Patent Publication Number: US-2016237963-A1

Title: Connector and manufacturing process for the same

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     The present application is a Continuation Application of International Application No. PCT/JP2015/077905, filed on Oct. 1, 2015, which is incorporated herein by reference The present invention is based on Japanese Patent Application No. 2014-204489, filed on Oct. 3, 2014, the entire contents of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a connector connecting a first pipe with a second pipe, and to a manufacturing process for the same. 
     2. Description of the Related Art 
     For example, piping to be applied to an automotive fuel supply system carries out transferring a fuel by pressurizing the fuel within the piping by a pump so as to make a set-up constant pressure therein. When an injection apparatus, such as an injector, is opened and closed in order to control a supply of the fuel, the pressure within the piping fluctuates so that the fuel pulsates. When the fuel pulsates, excess and deficiency occur in a pressure of the fuel at the injector apparatus, and accordingly such a fear might possibly arise as errors occur in an amount of the fuel to be injected by the injector apparatus with respect to the desired amount. 
     Hence, in a connector set forth in Japanese Unexamined Patent Publication (KOKAI) Gazette No. 2011-163154 (Patent Literature 1), a cylinder is disposed in a housing, and then a piston moves within the cylinder, in order to reduce pulsating motions. Incidentally, various piping constructions are set forth in Japanese Unexamined Patent Publication (KOKAI) Gazette No. 2005-163836 (Patent Literature 2), Japanese Unexamined Utility Model Publication (KOKAI) Gazette No. 2-85606 (Patent Literature 3), Japanese Unexamined Patent Publication (KOKAI) Gazette No. 2008-57388 (Patent Literature 4) and Japanese Unexamined Patent Publication (KOKAI) Gazette No. 9-257185 (Patent Literature 5), although they are not for the purpose of reducing pulsating motions. Patent Literature 2 sets forth a connector having a built-in valve. Patent Literature 3 sets forth a piping construction for air suspension, the piping construction having an orifice. Patent Literature 4 sets forth a distribution member for vaporized fuel, the distribution member having an orifice. Patent Literature 5 sets forth a tube having an orifice. 
     Since the connector set forth in Patent Literature 1 is disposed so that part of the cylinder protrudes from out of the housing, the entire connector increases in size. 
     Objects of the present invention are to provide a connector that can reduce pulsating motions without increasing in size, and to provide a manufacturing process for the same. 
     SUMMARY OF THE INVENTION 
     A quick connector directed to the present invention is a connector connecting a first pipe with a second pipe, and comprises: 
     a first-pipe insertion portion made of resin, formed as a tubular shape, and including a first opening into which the first pipe is inserted; and
 
a second-pipe installation portion made of resin, and formed as a tubular shape integrally with the first-pipe insertion portion by integral molding, the second-pipe installation portion on which the second pipe is installed on an outer peripheral side thereof from a side of a second opening thereof.
 
     The second-pipe installation portion includes: 
     a tubular section forming a second flow passage on a side of the second opening of the second-pipe installation portion; and
 
a wall section not only demarcating a first f low passage in the first-pipe insertion portion from the second flow passage in the tubular section but also formed so as to elongate in the same direction as the second flow passage does, and forming an orifice communicating the first flow passage with the second flow passage.
 
     The first pipe is inserted into the first-pipe insertion portion of the connector. The second pipe is installed on an outer peripheral side of the second-pipe installation portion of the connector. Thus, the connector connects the first pipe with the second pipe. The first-pipe insertion portion, and the second-pipe installation portion are molded integrally by resin. Consequently, the connector exhibits high strength. 
     Moreover, the connector further comprises the orifice. The orifice is formed in the wall section that makes a demarcation between the first-pipe insertion portion and the tubular section of the second-pipe installation portion. Therefore, pulsating motions are reduced in fluid that passes through the first flow passage in the first-pipe insertion portion, the orifice in the wall section of the second-pipe installation portion and the second flow passage in the tubular section of the second-pipe installation portion. The connector can reduce the pulsating motions without disposing any such other structural bodies as a cylinder and piston, in addition to the flow passages. That is, the connector can reduce the pulsating motions without increasing in size. 
     In addition, the orifice is formed so as to elongate in the same direction as the second flow passage does in the tubular section of the second-pipe installation portion. A core for forming the second flow passage accordingly makes it feasible to form the orifice simultaneously with the second flow passage. Therefore, it becomes feasible to integrally mold the first-pipe insertion portion and second-pipe installation portion securely, while forming the orifice. 
     Moreover, a manufacturing process for the connector directed to the present invention uses; 
     an outer mold forming an outer face of the connector;
 
a first core forming an inner peripheral face of the first-pipe insertion portion; and
 
a second core forming an inner peripheral face of the tubular section of the second-pipe installation portion, and the orifice in the wall section; and
 
the manufacturing process comprises:
 
an arrangement step of arranging the first core and the second core inside the outer mold; and
 
a resin injection step of injecting molten resin into a cavity formed between the first core, the second core and the outer mold.
 
     In accordance with the present manufacturing process, it becomes feasible to integrally mold the first-pipe insertion portion and second-pipe installation portion securely, while forming the orifice. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective-view diagram of a connector  1  according to First Embodiment before it is connected with a first pipe  3  and a second pipe  4 ; 
         FIG. 2  is a cross-sectional diagram of the connector  1  according to First Embodiment taken in the flow-passage direction in a state where it is connected with the first pipe  3  and second pipe  4 ; 
         FIG. 3  is a cross-sectional diagram of the connector  1  alone taken along the “ 3 ”-“ 3 ” line in  FIG. 2 ; 
         FIG. 4  is a cross-sectional diagram of the connector  1  alone taken along the “ 4 ”-“ 4 ” line in  FIG. 2 ; 
         FIG. 5  is a cross-sectional diagram illustrating a forming mold for molding the connector  1  according to First Embodiment; and 
         FIG. 6  is a cross-sectional diagram of a connector  100  according to Second Embodiment taken in the flow-passage direction. 
     
    
    
     DESCRIPTION OF THE EMBODIMENTS 
     First Embodiment 
     
         
         
           
             (1) Outline of Connector  1   
           
         
       
    
     Regarding an outline of a connector  1  according to the present embodiment, explanations will be made with reference to  FIG. 1  and  FIG. 2 . The connector  1  is used for constituting automotive fuel piping, for instance. Note that, in addition to the fuel piping, the connector  1  is also applied to the other piping variously. In the present embodiment, the connector  1  forms a flow passage for distributing a fuel. As illustrated in  FIG. 1  and  FIG. 2 , a first pipe  3  made of a metal, for instance, is inserted into the connector  1 , and a second pipe  4  made of a resin, for instance, is installed thereon. Thus, the connector  1  connects the first pipe  3  with the second pipe  4 . 
     As illustrated in  FIG. 1 , the first pipe  3  is formed in a metallic tubular shape, for instance, and is provided with an annular boss  3   a  (being also referred to as a “flanged portion,” or a “bead”) formed to protrude outwardly in the diametric direction at a position that is separated off at a distance from the leading end in the axial direction. In the following explanations, a minor-diameter part of the first pipe  3 , which is present on a more leading-end side than the annular boss  3   a,  is designated as a leading-end portion  3   b  thereof. 
     The connector  1  comprises a connector body  10 , a retainer  30 , and a sealing unit  40 . The connector body  10  is formed integrally by a resin. The connector body  1  is made of glass-fiber reinforced polyamide, for instance. The connector body  10  is molded so as to have penetrated flow passages ( 11   a,    61 ,  51 ) therein. The connector body  10  shown in.  FIG. 1  exhibits a configuration that is formed to penetrate in a letter-“L” shape. 
     As illustrated in  FIG. 1  and  FIG. 2 , the connector body  10  comprises a first-pipe insertion portion  11  into which the first pipe  3  is inserted, and a second-pipe installation portion  12  on whose outer peripheral surface the second pipe  4  is installed. The first-pipe insertion portion  11 , and the second-pipe installation portion  12  are molded integrally by a resin. Consequently, the connector body  10  exhibits high strength. 
     The first-pipe insertion portion  11  is formed in a tubular shape to form a first flow passage  11   a  therein. The first-pipe insertion portion  11  has a first opening  11   b  through which the first pipe  3  is inserted. Into the first-pipe insertion portion  11 , parts of the first pipe  3 , such as the leading-end portion  3   b  and annular boss  3   a , are inserted. On an axial central section of the inner peripheral side in the first-pipe insertion portion  11 , the sealing unit  40  is arranged. 
     The second-pipe installation portion  12  is formed in a tubular shape to make the second pipe  4  install on the outer peripheral side starting at a side of the second opening  12   a.  A flow passage in the second-pipe installation portion  12  is communicated with the first flow passage  11   a  in the first-pipe insert ion port ion  11 . The outer peripheral face of the second-pipe installation portion  12  is formed in an irregular or zigzagged shape in a direction along the flow passage in order not to make the second pipe  4 , which is put in a state of being fitted around, fall off therefrom. 
     The retainer  30  is made of glass-fiber reinforced polyamide, for instance. The retainer  30  is retained in the first-pipe insertion portion  11  of the connector body  10 . The retainer  30  is capable of moving in the diametric direction of the first-pipe insertion portion  11  through a push-in operation and pull-out operation by an operator or worker. When the first pipe  3  has been inserted into the first-pipe insertion portion  11  to a normal position therein, the retainer  30  becomes movable from an initial position shown in  FIG. 1  to a confirmation position shown in  FIG. 2 . Therefore, when the operator or worker can operate the retainer  30  by the push-in operation, he or she can confirm that the first pipe  3  has been inserted into the first-pipe insertion portion  11  to the normal position. 
     Moreover, in a state where the retainer  30  is operated to be pushed in to the confirmation position, the retainer  30  locks the annular boss  3   a  of the first pipe  3  in a pipe pull-out direction, thereby stopping the first pipe  3  from coming off. That is, an operator or worker can confirm the following by operating the retainer  30  to push in: the first pipe  3  has been inserted into the first-pipe insertion portion  11  to the normal position; and the first pipe  3  is stopped from coming off by the retainer  30 . 
     The sealing unit  40  is constituted of the following, for instance: annular sealing members ( 41 ,  42 ) made of fluororubber; a collar  43  made of a resin and held between the annular sealing members ( 41 ,  42 ) in the axial direction; and a bushing  44  made of a resin for positioning the annular sealing member ( 41 ,  42 ) and collar  43  in the first-pipe insertion portion  11 . As illustrated in  FIG. 2 , the leading-end potion  3   b  of the first pipe  3  is inserted into the inner peripheral side of the sealing unit  40 ; and the annular boss  3   a  of the first pipe  3  is positioned on a side more adjacent to the first opening  11   b  than the sealing unit  40  is positioned.
         (2) Detailed Construction of Connector Body  10         

     Regarding detailed construction of the connector body  10 , explanations will be made hereinafter with reference to  FIG. 2  through  FIG. 4 . The second-pipe installation portion  12  comprises the tubular section  50 , and the wall section  60 . The tubular section  50  forms the second flow passage  51  on a side of the second opening  12   a.  An inner peripheral face of the tubular section  50  is formed as a cylindrical face. An outer peripheral face of the tubular section  50  is formed in an irregular or zigzagged shape in a direction along the second flow passage  51 . Therefore, an inside diameter of the tubular section  50  is formed to be smaller than an inside diameter of the second pipe  4 . 
     The wall section  60  demarcates the first flow passage  11   a  in the first-pipe insertion portion  11  from the second flow passage  51  in the tubular section  50 . The wall section  60  forms the orifice  61  communicating the first flow passage  11   a  with the second flow passage  51 . A cross-sectional area of the orifice  61  is smaller than a flow-passage cross-sectional area of the first flow passage  11   a  and a flow-passage cross-sectional area of the second flow passage  51 . 
     The orifice  61  is formed so as to elongate in the same direction as does the second flow passage  51  in the tubular section  50 . In the present embodiment, the orifice  61  is formed coaxially with the inner peripheral face of the tubular section  50 . The orifice  61  comprises a cylindrical inner-peripheral section  61   a,  and a tapered section  61   b.    
     The cylindrical inner-peripheral section  61   a  is positioned on a side of the first flow passage  11   a,  and opens in the first flow passage  11   a . The cylindrical inner-peripheral section  61   a  has an identical inside diameter in the axial direction. The tapered inner-peripheral section  61   b  is positioned on a side of the second flow passage  51 , and opens in the second flow passage  51 . The tapered inner-peripheral section  61   b  communicates the second flow passage  51  with the cylindrical inner-peripheral section  61   a.  The tapered inner-peripheral section  61   b  has an inner peripheral face shaped as a circular truncated cone. The tapered inner-peripheral section  61   b  is reduced diametrically from the second flow passage  51  toward the cylindrical inner-peripheral section  61   a.    
     In the present embodiment, the first-pipe insertion portion  11  and second-pipe installation portion  12  are formed in a letter-“L” shape. That is, the central axis of the first flow passage  11   a  in the first-pipe insertion portion  11 , and the central axis of the second flow passage  12  in the tubular section  50  of the second-pipe insertion portion  12  exhibit an angle of 90 degrees one another at. And, the central axis of the orifice  61  is coaxial with the central axis of the second flow passage  51 . 
     Therefore, one of the opposite faces of the wall section  60  (i.e., the upper face in  FIG. 2 ) constitutes a peripheral wall face of the first flow passage  11   a,  and another one of the opposite faces of the wall section  60  (i.e., the lower face in  FIG. 2 ) constitutes an end wall face of the second flow passage  51 . That is, the cylindrical inner-peripheral section  61   a  of the orifice  61  opens in the peripheral wall face of the first flow passage  11   a.    
     The one of the opposite faces of the wall section  60  (i.e., the upper face in  FIG. 2  through  FIG. 4 ) is formed in a shape of flat face. Therefore, a flow-passage length of the cylindrical inner-peripheral section  61   a  becomes identical throughout the entire circumference. That is, on a side of the first flow passage  11   a,  the cylindrical inner-peripheral section  61   a  has an opening configuration that becomes a circular shape identical with a cross-sectional inner-peripheral-face configuration that the cylindrical inner-peripheral section  61   a  has in the diametrical direction. 
     Note herein that, on an inner side of the flow passage  11   a  in the first-pipe insertion portion  11 , an innermost part  11   c  involving the one of the opposite faces of the wall section  60  is formed in a noncircular shape. That is, since the one of the opposite faces of the wall section  60  has a planar shape, some of the peripheral face of the innermost part  11   c  is formed in a planar shape. The remaining peripheral face of the innermost part  11   c  is formed in an arc shape. 
     In the first flow passage  11   a,  the leading-end portion  3   b  of the first pipe  3  is inserted between the innermost part  11   c  and the installation part of the sealing unit  40 . The part is hereinafter referred to as a pipe leading-end arrangement part  11   d . The pipe leading-end arrangement part  11   d  has a circular cross-sectional configuration corresponding to the leading-end portion  3   b  of the first pipe  3 . 
     The arc-shaped peripheral face of the innermost part  11   c  is positioned on an extension of the circular inner-peripheral face of the pipe leading-end arrangement part  11   d.  Meanwhile, the planar-shaped peripheral face of the innermost part  11   c , namely, the one of the opposite faces of the wall section  60  is positioned so as to protrude more inward in the diametric direction than does the position of the inner peripheral face of the pipe leading-end arrangement part  11   d.  Therefore, the innermost part  11   d  is formed as a configuration that makes it impossible to insert the leading-end portion  3   b  of the first pipe  3 . And, the innermost part  11   c,  namely, the one of the opposite faces of the wall section  60  is positioned on a more inner side in the first flow passage  11   a  than is the leading-end face of the leading-end portion  3   b  of the first pipe  3 .
         (3) Liquid Flows within Connector  1         

     The connector body  10  comprises the orifice  61  communicating the first flow passage  11   a  with the second flow passage  51 . The orifice  61  is formed in the wall section  60  that makes a demarcation between the first-pipe insertion portion  11  and the tubular section  50  of the second-pipe installation section  12 . Therefore, pulsating movements are reduced in a fluid passing through the first flow passage  11   a  in the first-pipe insertion portion  11 , the orifice  61  in the wall section  60  of the second-pipe installation portion  12 , and the second flow passage  51  in the tubular section  50  of the second-pipe installation portion  12 . According to the connector body  10 , it is possible to reduce the pulsating movements without disposing any such structural bodies as a cylinder and piston, in addition to the flow passages. That is, it is possible to reduce the pulsating movements without increasing the connector body  10  in size.
         (4) Manufacturing Process for Connector Body  10         

     Regarding a manufacturing process for the connector body  10 , explanations will be made hereinafter with reference to  FIG. 5 . The connector body  10  is manufactured by injection molding. Hence, as illustrated in  FIG. 5 , the following are used in manufacturing the connector body  10 : two or more outer molds  71  forming the outer faces of the connector body  10 ; a first core  72  forming the inner peripheral faces of the first-pipe insertion portion  11 ; and a second core  73  forming the inner peripheral faces of the tubular section  50  of the second-pipe installation portion  12  as well as the orifice  61  in the wall section  60 . 
     And, an operator or worker arranges the first core  72  and second core  73  inside the outer molds  71  (i.e., an arrangement step); subsequently, the operator or worker injects a molten resin into a cavity  74  formed between the first core  72 , the second core  73  and the outer molds  71  (i.e., a resin injection step). Subsequently, the operator or worker removes the outer molds  71 , the first core  72 , and the second core  73  (i.e., a mold separation step). Thus, the connector body  10  is manufactured. 
     Note herein that, as illustrated in  FIG. 5 , the first core  72  is formed in an axial shape. The leading end of the first core  72  is formed in configurations corresponding to the innermost part  11   c  and pipe leading-end arrangement part  11   d  of the first flow passage  11   a.  That is, the cross-sectional configuration of the first core  72  becomes smaller as it goes to the leading end. The second core  73  is formed in an axial shape. The second core  73  is formed, as it goes to the leading end, in configurations corresponding to the following in the order of the second flow passage  51  in the tubular section  50  and the tapered inner-peripheral section  61   b  and cylindrical inner-peripheral section  61   a  of the orifice  61 . That is, the cross-sectional configuration of the second core  73  becomes smaller as it goes to the leading end. 
     Thus, the cross-sectional configurations of the first core  72  and second core  73  are both formed to be smaller as they go to the leading end. And, the orifice  61  is formed so as to elongate in the same direction as the second flow passage  51  does. That is, the second core  73  for forming the second flow passage  51  makes it feasible to form the orifice  61  simultaneously with the second flow passage  51 . Therefore, constituting the connector body  10  as set forth above leads to making it feasible to securely mold the first-pipe insertion portion  11  and second-pipe installation portion  12  integrally while forming the orifice  61 . 
     If the orifice  61  should have been formed in the vicinity of the second opening  12   a  of the second-pipe installation portion  12 , it is not possible to integrally mold the connector body  10 . It is reasoned that a core similar to the second core  73  makes an undercut configuration so that it cannot be pulled or drawn out from a product. 
     Moreover, the second core  73  further comprises a tapered portion, which corresponds to the tapered inner-peripheral section  61   b  of the orifice  61 , between the major-diameter portion, which corresponds to the second flow passage  51  in the tubular section  50 , and the minor-diameter portion, which corresponds to the cylindrical inner-peripheral section  61   a  of the orifice  61 . Therefore, the second core  73  does not change to make the diameter smaller sharply as it goes to the leading end, but changes to make it smaller gradually. Consequently, even when the leading-end portion of the second core  73  comprises the minor-diameter portion, it exhibits high strength. 
     Moreover, a radial dent  72   a  is formed, as shown in  FIG. 5 , at a position in some of the leading-end portion of the first core  72  corresponding to the innermost part  11   c.  A minor-diameter portion in the second core  73  corresponding to the cylindrical inner-peripheral section  61   a  is formed to be longer than the actual axial length of the cylindrical inner-peripheral section  61   a.  The minor-diameter portion is inserted into the dent  72   a  of the first core  72 . Therefore, the orifice  61  opens in the first flow passage  11   a  securely. 
     Second Embodiment 
     Regarding a connector  100  according to the present embodiment, explanations will be hereinafter made with reference to  FIG. 6 . In contrast to the connector  1  according to First Embodiment, the connector  100  according to the present embodiment is distinct in that a connector  110  is not a letter-“L” type but has a linear shape. Note that, of the constituents of the connector  1  according to First Embodiment, identical constituents therewith in the connector  100  according to the present embodiment are labeled with the same reference numerals to omit the explanations hereinafter. 
     The connector  100  comprises the connector  110 , a retainer  30 , and a sealing unit  40 . The connector body  110  is molded integrally by a resin. As illustrated in  FIG. 6 , the connector body  110  is molded so as to include flow passages ( 11   a ,  161 ,  51 ) penetrating therethrough in a linear manner. 
     The connector body  110  comprises a first-pipe insertion portion  11 , and a second-pipe installation portion  112 . The second-pipe installation portion  112  includes a tubular section  50 , and a wall section  160 . In the same manner as the tubular sect ion  50  according to First Embodiment, the tubular section  50  forms a second flow passage  51  therein on a side of the second opening  12   a.    
     The wall section  160  demarcates the first flow passage  11   a  in the first-pipe insertion portion  11  from the second flow passage  51  in the tubular section  50 . The wall section  160  forms an orifice  161  communicating the first flow passage  11   a  with the second flow passage  51 . A cross-sectional area of the orifice  161  is smaller than a cross-sectional area of the first flow passage  11   a  and a cross-sectional area of the second flow passage  51 . 
     The orifice  161  is formed so as to elongate in the same direction as do the first flow passage  11   a  in the first-pipe insertion portion  11  and the second flow passage  51  in the tubular section  50 . In the present embodiment, the orifice  161  is formed coaxially with the inner peripheral face of tubular section  50 . The orifice  161  comprises a cylindrical inner-peripheral section  161   a,  and a tapered inner-peripheral section  161   b.    
     In the present embodiment, the first-pipe insertion portion  11 , and the second-pipe installation portion  112  are formed on a straight line. That is, a central axis of the first flow passage  11   a  in the first-pipe insertion portion  11 , and a central axis of the second flow passage  51  in the tubular section  50  of the second-pipe installation portion  112  are disposed coaxially. And, a central axis of the orifice  161  is coaxial with the central axes of the first flow passage  11   a  and second flow passage  51 . 
     Therefore, one of the opposite faces of the wall section  160  (i.e., the right face in  FIG. 6 ) constitutes an end wall face of the first flow passage  11   a , and another one of the opposite faces of the wall section  160  (i.e., the left face in  FIG. 6 ) constitutes an end face of the second flow passage  51 . The cylindrical inner-peripheral section  161   a  of the orifice  161  opens in the end wall face of the first flow passage  11   a.  Moreover, the one of the opposite faces of the wall section  160  (i.e., the right face in  FIG. 6 ) is formed in a shape of flat face. Therefore, a flow-passage length of the cylindrical inner-peripheral section  161   a  becomes identical throughout the entire circumference. That is, on a side of the first flow passage  11   a , the cylindrical inner-peripheral section  161   a  has an opening configuration that becomes a circular shape identical with a cross-sectional inner-peripheral-face configuration that the cylindrical inner-peripheral section  161   a  has in the diametrical direction. 
     In the same manner as the connector  1  according to First Embodiment, the connector  100  according to the present embodiment can reduce pulsating movements. 
     Moreover, the wall section  160  including the orifice  161  is formed between the first flow passage  11   a  and the second flow passage  51 . Accordingly, in manufacturing the connector body  110 , the following come to be used: a first core to be pulled or drawn out through the first opening  11   b ; and a second core to be pulled or drawn out through the second opening  12   a.  It is possible to make each of the axial lengths of the first core and second core shorter, and so it is possible to secure strengths of the first core and second core sufficiently. Consequently, in an instance where the connector body  110  is molded integrally, the connector body  110  becomes satisfactory in the moldability.