding costly post-moulding internal machining operations to provide suitable surfaces for engagement and sealing. 
         [0048]    With reference to  FIG. 10 , it can be seen that lug  50   c,  which corresponds to the central engaging member  30   c,  is axially offset from lugs  50   a  and  50   b.  This delays engagement of the central engaging member  30   c  with corresponding lug  50   c  until the lateral engaging members  30   a,    30   b  have passed over their respective lugs and are in a longitudinal position to engage their respective lugs once the central engaging member  30   c  is engaged with lug  50   c.    
         [0049]    As described above, once the central engaging member  30   c  has moved radially inward and engaged its corresponding lug  50   c,  the lateral engaging members  30   a,    30   b  are moved from a position where they interfere with the body  16  of the connector, and move radially inward under the resilient action of the clip  18 , thus only allowing the lateral engaging members  30   a,    30   b  to drop into position when they have passed over lugs  50   a,    50   b,  thereby ensuring engagement of each engaging portion with each lug during connection. 
         [0050]    In one example, the lugs are offset a predetermined distance so that once the central engaging member  30   c  is in a position for engagement, the lateral engaging members  30   a ,  30   b  have passed well over their respective lugs and can no longer engage a groove  67  formed behind the lugs. In this example, the connector  10  may be configured so as to be advanced along duct  14  until the central engaging member  30   c  has engaged lug  50   c  and then retracted slightly so that the lateral engaging members  30   a,    30   b  can engage their respective lugs  50   a,    50   b.  Alternatively, the connector can be configured so that once it has been received by the duct  14  and the lateral engaging members  30   a,    30   b  have passed over their respective lugs, the central engaging member  30   c  can be further longitudinally advanced along the connector  10  by pushing it toward the duct  14  so that it engages its corresponding lug  50   c,  thus allowing the lateral engaging members  30   a,    30   b  to drop into position and engage their corresponding lugs. 
         [0051]    The shape of slot  22 , as seen in  FIG. 3 , allows axial movement between the engaging members to occur to accommodate the axially offset lugs on the duct. The delayed engagement of the central engaging member prevents engagement of only one or two lugs by the clip, thereby providing a positive locking action between the duct  14  and the connector  10 . 
         [0052]      FIG. 12  further illustrates the configuration of seal  20 . Seal  20  has a pair of lips  60   a,    60   b  in the form of inwardly turned flanges. As can be seen in  FIG. 2 , the lips  60   a,    60   b  engage an outer surface of the ducts  12 ,  14  so that the seal  20  acts upon the ducts to be joined and does not need to form a seal with the connector. Advantageously, a single seal can be used to seal both ducts without interaction with the connector. The configuration of the lips  60   a,    60   b  provides that pressure from a fluid, such as air, flowing through the duct causes the lips  60   a,    60   b  to be brought into tighter engagement with each of the ducts  12 ,  14  to increase the effectiveness of the seal as the fluid pressure increases. The configuration of the seal also provides that a single seal can seal both ducts  12 ,  14  and also provides that the seal does not need to support clamping loads and can thus be optimised for sealing. The seal  20  can be made from Nitrile for low temperature applications and Viton or SI (Q) for high temperature applications. 
         [0053]    During assembly of the connector, the seal  20  is inserted into the connector  10  prior to connection of the connector  10  with either duct  12 ,  14 . Insertion of the seal  20  involves pushing the seal  20  into the connector  10  until a first side of the seal  20  abuts shoulder  62  formed on an internal surface of the connector  10 . Due to the improved sealing characteristics of the double lip arrangement of the seal  20 , it can be made of a softer material, thereby making insertion of the seal  20  into the connector  10  easier than it may otherwise be if the seal  20  were made of a harder material. Connection of the connector  10  and the first duct  12  brings shoulder  64  into contact with a second side of the seal  20  to retain the seal  20  in position. 
         [0054]    Second duct  14  may have an annular ramp  66  extending around its circumference so that the seal  20  moves up the ramp as the second duct  14  is introduced into the connector to increase the contact between the seal  20  and the duct  14 . 
         [0055]    The seal  20  shown in  FIG. 12  has been arranged for high pressure applications and would not be suitable in its present form for applications where a fluid is passing through the ducts under vacuum conditions. It is envisaged that the connector could be reconfigured so that the lips  60   a,    60   b  are alternatively configured to provide a similar sealing action for vacuum applications. 
         [0056]      FIG. 13  illustrates an example of a seal  120  suitable for vacuum applications. The seal  120  has a first rib  160  and a second rib  161  extending radially inwardly from each end of the seal  120  to engage an outer surface of ducts  12 ,  14 . In the example shown, ribs  160 ,  161  extend through a surface of ducts  12 ,  14  to indicate an interference fit between the parts. In practice, each rib deforms slightly during assembly so that they are biased against the ducts to provide a positive seal. 
         [0057]    In the example shown, the fluid flowing through ducts  12 ,  14  under vacuum conditions acts to draw air from around the connector and deform the ribs  160 ,  161 . Providing first and second ribs reduces this action so that a positive seal can be provided between the first and second ducts  12 ,  14  within the connector  10 . 
         [0058]    The embodiments have been described by way of example only and modifications are possible within the scope of the invention disclosed. For example the connector  10  may be provided with a resilient clip on opposing ends of the connector. The connector  10  may also connect to a spigot formed on an intermediate mating part and not directly to either duct. The connector may be also configured for use with ducts through which either a fluid or a gas is flowing.