Abstract:
An automobile climate control system having a liquid dispersing device to allow coolant to flow. The system also utilizes a heat exchanger to cool the liquid. A manifold block handles the transfer of coolant between the coolant dispersing device and the heat exchanger. The manifold block is in communication with the heat exchanger and the coolant dispersing device; and at least one clasp connects the manifold block to the heat exchanger. A fitting clasp made from the clad material couples the heat exchanger to the at least one clasp.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to the art of automobile climate control systems, and more particularly, to a system, method, and apparatus for connecting the climate control system to a condenser by coupling a manifold block to a condenser manifold. 
     2. Discussion of the Related Art 
     Automotive climate control systems are well known in the art. Automobiles typically utilize climate control systems to absorb and dissipate heat from inside the passenger cabin to the outside of the car. In such systems, a manifold block connects the condenser manifold to both the compressor and the expansion valve. The manifold block connects the compressor to the condenser and the condenser to the evaporator, so that refrigerant can flow between them. Refrigerant at high temperature and high pressure in vapor form flows through the pipes from the compressor to the condenser, via the condenser manifold. In the condenser, the high temperature and high pressure refrigerant in vapor form is condensed to form refrigerant in high temperature high pressure liquid form. Then, the liquid is passed through an expansion valve. The valve restricts the flow of the refrigerant, lowering the pressure of the liquid forming low pressure, low temperature liquid. This liquid is then passed through an evaporator, where heat from the passenger cabin is absorbed as the refrigerant liquid evaporates. The resulting low pressure, low temperature refrigerant liquid is connected to the compressor, which pressurizes the refrigerant into high pressure high temperature vapor form, repeating the process. 
     In such systems, the manifold block may be coupled to the condenser manifold via a clasp that is physically part of the manifold block. When the manifold block is coupled to the condenser, the clasp is typically soldered or brazed to the condenser. However, it is relatively inefficient for the fitting clasp to be a physical molded part of the manifold block, because if the fitting clasp is damaged or bent in any way before being soldered or coupled in any way to the condenser, the entire manifold block may be unusable. Also, the fitting clasp is susceptible to breakage after soldering, because it is only soldered/brazed to the condenser manifold at certain points. In other words, only a portion of the surface of the fitting clasp is soldered/brazed to the condenser manifold. Moreover, traditional fitting clasps are typically much shorter than the length of the manifold block and therefore may break if the manifold block is subjected to a twisting force. If traditional fitting clasps are to be intentionally designed with longer clasps, piece of metal from which the block is extruded or machined from needs to be made larger, thus increasing the overall material and process cost. 
     Some systems also solder or braze the fitting clasps onto the manifold block. Such systems require a direct connection between the manifold block and the condenser body, allowing flow of fluid between the manifold block and the condenser. This type of system requires an additional solder or braze process to complete the connection between the block and the condenser. In such systems, either the solder or the braze material is typically manually placed onto specific points of the clasps, and then heated up, forming a connection between the clasps and the manifold block, and between the clasps and the condenser manifold. However, such use of solder or braze material can be problematic, because solder or brazing material in ring or paste form, is typically on the manifold block and the condenser manifold, or the clasps; before being heated. Such solder/braze material may be knocked off before heating, or an operator may simply forget to include them. Consequently, the bond between the clasps and the manifold block, or between the clasp and the condenser, is weakened. Furthermore, parts are susceptible to move during soldering or brazing, leading to higher defect rates. 
     Systems in the art use a manifold block that is formed of a single piece of material. However, if either of an inlet or an outlet aperture in the manifold block is damaged, the entire manifold block must typically be discarded. This is true even if only one aperture or a portion of the manifold block is damaged. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 shows a general overview of a manifold block coupled to a condenser of an automotive climate control system according to an embodiment of the present invention; 
     FIG. 2 illustrates a close-up view of the manifold block coupled to a condenser manifold according to an embodiment of the present invention; 
     FIG. 3 illustrates an exploded close-up view of the manifold block, the fitting clasps, the condenser manifold and a pipe connected to the manifold block according to an embodiment of the present invention; 
     FIG. 4 illustrates a close-up view of top and bottom fitting clasps according to an embodiment of the present invention; 
     FIG. 5 illustrates a close-up view of a second manifold block connected, via a fitting clasp, to a condenser manifold according to an embodiment of the present invention; 
     FIG. 6 illustrates a close-up exploded view of the second manifold block, the condenser, manifold, the fitting clasp, and the pipe connected to the second manifold block according to an embodiment of the present invention; and 
     FIG. 7 illustrates the process by which the fitting clasp is coupled to the condenser manifold and the manifold block according to an embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION 
     According to an embodiment of the present invention, fitting clasps couple a manifold block to a condenser manifold. The fitting clasps are coupled to both the manifold block and the condenser manifold by an aluminum clad material having a melting temperature below that of the material forming the manifold block, the fitting clasps, and the condenser manifold. The fitting clasps are made from aluminum clad material, and are then placed in between the manifold block and the condenser manifold. The entire device is heated to a temperature where the clad material on the outer surface of the fitting claps melts, but the material forming the manifold block, the base material of the fitting clasps, and the condenser manifold does not. After the clad material melts, the entire device is allowed to cool. As the clad material cools, a, strong bond is formed, making a sturdy connection between the manifold block, the fitting clasps, and the condenser manifold. Such an embodiment is suitable for use within an automotive climate control system of an automobile, for example. 
     FIG. 1 shows a general overview of a manifold block  105  coupled to a condenser  100 , or a heat exchanger, of an climate control system according to an embodiment of the present invention. In the embodiment, the automotive climate control system may serve to remove excess heat from inside the passenger cabin of an automobile. A refrigerant, such as Freon, may flow through pipes or fins of an evaporator, located inside the passenger cabin. As the refrigerant in liquid form flows through the evaporator, it absorbs heat from the passenger cabin, as it evaporates into vapor form. A compressor serves to compress the resulting refrigerant to a high temperature, high pressure form. The resulting high pressure, high temperature refrigerant vapor reaches an inlet aperture  120  of the manifold block  105 . Refrigerant vapor flowing through the inlet aperture  120  enters into a pipe  122 , and then into a condenser manifold  110  and the condenser  100 , where it is condensed into liquid form. 
     The condenser  100  is comprised of a plurality of tubes or pipes through which refrigerant may circulate. The condenser  100  may also be made using “fin” like flat tubes. The tubes or pipes may be formed of a heat conductive material, such as metal. In an embodiment within an automobile, as the automobile is driven, air from outside the car comes in contact with the tubes or pipes of the condenser  100 , and absorbs heat from the condenser  100  pipes, effectively cooling the refrigerant contained therein. A compressor pump pumps the refrigerant between the condenser  100  and an evaporator. Once the refrigerant within the pipes of the condenser  100  has condensed back into liquid form, it is connected to the expansion valve through the outlet aperture  115 . The drop in pressure as the refrigerant passes through the expansion valves returns the refrigerant back to its low pressure, low temperature form. The refrigerant in the low pressure, low temperature form can then be returned to the evaporator, completing the cycle. 
     The climate control system allows the refrigerant in the climate control system to absorb the heat from the passenger cabin, as the refrigerant evaporates in the evaporator. Once the refrigerant is pumped into the condenser  100 , the refrigerant flows throughout pipes or fins of the condenser  100 , and radiate of “give off” heat, as heat is absorbed by air external to the automobile, effectively cooling the refrigerant contained within the condenser&#39;s  100  pipes. After the refrigerant gives off enough heat, the refrigerant condenses into liquid form. The refrigerant in liquid from can then be returned to the evaporator via the expansion valve, where the process repeats. The process serves to help keep the passenger cabin cool. 
     As shown in FIG. 1, when the refrigerant is received through the inlet aperture  120  of the manifold block  105 , it flows through a pipe  122  to an aperture  125  at the bottom of the condenser manifold  110 . The refrigerant travels upward through the pipes of the condenser  100 , and condensed refrigerant in the pipes near the top of the condenser  100  is then pumped back into to the expansion valve through the outlet aperture  115 . Although the embodiment shown in FIG. 1 has a manifold block  105  connected near the top of the condenser manifold  110 , the manifold block  105  may be connected to the bottom of the condenser manifold  110 , or in an other suitable location on the condenser manifold  110 , in other embodiments. Other embodiments may also include an inlet aperture  120  located above the outlet aperture  115  on the manifold block  105   
     FIG. 2 illustrates a close-up view of the manifold block  105  connected to the condenser manifold  110  according to an embodiment of the present invention. In the embodiment, two fitting clasps  200 ,  205  connect the manifold block  105  to the condenser manifold  110 . The manifold block  105  is located on top of the front vertical face of the condenser manifold  110 . A top fitting clasp  200  has a set of legs  210  that contact the front vertical face of the condenser manifold  110  and extend along the side vertical faces of the condenser manifold  110 . As explained in further detail in the discussion of FIG. 2 below, the top fitting clasp  200  has an aperture that allows refrigerant to flow from the condenser manifold  110  through the aperture in the top fitting clasp  200 , and through the outlet aperture  115  of the manifold block  105 . In the embodiment shown in FIG. 2, a bottom fitting clasp  205  is coupled to the manifold block  105  and the condenser manifold  110  at a location below the top fitting clasp  200 . The bottom fitting clasp  205  also has a plurality of legs  210  that serve to couple the manifold block  105  to the condenser manifold  110 . The manifold block  105  has an aperture  220 , which allows liquid to flow from the inlet aperture  120  to the pipe  122 , and ultimately into the condenser manifold  110 . 
     The legs  210  of the top  200 ,and bottom  205  clasps fit tightly around the front vertical face and side vertical faces of the condenser manifold  110  and serve to prevent slippage between the manifold block  105  and the condenser manifold  110 . Connected to a hole  220  on the bottom side of the manifold block  105  is a pipe  122  that extends to an aperture  125  near the bottom of the condenser manifold  110  (see FIG.  1 ). The metal pipe  122  is utilized to allow refrigerant to flow to the bottom of the condenser  100 . In an embodiment of the invention, refrigerant from the compressor enters the manifold block  105  through the inlet aperture  120 . Once inside the manifold block  105 , the refrigerant flows down the metal pipe  122  to the aperture  125  at the bottom of the condenser manifold  110 . The pipe  122  may be formed of metal, or of any other suitable material. 
     The outlet aperture  115  allows refrigerant to flow from the condenser  100  to the expansion valve. When an automobile or other device utilizing this system is in operation, heated refrigerant gas may flow into the condenser  100  through the inlet aperture  120  and flow throughout the condenser  100  while outside air absorbs heat from the refrigerant. After the refrigerant has flowed through the condenser  100 , the condensed refrigerant may exit the condenser  100  and return to the evaporator via the expansion valve through the outlet aperture  115 . 
     The top  200  and bottom  205  clasps serve to prevent slippage between the manifold block  105  and the condenser manifold  110 . Although only top  200  and bottom  205  clasps are illustrated in FIG. 2, other embodiments may use more or fewer than two clasps. In the embodiment shown in FIG. 2, each clasp has four “legs”  210 , or metal extensions extending in a direction perpendicular to front face of the clasp. In an embodiment having four legs  210  on each clasp, two legs  210  extend on each side of the clasp, with a space between each leg  210  on each side. Other embodiments may use more or less than four legs  210 . 
     FIG. 3 illustrates an exploded close-up view of the manifold block  105 , the top and bottom fitting clasps  200  and  205 , the condenser manifold  110  and the pipe  122  connected to the manifold block  105  according to an embodiment of the present invention. The top fitting clasp  200  has a connection aperture  305  through which refrigerant may pass when the top fitting clasp  200  is coupled to the condenser manifold  110  and the manifold block  105 . The condenser manifold  110  also has an aperture  315  near its top through which the refrigerant may flow. The refrigerant flows out of the aperture  315  in the top of the condenser manifold  110 , through the connection aperture  305 , and into the evaporator after passing through the outlet aperture  115 . 
     In an embodiment of the present invention, the top fitting clasp  200  and the bottom fitting clasp  205  are made from aluminum clad material, and the manifold block  105  and the condenser manifold  110  are formed of an aluminum alloy having a melting temperature higher than that of the clad material on the outer surface of the aluminum clad material. In the embodiment, the melting point of the aluminum alloy may be 100 degrees higher than that of the aluminum clad material, for example. The top  200  and bottom  205  fitting clasps are placed underneath the manifold block  105 , and on top of the condenser manifold  110 . The top fitting clasp  200  is positioned so that connection aperture  305  lines up with the aperture  315  on the top of the condenser manifold  110  and with outlet aperture  115  on manifold block  105 . The manifold block  105 , the top  200  and bottom  205  fitting clasps, and the condenser manifold  110  are then all heated to a temperature greater than the melting point of the aluminum clad material, but below that of the aluminum alloy forming the core of the top  200  and bottom  205  fitting clasps, manifold block  105 , and the condenser manifold  110 . The aluminum clad material melts, and then the condenser manifold  110 , the top  200  and bottom  205  fitting clasps, and the manifold block  105  are allowed to cool. As they cool, the aluminum clad material solidifies and forms a strong bond between the top  200  and bottom  205  fitting clasps, the condenser manifold  110 , and the manifold block  105 . In other embodiments, suitable materials other than aluminum or the aluminum clad material may be utilized. 
     FIG. 3 also illustrates the bottom fitting clasp  205 . In the illustrated embodiment, the bottom fitting clasp  205  has four legs  210 . Other embodiments may use more or fewer than tour legs  210 . The bottom fitting clasp  205  has an vertical face  300  that extends in a direction perpendicular to the front face of the bottom fitting clasp  205 , away from the legs  210 . The vertical face  300  has an aperture  310  located around its center. The pipe  122  connects to the aperture  220  through the aperture  310  on the vertical face  300  of the bottom fitting clasp  205 . When the bottom fitting clasp  205  is correctly positioned, the vertical face  300  is bonded to the bottom face of the manifold block  105  via the clad material. When bonded, the vertical face  300  serves to prevent the manifold block  105  from rotating in an angular direction. In other embodiments, the vertical face may not be necessary based on the requirements of the application. 
     When in place, each leg  210  of the top  200  and bottom  205  clasps wrap onto a side of the condenser manifold  110 . When the legs  210  have been coupled to the condenser manifold  110 , they serve to prevent the manifold block  105  from rotating when subjected to an angular force or torque. This is necessary because the metal pipe  122  extending to the bottom of the condenser manifold  110  may break or become dislodged if the manifold block  105  were to rotate in such a direction. The connection aperture  305  allows liquid to flow between the condenser manifold  110  and the manifold block  105  when the top fitting clasp  200  is coupled to the manifold block  105  and the condenser manifold  110 . 
     FIG. 4 illustrates a close-up view of top  200  and bottom  205  fitting clasps according to an embodiment of the present invention. The aluminum clad material is used to form the material surrounding the connection aperture  305  before the manifold block  105  is positioned on top of it. During the heating process, the aluminum clad material on material surrounding the connection aperture  305  melts, and is later cooled, forming a strong bond with the structure of the manifold block  105  having the outlet aperture  115 . 
     FIG. 5 illustrates a close-up view of a second manifold block  500  connected via a fitting clasp  502 , to a condenser manifold  110  according to an embodiment of the present invention. The second manifold block  502  includes an outlet block  505  containing the outlet aperture  515  and an inlet block  510  containing the inlet aperture  520 . The outlet block  505  is coupled to the inlet block  510  by a notch  535  on the inlet block  510 , which fits into a groove  540  on the outlet block  505 . The second manifold block  500  is coupled to the fitting clasp  502 . The fitting clasp  502  has legs  525  that wrap around the vertical sides of the condenser manifold  110 . The fitting clasp  502  contains a vertical face  530  extending in a direction perpendicular to the top face of the fitting clasp, in a direction away from the legs  525  thereof The vertical face  530  has an aperture through which a pipe  122  extends. In other embodiments, the vertical face may not be necessary based on the requirements of the application. On its other end, the pipe  122  connects to an aperture  125  at the bottom of the condenser manifold  110 . When in place, refrigerant may enter the inlet aperture  520  of the second manifold block  500 , and then pass through the pipe  122  and into the condenser manifold  110  through the aperture  125  at the bottom of the condenser manifold  110 . 
     FIG. 6 illustrates a close-up exploded view of the second manifold block  500 , the condenser manifold  110 , the fitting clasp  502 , and the pipe  122  connected to the second manifold block  500  according to an embodiment of the present invention. The fitting clasp  502  contains a connection aperture  600 . The outlet block  505  contains an aperture  605  through which refrigerant from the condenser manifold  110  may flow. When the outlet block  505  is positioned on top of the fitting clasp  502 , the connection aperture  600  fits underneath the aperture  605  on the top of the outlet block  505 . 
     FIG. 7 illustrates the process by which the fitting clasp  502  is coupled to the condenser manifold  110  and the manifold block  500  according to an embodiment of the present invention. First, the fitting clasp  502  is formed  700  from aluminum  700  clad material. In other embodiments, clad material other than aluminum may be utilized. 
     In a situation where the condenser manifold  110 , the manifold block  500 , and the fitting clasp  502  are all formed of an aluminum clad material, the cladding material on the outer surfaces may have a melting point one hundred degrees below that of the core of the aluminum alloy, for example. In other embodiments, the manifold block  105  and the condenser manifold  110  may also be formed from the aluminum clad material. At step  705 , the fitting clasp  502  is positioned between the manifold block  500  and the condenser manifold  110 . Next, the combination of the fitting clasp  502 , the manifold block  500 , and the condenser manifold  110  is heated  710  to a predetermined temperature. The predetermined temperature is typically above the melting point of the clad material, but below that of the core aluminum alloy. Finally, the entire assembly is allowed to cool  715 . As the assembly cools, the clad material solidifies, forming a strong bond between the condenser manifold  110  and the fitting clasp  502 , and between the manifold block  500  and the fitting clasp  502 . 
     The outlet block  505  and the inlet block  510  may be manufactured separately. This can result in cost savings because if the inlet aperture  520  is deformed, for example, a new inlet block  510  need only be manufactured to replace the deformed part, rather than an entirely new manifold block  500 . Additional cost savings is possible if the blocks made separately features a shape or a profile that is very different from each other as it will decrease the need to remove excess aluminum material to form the net part. This may result in savings in processing as well as materials cost. 
     While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.