Abstract:
A one-piece, flanged, fluid-flow connector for connecting tube, pipe, hose or the like to a port face includes a base having a flat port face on one end, and a connection piece fixed to and extending from the other end. At least four tabs extend from the base, the tabs having apertures for mounting the connector. The base includes a reinforcement portion that transitions continuously from a lesser thickness adjacent the tabs to a greater thickness adjacent to the connection piece. The connector makes it feasible to provide a one-piece, four-bolt connector which occupies substantially less space than a comparable connector of the prior art, but which handles at least the same fluid pressures.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to a compact, mechanically-connected, fluid-flow system having compact port-face tube, pipe and hose connectors. More particularly, the system has compact two-bolt and four-bolt flanged and modular connectors which meet or exceed the working pressure specified in SAE standard J518 and which fit within the minimum pad width specified in SAE standard J518.  
         BACKGROUND OF THE INVENTION  
         [0002]    Four-bolt, split-flange connectors, such as illustrated in SAE standard J518, are known for connecting tube, pipe, hose or the like to a fluid-flow port face on an adapter plate, pump, or the like. These connectors are intended for use in hydraulic systems, or in industrial and commercial products, where it is desired to avoid the use of threaded connectors.  
           [0003]    Referring to FIGS. 1 and 2 (prior art), known split-flange connectors  8  have a flanged head fitting  10 , two split-flange clamp halves  18 , and four bolts  14  which are inserted through the clamp halves  18  and into threaded apertures  22  in the face plate  24 . The bolts  14  properly align the connector  8  with the port  6 . The four-bolt, split-flange connector  8  may optionally include lock washers  16  and an O-ring seal  20  on its port face mating surface.  
           [0004]    In mechanical, fluid-flow systems, it is common to design several fluid-flow ports  6  adjacent one another.  
           [0005]    The proximity with which fluid-flow ports  6  may be arranged is directly related to the diameter of the port and the widthwise and lengthwise dimensions of the prior art split-flange connectors  8 . The Engineering Society for Advancing Mobility Land Sea Air and Space (SAE) has developed a standard which covers the specifications for the flanged head  10  and split-flange clamp halves  18  applicable to the aforementioned prior art four-bolt, split-flange hydraulic connectors  8 .  
           [0006]    SAE standard J518 covers complete general and dimensional specifications for the port  6 , flange head  10  and split-flange clamp halves  18  applicable to four-bolt, split-flange type tube, pipe and hose connectors. In addition to specifying the dimensions of four-bolt hydraulic flanged connectors and port dimensions for bolted flange connectors, SAE standard J518 specifies the material, finish, workmanship, material properties (minimum yield and minimum elongation), and maximum working pressure. Code 61 of SAE standard J518 recites the dimensions of standard pressure hydraulic flanged connectors while Code 62 recites the dimensions of high pressure hydraulic flanged connectors.  
           [0007]    The minimum and recommended dimensions between adjacent fluid-flow ports  6  for bolted flange connectors are specified in SAE standard J518 with reference to a drawing reproduced substantially herein as FIG. 3. SAE standard J518 specifies dimensions BB, CC, and DD as the minimum vertical and horizontal distances between the center of adjacent fluid-flow ports  6 . The recommended distances BB, CC, and DD are based on the recommended dimensions of the above-described four-bolt hydraulic flanged connectors and factor in a 0.06 inch clearance between flanges, dimensionally on the high limit, when the same size flanges are used on adjacent ports. SAE standard J518 also specifies the minimum pad width EE of the port face for both the standard pressure series Code 61 and high pressure series Code 62.  
           [0008]    As used herein, the term “pad” refers to the surface of a block, pump, or the like immediately surrounding a port  6  to which a flanged hydraulic connector is attached. As used herein, the term “footprint” is used to describe the projected area of the mounting surface of the connector which abuts the “pad” of the block, pump, etc.  
           [0009]    Referring to FIGS.  1 - 3  (prior art), the recommended pad width FF of the hydraulic flanged connector is much wider than the minimum pad width EE. In order to design a high-pressure fluid flow system more compact than the prior art, it would be desirable to provide a flanged connector having a widthwise dimension which is equal to or less than the minimum pad width EE so that the port dimensions CC and DD can be reduced.  
           [0010]    In order to satisfy the aforementioned objects, the widthwise dimension of prior art two-bolt or four-bolt, split-flange connectors cannot simply be reduced. A reduction in the widthwise dimension would likely reduce the maximum working pressure of the connector below the value specified in SAE standard J518. Therefore, it is a further object of the invention to provide a compact connector which requires only the minimum pad width EE but which also meets or exceeds the working pressure specified in SAE standard J518.  
         SUMMARY OF THE INVENTION  
         [0011]    The present invention provides a flanged connector having a widthwise dimension W which is less than the recommended pad width FF, preferably equal to or less than the minimum pad width EE, so that the port dimensions CC and DD can be reduced, and which also can meet or exceed the working pressure specified in SAE standard J518.  
           [0012]    A one-piece, flanged fluid-flow connector of the invention can be used for connecting tube, pipe, hose or the like to a port face having a port diameter D1. The connector has an overall length L 1 .  
           [0013]    The flanged connector has base portion having a height H, width W, a generally-flat port face mounting surface on one end, a generally cylindrical connection piece at the other end, and a reinforcement portion intermediate the port face mounting surface and the connection piece. The port face mounting surface may have an annular recess formed therein which is designed to receive an “O”-ring to seal the connector on a desired port face. The reinforcement portion may comprise a generally-conical, rectangular or ribbed extension.  
           [0014]    A central, elongate, cylindrical channel extends lengthwise through the connector. The central channel has a nominal port diameter D1 at the port face mounting surface.  
           [0015]    The base has a maximum width W which is less than the minimum pad width FF, preferably less than or equal to the minimum pad width EE, specified in SAE standard J518 corresponding to the nominal port diameter D1 of the connector.  
           [0016]    A generally-cylindrical connection piece is fixed to and extends from the reinforcement portion. The connection piece has means for interconnecting with a variety of elements such as a tube extension, hose, or pipe. The connection piece may have a variable length depending on the intended element to which the connector is attached. The connection piece may have a threaded outer or other surface for releasable interconnection with the desired tube, pipe, hose or the like. Alternatively, the connection piece may be permanently connected to a tube, pipe or the like by, for example, brazing, welding or swaging. The connection piece may be straight or bent to change the direction of fluid flow. The connection piece has a length L 2 .  
           [0017]    A plurality of tabs are fixed to and extend outwardly from the base portion. Each of the tabs has an aperture extending therethrough. In a preferred embodiment, the (two-bolt) connector has two tabs diametrically opposed from one another on opposed sides of the central port. Alternatively, the (four-bolt) connector has two pair of tabs, each pair of tabs diametrically opposed from one another on opposed sides of the central port. The apertures are spaced apart a distance Z from one another in the two-bolt connector. The heightwise and widthwise spacing between apertures in the four-bolt connector are equal to Q and GG, respectively, as defined in SAE standard J518.  
           [0018]    The tabs have a flat face surrounding the apertures on which the heads of fastening bolts are torqued. Preferably, the flat face comprises a semi-circular cut-out in the reinforcement portion in the area proximate the aperture.  
           [0019]    The connector is manufactured from a high-strength structural material such as steel, iron or aluminum, or composite, preferably a medium carbon steel.  
           [0020]    The dimensions of the connector are preferably selected such that W≦EE, D1≦A, and Z=(Q 2 +GG 2 ) ½  wherein EE, A, Q, O and GG are defined in SAE standard J518. The connector has nested horizontal and vertical port dimensions bb, cc, and dd corresponding to nested horizontal and vertical port dimensions BB, CC, and DD in SAE standard J518. In the two-bolt embodiment, the dimension H is approximately equal to but slightly larger than the dimension O defined in SAE standard J518; the dimension bb is at least 15% smaller than the dimension BB; the dimension cc is smaller than the dimension CC; and, the dimension dd being at least 20% smaller than the dimension DD. In the four-bolt embodiment, the dimension H is equal to or less than the dimension O defined in SAE standard J518; cc is smaller than the dimension CC and the dimension dd is at least 20% smaller than the dimension DD.  
           [0021]    The invention also provides modular block connectors having a port face mounting surface width less than the recommended pad with FF established in SAE standard J518. Preferably, the port face mounting surface width is equal to EE, the minimum pad width specified in SAE standard J518 corresponding to the nominal port diameter D1. The port face mounting surface width may be less than EE provided the width of the footprint of the mating flange connector is less than the width of the port face mounting surface, thereby maintaining a widthwise differential between the port face mounting surface and the flange connector. The modular block connectors have fluid flow channels such as an Elbow, Tee, Cross, and other shapes.  
           [0022]    The one-piece, block, connector for connecting flanged connectors has a plurality of mounting surfaces. Each mounting surface has a width W and a height H. A fluid-flow channel extends from one mounting surface to each of the other mounting surfaces. The fluid-flow channel may have an Elbow, Tee, or Cross shape. The channel has ports on each mounting surface. The ports have a nominal diameter D1at the mounting surfaces. The connector has a plurality of threaded bores on each mounting surface for fastening a flanged connector to the mounting surface.  
           [0023]    The width W of at least one mounting surface is less than the recommended pad width FF, preferably less than or equal to the minimum pad width EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. The connector may have two, three, or four mounting surfaces having a width W 1 , W 2 , W 3 , W 4  less than FF, preferably less than or equal to the minimum pad width EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. The height H of the block connector is preferably equal to the dimension O specified in SAE standard J518 corresponding to the nominal diameter D1. The connector has a working pressure rating greater than or equal to the working pressure rating specified in SAE standard J518 corresponding to the nominal diameter D1.  
           [0024]    In one embodiment, at least one mounting surface has multiple fluid flow ports thereon. Each of the ports is connected to the fluid-flow-channel. The multiple ports are spaced apart a distance dd wherein dd is less than FF specified in SAE standard J518 corresponding to said nominal port diameter D1. Preferably, the dimension dd is less than or equal to the dimension EE specified in SAE standard J518 corresponding to said nominal port diameter D1. The multiple port mounting surface has a width W 2  less than or equal to n times FF, preferably less than or equal to n times EE.  
           [0025]    In another embodiment, the connector has more than one mounting surface with multiple (N) ingredient (unconnected) fluid flow channels. Each of the fluid-flow channels extends from one mounting surface to another. The mounting surfaces have multiple (n) ports thereon. The multiple ports are spaced apart a distance dd which is equal to the dimension O specified in SAE standard J518 corresponding to said nominal port diameter D1. In another embodiment, the dimension dd is less than FF, more preferably less than or equal to EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. The multiple port mounting surfaces have a width W 2  less than or equal to n times O specified in SAE standard J518 corresponding to said nominal port diameter. Preferably, the multiple port surfaces have a width W 2  less than n times FF, more preferably less than or equal to n times EE.  
           [0026]    The invention also provides a stackable, one-piece, block connector for connecting flanged connectors to a port face. The stackable connector has a flange mounting surface, a port face mounting surface and a stacking surface opposite the port face mounting surface. Each surface has a width W and a height H.  
           [0027]    A fluid-flow channel extends from the port face mounting surface to at least one other mounting surface. The fluid-flow channel may have an Elbow, Tee, Cross or other shape. The channel has ports on the port face mounting surface and the mounting surface. The port has a nominal diameter D1 at the port face mounting surfaces.  
           [0028]    A plurality of threaded fastening bores are located on each mounting surface for fastening the flanged connector to the mounting surface. A plurality of through bores extend from the stacking surface to the port face mounting surface. Each through bore may have a counterbore in the stacking surface on the two bolt embodiment. An annular recess is formed in the port face mounting surface proximate the fluid-flow port.  
           [0029]    The flange mounting surfaces have a height H less than or equal to the dimension O specified in SAE standard J518 corresponding to said nominal diameter D1. The width W of at least one flange mounting surface is less than FF, preferably less than or equal to the minimum pad width EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. The connector has a working pressure rating greater than or equal to the working pressure rating specified in SAE standard J518 corresponding to the nominal diameter D1.  
           [0030]    In one embodiment, the stackable connector has at least one mounting surface with multiple (n) fluid-flow ports thereon. Each of the ports are connected to the fluid-flow channel. The multiple ports are spaced apart a distance dd wherein dd is less than FF, preferably less than or equal to EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. The multiple port mounting surface has a width W 2  less than or equal to n times dd.  
           [0031]    In another embodiment, the stackable connector has more than one mounting surface with multiple (n) ports thereon, each of the ports being connected to an independent (unconnected) fluid flow channel extending from one multiple port mounting surface to another. The multiple ports are spaced apart a distance dd wherein dd is equal to the dimension O specified in SAE standard J518 corresponding to said nominal port diameter D1. The multiple port mounting surfaces having a width W 2  less than or equal to n times the dimension O specified in SAE standard J518 corresponding to said nominal port diameter.  
           [0032]    Alternatively, dd is less than FF, preferably less than or equal to EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. In this embodiment, the multiple port surfaces have a width W 2  less than or equal to n times EE.  
           [0033]    The invention also provides a one-piece, 180-degree flow turn around connector. The turn around connector has a single mounting surface having a width W and a height H, an input and output fluid-flow port on the mounting surface, and a 180-degree fluid-flow channel connecting the input and output ports. The ports have a nominal diameter D1 at the mounting surface. The centers of the ports are separated by a distance dd wherein dd is less than FF, preferably less than or equal to EE, specified in SAE standard J518 corresponding to the nominal port diameter.  
           [0034]    The width W of the mounting surface is less than or equal to twice the recommended pad width FF, preferably less than or equal to twice the minimum pad width EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. The height H is preferably equal to the dimension O specified in SAE standard J518 corresponding to the nominal diameter D1. The connector has a working pressure rating greater than or equal to the working pressure rating specified in SAE standard J518 corresponding to said nominal diameter D1.  
           [0035]    A plurality of through bores extend through each mounting surface. An annular recess is formed in the port face mounting surface proximate each fluid-flow port.  
           [0036]    The invention also provides a one-piece, 90-degree divide/combine flow connector. The divide/combine flow connector has a flange mounting surface, a port face mounting surface, a fluid-flow channel connecting the port face mounting surface and the flange mounting surface, and a plurality of through bores on the port face mounting surface. An annular recess is formed in the port face mounting surface proximate each fluid-flow port.  
           [0037]    The flange mounting surface has a width W, a height H, and a single port having a nominal diameter D1 at the first mounting surface. The port face mounting surface has a height H and two ports having a nominal diameter up to D1 at the port face mounting surface.  
           [0038]    The height H is preferably equal to the dimension O specified in SAE standard J518 corresponding to said nominal diameter D1. The center of the ports are spaced apart from one another a widthwise distance dd wherein dd is less than or equal to the width FF, preferably at least 20% smaller than the width FF, and more preferably less than or equal to EE, specified in SAE standard J518 corresponding to said nominal port diameter D1.  
           [0039]    The width W of the flange mounting surface is less than FF, preferably less than or equal to the minimum pad width EE, specified in SAE standard J518 corresponding to said nominal port diameter D1. The connector has a working pressure rating greater than or equal to the working pressure rating specified in SAE standard J518 corresponding to said nominal diameter D1.  
           [0040]    The invention also provides a one-piece, in-line divide/combine flow connector. The in-line divide/combine flow connector has a flange mounting surface having a width W, a height H, a port face mounting surface, a fluid-flow channel connecting the port face mounting surface and the flange mounting surface, a plurality of through bores on the port face mounting surface, and a plurality of threaded bores on said flange mounting surface. An annular recess is formed in the port face mounting surface proximate each fluid-flow port.  
           [0041]    The flange mounting surface has a single port having a nominal diameter D1. The port face mounting surface has a height H and two ports having a nominal diameter up to D1. The center of the ports are spaced apart from one another a widthwise distance dd wherein the width dd is less than or equal to 1⅓ times EE specified in SAE standard J518 corresponding to said nominal port diameter D1. The height H is preferably equal to the dimension O specified in SAE standard J518 corresponding to said nominal diameter D1. The connector has a working pressure rating greater than or equal to the working pressure rating specified in SAE standard J518 corresponding to said nominal diameter D1. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0042]    [0042]FIG. 1 is a front elevational view of an assembled split flanged connection in accordance with SAE standard J518 (prior art);  
         [0043]    [0043]FIG. 2 is a partial cross-sectional view taken along lines Y-Y of FIG. 1 (prior art);  
         [0044]    [0044]FIG. 3 is a schematic illustration of the port dimensions of hydraulic flanged, tube, pipe, and hose connections, four-bolt split flange type of SAE standard J518 (prior art);  
         [0045]    [0045]FIG. 4 is a perspective view of a two-bolt connector having a generally-conical reinforcement portion in accordance with an embodiment of the present invention;  
         [0046]    [0046]FIG. 5 is a cross-sectional view of the connector illustrated in FIG. 4;  
         [0047]    [0047]FIG. 5 a  is a side elevational view with a partial section of a two-bolt connector having a ribbed reinforcement portion in accordance with an embodiment of the invention;  
         [0048]    [0048]FIG. 5 b  is a side elevational view with a partial section of a two-bolt connector having an increased thickness reinforcement portion in accordance with an embodiment of the invention;  
         [0049]    [0049]FIG. 6 is a front elevational view of the connector of FIG. 4;  
         [0050]    [0050]FIG. 6 a  is a front elevational view of the connector of FIG. 5 a;    
         [0051]    [0051]FIG. 6 b  is a front elevational view of the connector of FIG. 5 b;    
         [0052]    [0052]FIG. 7 is a schematic illustration of the minimum four-bolt flange port dimensions set forth in SAE standard J518;  
         [0053]    [0053]FIG. 8 is a footprint including reference dimensions of the connector illustrated in FIG. 4;  
         [0054]    [0054]FIG. 9 is a schematic illustration of a footprint of the connector of FIG. 4 superimposed on the minimum four-bolt flange port dimensions of FIG. 7;  
         [0055]    [0055]FIG. 10 is a schematic illustration of nested footprints including referenced dimensions of the connector illustrated in FIG. 4;  
         [0056]    [0056]FIG. 11 is a schematic illustration of a footprint of the connector of FIG. 4 superimposed on the minimum four-bolt flange port dimensions of FIG. 7 rotated about the fluid-flow port central axis;  
         [0057]    [0057]FIG. 12 is a perspective view of a four-bolt connector in accordance with an embodiment of the invention;  
         [0058]    [0058]FIG. 13 is a side elevation with a partial fragmentary view of the connector illustrated in FIG. 12;  
         [0059]    [0059]FIG. 14 is a front elevational view of the connector illustrated in FIG. 12 including reference dimensions;  
         [0060]    [0060]FIG. 15 is a schematic illustration of nested footprints of the four-bolt connector illustrated in FIG. 12 including referenced dimensions;  
         [0061]    [0061]FIG. 16 is a front elevational view of a offset 90-degree, flanged connector in accordance with an embodiment of the invention;  
         [0062]    [0062]FIG. 17 is a side elevational view of the connector shown in FIG. 16;  
         [0063]    [0063]FIG. 18 is a front elevational view of an in-line 90-degree flanged connector in accordance with an embodiment of the invention;  
         [0064]    [0064]FIG. 19 is a side elevational view of the connector shown in FIG. 18;  
         [0065]    [0065]FIGS. 20, 21 and  22  are perspective views of integral Elbow, Tee and Cross modular connectors in accordance with embodiments of the invention;  
         [0066]    [0066]FIGS. 22 a ,  22   b , and  22   c  are perspective views of four-port and six-port modular connectors in accordance with embodiments of the invention;  
         [0067]    [0067]FIG. 22 d  is a perspective view of a header module in accordance with an embodiment of the invention;  
         [0068]    [0068]FIG. 22 e  is a perspective view of a junction module in accordance with an embodiment of the invention;  
         [0069]    [0069]FIGS. 23, 24,  25  are perspective views of stackable Elbow, Tee and Cross modular connectors in accordance with an embodiment of the invention;  
         [0070]    [0070]FIG. 25 a  is a perspective view of a four-port modular connector in accordance with an embodiment of the invention;  
         [0071]    [0071]FIG. 25 b  is a perspective view of a stackable header module in accordance with an embodiment of the invention;  
         [0072]    [0072]FIGS. 26, 27,  28  are perspective views of integral Elbow, Tee and Cross modular connectors in accordance with an embodiment of the invention;  
         [0073]    [0073]FIGS. 29, 30,  31  are perspective views of integral Elbow, Tee and Cross modular connectors in accordance with an embodiment of the invention;  
         [0074]    [0074]FIGS. 32 and 33 are perspective views of integral adapters in accordance with an embodiment of the invention;  
         [0075]    [0075]FIG. 34 is a top plan view of a 180-degree flow turn around flanged modular connector in accordance with an embodiment of the invention;  
         [0076]    [0076]FIG. 35 is a front elevational view of the connector shown in FIG. 34;  
         [0077]    [0077]FIG. 36 is a top plan view of a 180-degree flow turn around block modular connector in accordance with an embodiment of the invention;  
         [0078]    [0078]FIG. 37 is a front elevational view of the connector shown in FIG. 36;  
         [0079]    [0079]FIG. 38 is a top plan view of an offset flow modular block connector in accordance with an embodiment of the invention;  
         [0080]    [0080]FIG. 39 is a front elevational view of the connector shown in FIG. 38;  
         [0081]    [0081]FIG. 40 is a top plan view of an in-line divide flow/combine flow modular connector in accordance with an embodiment of the invention;  
         [0082]    [0082]FIG. 41 is a front elevational view of the connector shown in FIG. 40;  
         [0083]    [0083]FIG. 42 is a top plan view of a right angle divide flow/combined flow modular connector in accordance with an embodiment of the invention;  
         [0084]    [0084]FIG. 43 is a side elevational view of the connector shown in FIG. 42;  
         [0085]    [0085]FIG. 44 is a front elevational view of the connector shown in FIG. 42; and,  
         [0086]    [0086]FIG. 45 is a front plan view of a connector having multiple, interconnected fluid flow ports having different sizes.  
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0087]    The high-pressure, fluid-flow system of the present invention is described below with reference to FIGS.  4 - 45  wherein like reference numerals are used throughout to designate like structural elements.  
         [0088]    The one-piece, flanged connector of the present invention may have a two-bolt design  30  or a four-bolt design  130 . A first embodiment of the flanged connector of the present invention is described with reference to FIGS.  4 - 11  which show a two-bolt flanged connector designated generally by reference numeral  30 .  
         [0089]    The two-bolt, flanged connector  30  has a one-piece construction in contrast with the prior art two-piece, split-flange connector  8  illustrated in FIGS.  1 - 3 . The connector  30  is preferably manufactured from a high-strength structural material such as steel, iron, or aluminum, or composite and preferably medium carbon steel.  
         [0090]    Referring to FIGS.  4 - 6 , the connector  30  generally has an irregularly-shaped base portion, a reinforcement portion, and a connection piece. The base portion  32  has a height H and width W as best seen in FIGS. 5 and 6. The tabs  34  (described below) have a thickness T. The connection piece  36  has a length L 2  and an outer diameter D 3 . The connector has an overall length L 1 .  
         [0091]    In one embodiment, best seen in FIGS.  4 - 6 , the reinforcement portion comprises a lengthwise extending, generally-conical extension  32   b  at one end of the base. This embodiment is preferred when manufacturing small quantities of the connector  30 .  
         [0092]    When manufacturing large quantities of the connector  30 , the conical reinforcement portion is reduced in thickness in the areas  1750  indicated by hash marks in FIGS. 5 a  and  6   a , thereby forming a plurality or ribs  1732   b . In this embodiment, it is recognized that the maximum working stress does not occur in an area midway between the two mounting bolts, but rather in areas that are rotated about 40 degrees from this centrum adjacent to the mounting bolts and at the maximum widthwise portion of the extension. Therefore, the ribs  1732   b  are located in the areas shown in FIGS. 5 a  and  6   a.    
         [0093]    In a further embodiment shown in FIGS. 5 b  and  6   b , the reinforcement portion comprises an enlarged thickness T extension  1832   b  of the base portion  1832 . Due to the enlarged thickness of the base portion  1832 , and tab  1834  (described below) has a counterbore  1832   c  in the lengthwise-extending apertures  1838  to receive a fastening bolt.  
         [0094]    The reinforcement portion provides added strength to the connector  30  which is required to meet the working pressure specified in SAE standard J518. The invention is described hereinafter with reference to the embodiment disclosed in FIGS. 4, 5 and  6 .  
         [0095]    The base has a port face mounting surface  32   a  at one end. The port face mounting surface  32   a  has an annular recess  42  formed therein which is designed to receive an “O” ring which seals the connector  30  on a desired port face  24 .  
         [0096]    The connector  30  has a generally-cylindrical connection piece  36  fixed to and extending from the narrow or tapered end of the conical extension  32   b . The connection piece  36  is designed to interconnect with a variety of elements such as a tube extension, hose, or pipe. The length L 2  of the connection piece  36  can be varied depending on the intended element to which the connector is attached. The connection piece  36  may have a threaded outer or other surface for releasable interconnection with the desired tube, pipe, hose or the like. Alternatively, the connection piece is permanently fastened to a tube, pipe, hose, or the like by, for example, brazing, welding or swaging.  
         [0097]    A central, elongate cylindrical channel extends lengthwise through the connector  30 . As shown in FIG. 5, the central channel has a uniform diameter D1along its length. However, the diameter of the channel may be varied along its length if desired. The channel has ports  40  at the port face mounting surface  32   a  and the end of the connection piece  36 .  
         [0098]    The connector  30  has a plurality of tabs  34  fixed to and extending outwardly from the base portion  32 . In the embodiment illustrated in FIGS.  4 - 6 , the connector has two tabs  34  diametrically opposed from one another. Each tab  34  has a lengthwise-extending aperture  38  extending therethrough. Each aperture  38  is designed to align with a threaded bore  22  in the port face surrounding the fluid-flow port  6 . Referring to FIG. 6, the tabs have a flat surface or spot face  34   a  on which the heads of fastening bolts are torqued. The conical extension  32   b  has semi-circular cut-outs  32   c  in the area proximate the apertures  38  to provide clearance for the fastening bolt heads.  
         [0099]    The dimensions of the connector  30  are described below in Tables IA and IB. The dimensions of the connector  30  are selected such that the tab apertures  38  align with the threaded bores  22  in the port face  24  and such that the central port  40  aligns with the fluid-flow port  6 . Thus, the dimensions of the connector  30  are dictated in part by the port dimensions specified in SAE standard J518. However, the width W (2×R1) of the connector  30  has been reduced in accordance with the present invention to be equal to or smaller than the minimum pad width EE specified in SAE standard J518.  
                                                                                                     TABLE IA                           (English)       TWO-BOLT CONNECTOR SPECIFICATIONS            Nominal                   Flange           Maximum       Size   Foot Print Dimensions   Bolt   Working            D1   Z   R1   R2   T   D2   Size   Pressure       (in.)   (in.)   (in.)   (in.)   (in.)   (in.)   U.S.   (p.s.i.)                     ⅛   .750   .296   .156   .250   .180   #8-32NC   12,000        ¼   .875   .359   .188   .312   .205   #10-24NC   10,000        ⅜   1.125   .422   .203   .375   .281   ¼-20NC   8,500        ½   1.650   .640   .297   .500   .343   {fraction (5/16)}-18NC   5,000        ¾   2.070   .797   .325   .563   .406   ⅜-16NC   5,000       1   2.305   .922   .406   .625   .406   ⅜-16NC   5,000       1-¼   2.600   1.046   .375   .625   .469   {fraction (7/16)}-14NC   4,000       1-½   3.088   1.235   .437   .625   .531   ½-13NC   3,000       2   3.496   1.484   .437   .625   .531   ½-13NC   3,000                  
 
         [0100]    [0100]                                                                                                     TABLE IB                           (Metric)       TWO-BOLT CONNECTOR SPECIFICATIONS            Nominal                   Flange           Maximum       Size   Foot Print Dimensions   Bolt   Working            D1   Z   R1   R2   T   D2   Size   Pressure       (mm)   (mm)   (mm)   (mm)   (mm)   (mm)   Metric   (p.s.i.)                    3.2   19   7.5   4   6.4   4.5   M4-.7   12,000       6.4   22.2   9.1   4.8   7.9   5.6   M5-.8   10,000       9.5   28.6   10.7   5.2   9.5   6.8   M6-1   8,500       12.7   41.9   16.3   7.5   12.7   8.75   M8-1.25   5,000       19   52.6   20.2   8.3   14.3   10.5   M10-1.5   5,000       25   58.5   23.4   10.3   15.9   10.5   M10-1.5   5,000       31.7   66   26.6   9.5   15.9   12.5   M12-1.75   4,000       38   78.4   31.4   11.1   15.9   14.5   M14-2   3,000       50.8   88.8   37.7   11.1   15.9   14.5   M14-2   3,000                    
         [0101]    For example, the minimum pad width EE for a ½ inch flange connector according to SAE standard J518 is 1.31 inches. The width W of applicant&#39;s ½″ connector  30  is 1.28 inches (2×0.640 inches (R1)).  
         [0102]    The four-bolt flange minimum pad size of SAE standard J518 is illustrated in FIG. 7 wherein the various dimensions are identified by reference letters. For comparison, the dimensions (footprint) of the connector  30  are illustrated in FIG. 8 relative to the corresponding SAE standard J518 reference letter. Referring to FIG. 9, the footprint of FIG. 8 is shown superimposed on the pad of FIG. 7. FIG. 9 illustrates how the connector  30  fits within the minimum pad width EE set forth in SAE standard J518 and properly aligns with the threaded bores  22  and fluid-flow port  6 .  
         [0103]    Referring to FIG. 9, it can be seen that the radius R2 projects slightly above the port pad dimension O. This projection, however, is not great enough to cause any interference when the connectors are nested (described below) and mounted on ports that meet the minimum dimension BB of SAE standard J518.  
         [0104]    Because the width W of the connector  30  is reduced, and because of its unique geometry, the minimum spacing between adjacent fluid-flow ports  6  can be reduced compared to the prior art dimensions BB, CC, and DD. FIG. 10 illustrates how the connectors  30  can be nested to reduce the minimum port dimensions bb, cc, and dd between two-bolt flange connectors  30  of the present invention. A comparison of the minimum port dimensions BB, CC and DD of SAE standard J 518  and the reduced port dimensions bb, cc and dd of the two-bolt flange connector of the present invention is shown in Table II.  
                                                               TABLE II                           SAE Standard J518 Recommended Port Dimensions BB, CC, DD       vs. Reduced Port Dimensions bb, cc, dd of Two-Bolt Invention            Nominal                   Size   BB vs bb   CC vs cc   DD vs dd       (in.)   (in.)   (in.)   (in.)                     ⅛   XXX   0.906   XXX   0.844   xxx   0.625        ¼   XXX   1.031   XXX   1.000   XXX   0.750        ⅜   XXX   1.218   XXX   1.203   XXX   0.875        ½   2.22   1.765   2.06   1.843   1.91   1.312        ¾   2.66   2.093   2.41   2.343   2.16   1.625       1   2.84   2.343   2.62   2.531   2.41   1.875       1 ¼   3.22   2.531   3.09   2.796   2.97   2.125       1 ½   3.78   2.984   3.56   3.296   3.34   2.500       2   4.09   3.328   4.00   3.734   3.91   3.000                          
 
         [0105]    It can be readily seen that the connector  30  of the present invention enables one of ordinary skill in the art to design a fluid-flow system having a more compact design compared to the prior art since the fluid-flow ports  6  can be arranged much closer than the comparable ports for a four-bolt, split-flange connector as taught in SAE standard J518. One knowledgeable in the art will easily recognize the advantages of this reduced size.  
         [0106]    Referring to FIG. 11, it can be seen that the two-bolt flange connector  30  of the present invention can be rotated around the fluid-flow port  6  central axis to avoid tapped holes from intercepting with fluid flow passages as well as to avoid two-bolt flange installment interference.  
         [0107]    The two-bolt flange  30  of the present invention provides not only reduced port dimensions bb, cc, and dd compared to the dimensions specified in SAE standard J518, but also satisfies the strength requirements specified in SAE standard J518. Table I also shows that the maximum working pressure for the two-bolt connector  30  of the present invention meets or exceeds the maximum working pressure specified in Code 61 of SAE standard J518. For example, the maximum working pressure for the ½ inch, ¾ inch, and 1 inch, connectors of the present invention is 5,000 p.s.i. The maximum working pressure for the ⅛ inch, ¼ inch, and ⅜ inch connectors is even higher. Thus, many sizes of the two-bolt connector  30  of the present invention meet or exceed not only the working pressure specified in Code 61 (standard pressure series) but also Code 62 (high pressure series) specified in SAE standard J518 for four-bolt connectors.  
         [0108]    Further, the connector  30  meets or exceeds the working pressure specified in Code 61 with only a two-bolt design versus the four-bolt design specified in SAE standard J518. One knowledgeable in the art will easily recognize the advantages of a two-bolt design which include easier installation and manufacture.  
         [0109]    As described above, the flange  30  is preferably made of a high strength structural material so that the flange  30  meets or exceeds the working pressure rating specified in SAE standard J518. However, it should be appreciated that the flange  30  can also be used in low pressure systems requiring a compact design. In such applications, the flange can be made of a low strength material such as plastic.  
         [0110]    A further embodiment of the flanged connector of the present invention is illustrated with reference to FIGS.  12 - 15  which show a four-bolt flanged connector designated generally by reference numeral  130 .  
         [0111]    The four-bolt, flanged connector  130  has a one-piece construction in contrast with the prior art two-piece, split-flange connector  8  illustrated in FIGS.  1 - 3 . Similar to the two-bolt, flanged connector  30  described above, the connector  130  is preferably manufactured from a high-strength structural material such as steel, iron, aluminum, or composite preferably medium carbon steel.  
         [0112]    Referring to FIGS.  12 - 14 , the connector  130  has a rectangular base portion  132 , a reinforcement portion, and a generally-cylindrical connection piece  136 . The base portion  132  has a height H and width W as best seen in FIGS. 13 and 14. The tabs (described below) have a thickness T. The connection piece  136  has a length L 2  and outer diameter D3. The connector has an overall length L 1 .  
         [0113]    The base portion  132  has a lengthwise-extending, generally conical extension  132   b  at one end and a generally-flat, port face mounting surface  132   a  at the other end. The port face mounting surface  132   a  has an annular recess  142  which is designed to receive an “O”-ring which seals the connector  130  on a desired port face  24 . In the embodiment shown in FIGS.  12 - 14 , the reinforcement portion is a generally-conical extension  132   b  which provides added strength to the connector  130  which is required to meet the working pressure specified in SAE standard J518. Similar to the two-bolt design described above, the reinforcement portion may alternatively have the ribbed design or increased thickness design shown in FIGS. 5 a ,  6   a ,  5   b ,  6   b , respectively.  
         [0114]    The connector  130  has a generally-cylindrical connection piece  136  fixed to and extending from the narrow or tapered end of the conical extension  132   b . The connection piece  136  is designed to interconnect with a variety of elements such as a tube extension, hose, or pipe. The length L 2  of the connection piece  136  can be varied depending on the intended element to which the connector is attached. The connection piece  136  may have a threaded or other outer surface for releasable interconnection with the desired tube, pipe, hose or the like. Alternatively, the connection piece  136  may be permanently fixed to a tube, pipe, hose or the like by, for example, brazing, welding or swaging.  
         [0115]    A central, elongate cylindrical channel extends lengthwise through the connector  130 . As shown in FIG. 13, the central channel has a uniform diameter D1 along its length. However, the diameter of the channel may be varied along its length if desired. The channel has ports  140  on the port face mounting surface  132   a  and the end of the connection piece  136 .  
         [0116]    The connector  130  has four tabs  134  fixed to and extending outwardly from the base portion  132 . In the embodiment illustrated in FIGS.  12 - 14 , the connector has a pair of tabs on opposed height-wise ends of the base. Each tab has a lengthwise-extending aperture  138  extending therethrough. Each aperture  138  is designed to align with a threaded bore  22  in the port face  24  surrounding the fluid-flow port  6 . Referring to FIG. 14, the tabs have a flat surface or spot face  134   a  on which the heads of fastening bolts are torqued. The conical extension  132   b  has semi-circular cut-outs  132   c  in the area proximate the apertures  138  to provide clearance for the fastening bolt heads.  
         [0117]    The dimensions of the four-bolt connector are described below in Tables IIIA and IIIB. The dimensions of the connector  130  are selected such that the tab apertures  138  align with the threaded bores  22  in the port face  24  and such that the central port  140  aligns with the fluid-flow port  6 . Thus, the dimensions of the connector  130  are dictated in part by the port dimensions specified in SAE standard J518. However, the width W of the connector  130  has been reduced in accordance with the present invention to be equal to or smaller than the minimum pad width EE specified in SAE standard J518.  
                                                                                                             TABLE IIIA                           (English)       Four-Bolt Connector Specifications            Nominal                   Flange           Maximum       Size (in.)   Foot Print Dimensions   Bolt   Working            D1   Q   GG   W   R2   T   D2   Size   Pressure       (in.)   (in.)   (in.)   (in.)   (in.)   (in.)   (in.)   U.S.   (p.s.i.)                     ⅛   0.696   0.278   0.594   0.156   0.250   0.180   #8-32NC   12,000 psi         ¼   0.804   0.344   0.719   0.187   0.312   0.205   #10-24NC   11,000 psi         ⅜   1.038   0.430   0.844   0.203   0.375   0.281   ¼-20NC   8,500 psi        ½   1.500   0.688   1.281   0.297   0.500   0.343   {fraction (5/16)}-18NC   6,000 psi        ¾   1.875   0.875   1.594   0.325   0.562   0.406   ⅜-16NC   6,000 psi       1   2.062   1.031   1.844   0.406   0.625   0.406   ⅜-16NC   6,000 psi       1-¼   2.312   1.188   2.093   0.375   0.625   0.469   {fraction (7/16)}-14NC   6,000 psi       1-½   2.750   1.406   2.469   0.437   0.625   0.531   ½-13NC   6,000 psi       2   3.062   1.688   2.969   0.437   0.625   0.531   ½-13NC   6,000 psi                  
 
         [0118]    [0118]                                                                                                             TABLE IIIA                           (Metric)       Four-Bolt Connector Specifications            Nominal                   Flange           Maximum       Size (in.)   Foot Print Dimensions   Bolt   Working            D1   Q   GG   W   R2   T   D2   Size   Pressure       (mm)   (mm)   (mm)   (mm)   (mm)   (mm)   (mm)   Metric   (p.s.i.)                     ⅛   17.68   7.06   15   3.2   6.4   4.5   M4-7   12,000 psi         ¼   20.42   8.73   18.2   4.8   7.9   5.6   M5-8   11,000 psi         ⅜   26.36   10.92   21.4   5.2   9.5   6.8   M6-1   8,500 psi        ½   38.1   17.47   32.5   7.5   12.7   8.75   M8-1.25   6,000 psi        ¾   47.63   22.22   40.5   8.3   14.3   10.5   M10-1.5   6,000 psi       1   52.37   26.19   46.8   10.3   15.9   10.5   M10-1.5   6,000 psi       1-¼   58.73   30.18   53.1   9.5   15.9   12.5   M12-1.75   6,000 psi       1-½   69.85   35.71   62.7   11.1   15.9   14.5   M14-2   6,000 psi       2   77.77   42.87   75.4   11.1   15.9   14.5   M14-2   6,000 psi                    
         [0119]    For example, the minimum pad width EE for a ½ inch flange connector according to SAE standard J518 is 1.31 inches. The width W of applicant&#39;s ½ inch connector 130 is 1.281 inches.  
         [0120]    The four-bolt flange minimum pad size of SAE standard J518 is illustrated in FIG. 7 wherein the dimensions are identified by reference letters. For comparison, the dimensions of the connector  130  are illustrated in FIG. 14 relative to the corresponding SAE standard J518 reference letter. FIG. 14 shows that the connector  130  will fit within the minimum pad width EE set forth in SAE standard J518 and will properly align with the threaded bores  22  and fluid-flow port  6 .  
         [0121]    Because the width W of the connector  130  is reduced, the minimum spacing between adjacent fluid-flow ports  6  can be reduced compared to the prior art dimensions CC and DD of SAE standard J518. FIG. 15 illustrates how the connectors  130  can be nested to reduce the minimum port dimensions cc and dd between four-bolt flange connectors  130  of the present invention. A comparison of the minimum port dimensions CC and DD of SAE standard J518 and the reduced port dimensions cc and dd of the four-bolt flange connector  130  of the present invention is shown in Table IV.  
                                                                   TABLE IV                           SAE Standard J518 Recommended Port Dimensions vs.       Reduced Port Dimensions of Four-Bolt Invention                Nominal Size   CC vs. cc       DD vs. dd               (in.)   (in.)       (in.)                            ⅛   XXX   0.875   XXX   0.625           ¼   XXX   1.031   XXX   0.750           ⅜   XXX   1.234   XXX   0.875           ½   2.062   1.718   1.906   1.312           ¾   2.406   2.094   2.156   1.625           1   2.625   2.312   2.406   1.875           1¼   3.093   2.625   2.968   2.125           1½   3.562   3.094   3.344   2.500           2   4.000   3.500   3.906   3.00                                  
 
         [0122]    Since the connector  130  of the present invention has a more compact design compared to the prior art, the fluid flow ports  6  can be arranged much closer than the comparable ports for a four-bolt split flange connector as taught in SAE standard J518. One knowledgeable in the art will easily recognize the advantages of this reduced size.  
         [0123]    The four-bolt flange connector  130  of the present invention provides not only reduced port dimensions cc and dd compared to the dimensions specified in SAE standard J518, but also satisfies the strength requirements specified in SAE standard J518. Table III shows that the maximum working pressure for the four-bolt connector  130  of the present invention meets or exceeds the maximum working pressure specified in both Code 61 and Code 62 of SAE standard J518. For example, the maximum working pressure for the ½ inch, ¾ inch, 1 inch, 1¼ inch, 1½ inch, and 2 inch connectors is 6,000 p.s.i. The maximum working pressure for the ⅛ inch, ¼ inch, and ⅜ inch connectors  130  is 12,000, 11,000, and 8,5000 p.s.i. respectively. Thus, the four-bolt connector  130  of the present invention meets or exceeds not only the standard pressure series Code 61 but also the high pressure series Code 62 specified in SAE standard J518 for four-bolt connectors.  
         [0124]    Tables I-IV list several embodiments of the connectors of the present invention. The embodiments listed in tables I-IV correspond to a range of port diameters common in the industry. However, the connectors of the present invention are not limited to the sizes recited therein. One of ordinary skill in the art will readily recognize that the connectors  30  and  130  can be made in each of the sizes specified in SAE standard J518 and achieve each of the above-described objects of the invention.  
         [0125]    FIGS.  16 - 17  illustrate an offset 90-degree, flanged connector  230 . FIGS.  18 - 19  illustrate an in-line 90-degree flanged connector  330 . Similar to the two-bolt connector  30  described above, both 90-degree flanged connectors  230 / 330  have a one-piece design. (A slash / is used herein to separate reference numerals designating respective similar elements of different embodiments.) The connectors  230 / 330  have an irregularly-shaped base portion  232 / 332  having a lengthwise extending, generally-conical extension (reinforcement portion)  232   b / 332   b  at one end and a generally-flat, port face mounting surface  232   a / 332   a  at the other end. The port face mounting surface  232   a / 332   a  has an annular recess  242 / 342  formed therein which is designed to receive an O-ring which seals the connector  230 / 330  on a desired port face  24 .  
         [0126]    The 90-degree flanged connectors  230 / 330  have a connection piece  236 / 336  fixed to and extending from the narrow or tapered end of the conical extension  232   b / 332   b . The connection piece  236 / 336  is designed to interconnect with a variety of elements such as a tube extension, hose, or pipe.  
         [0127]    In contrast with the connector  30  described above, the connection piece  236 / 336  of the connectors  230 / 330  bends 90-degrees to change the fluid flow direction without requiring additional fittings. The connectors  230 / 330  otherwise have the same construction and dimensions as the two-bolt connector  30  described above. Specifically, the dimensions of the 90-degree connectors  230 / 330  are selected such that the flange apertures  238 / 338  align with threaded bores  22  in the port face  24  and such that the central port  240 / 340  aligns with the fluid-flow port  6 .  
         [0128]    Additionally, the width W of the connectors  230 / 330  is reduced to be equal to or smaller than the minimum pad width EE specified in SAE standard J518. The connectors  230 / 330  also satisfy the strength requirements specified in SAE standard J518 with only a two-bolt design verses the four-bolt design specified in SAE standard J518.  
         [0129]    Modular connectors in accordance with embodiments of the invention are illustrated in FIGS.  20 - 44 . Unless otherwise indicated, the height H of each of the modular connectors shown in FIGS.  20 - 44  is preferably equal to the dimension O specified in SAE standard J518. Each of the modular connectors has a working pressure rating greater than or equal to the working pressure rating specified in SAE standard J518 corresponding to the nominal diameter D 1  of the fluid-flow port.  
         [0130]    FIGS.  20 - 22  illustrate one-piece, block, fluid-flow connectors for connecting two or more two-bolt flanged connectors  30  (such as described above). The block connectors  400 / 440 / 480  have a plurality of mounting surfaces, each mounting surface having a width W and height H. A fluid flow channel extends from one mounting surface to each of the other mounting surfaces. The channel has ports  402 / 442 / 482  on each surface. The fluid-flow ports have a nominal diameter D 1  at the mounting surfaces. A plurality of threaded bores  406 / 446 / 486  are located on each mounting surface for fastening a flanged connector to the mounting surface. In the embodiments illustrated in FIGS.  20 - 22 , each connector has at least two mounting surfaces having a width W 1 , W 2 , each of which is less than FF, preferably less than or equal to the minimum pad width EE, specified in SAE standard J518 corresponding to the nominal port diameter D1.  
         [0131]    [0131]FIG. 20 illustrates an Elbow modular connector  400  in accordance with an embodiment of the invention. The Elbow connector  400  has a single-piece, block construction with a central channel extending therethrough. The central channel extends inwardly from a first mounting surface  404   a , bends 90-degrees, and exits through a second mounting surface  404   b . The connector  400  has a pair of threaded bores  406  diagonally located on opposed sides of the channel ports  402 .  
         [0132]    [0132]FIGS. 21 and 22 illustrate modular Tee  440  and Cross  480  connectors, respectively, in accordance with an embodiment of the invention. The Tee  440  and Cross  480  connectors have a construction similar to the Elbow connector  400  but have additional mounting surfaces  444   c / 484   c / 484   d  and a differently shaped fluid-flow channel. The shape of the fluid-flow channel of each connector is illustrated graphically in FIGS.  20 - 31  by fluid-flow lines on the top of or above each connector.  
         [0133]    The elbow connector  400  has two mounting surfaces having a width W 1 , W 2 . The Tee connector  400  has three mounting surfaces having a width W 1 , W 2 , W 3 . The Cross connector  480  has four mounting surfaces having a width W 1 , W 2 , W 3 , W 4 .  
         [0134]    Flanged two-bolt connectors  30 , such as described above, can be mounted on each mounting surface  404   a , 404   b / 444   a , 444   b , 444   c / 484   a , 484   b , 484   c , 484   d  of the Elbow  400 , Tee  440 , and Cross  480  connectors, respectively, by inserting socket head bolts through the connector tabs  34  and into the threaded bores  406 / 446 / 486 .  
         [0135]    FIGS.  20 - 22  illustrate that the width of each mounting surface of the connectors  400 / 440 / 480  is less than the recommended pad width FF established in SAE standard J518. Preferably, the width of each mounting surface is equal to EE, the minimum pad width specified in SAE standard J518 corresponding to the nominal diameter D 1  of the central port  402 / 442 / 482 . The mounting surface width may be less than EE provided the width of the mating flange connector  30  is less than the width of the mounting surface, thereby maintaining a widthwise differential between the mounting surface and the flange connector.  
         [0136]    [0136]FIGS. 22 a ,  22   b , and  22   c  illustrate further embodiments of the block, fluid-flow connectors for connecting two or more flanged connectors (such as described above). The block connectors  700 / 720 / 740  have a construction similar to the above-described connectors  400 / 440 / 480 . However, the connectors  700 / 720 / 740  have a top mounting surface  704   c / 724   c / 744   c  and a bottom mounting surface  704   d / 724   d / 744   d . FIGS. 22 a  and  22   b  show different embodiments of a four-port block connector while FIG. 22 c  shows a six-port block connector.  
         [0137]    [0137]FIGS. 22 a ,  22   b , and  22   c  show the dimensions of the connectors relative to the dimension EE. FIGS. 22 a ,  22   b , and  22   c  show that the width W 1  must be wider than EE.  
         [0138]    [0138]FIG. 22 d  illustrates a further embodiment of the block, fluid-flow connector for connecting two or more flanged connectors  30  (such as described above). FIG. 22 d  illustrates a header module onto which multiple connectors may be fastened and interconnected by a common fluid-flow channel  762 . The header module  760  illustrated in FIG. 22 d  has a plurality of mounting surfaces, each mounting surface having a width W and a height H. The fluid-flow channel extends from the first mounting surface  764   a  to each of the other mounting surfaces  764   b - d . The channel has ports on two of the mounting surfaces  764   a ,  764   b  and multiple (n) ports on the other two mounting surfaces  764   c ,  764   d . The fluid-flow ports have a nominal diameter D 1  at the mounting surfaces. A plurality of threaded bores  766  are located on each mounting surface proximate each fluid-flow port  762 .  
         [0139]    In the embodiment illustrated in FIG. 22 d , the header module  760  has two mounting surfaces  764   a ,  764   b  having a width W 1  which is less than FF, and preferably less than or equal to the minimum pad width EE, specified in SAE standard J518 corresponding to the nominal port diameter D1. The other mounting surfaces  764   c ,  764   d  have a width W 2  and a height H. The width W 2  of the header module  760  is less than or equal to three times dd which the widthwise distance between the port centers. The dimension dd is less than FF, and preferably less than or equal to EE specified in SAE standard J518 corresponding to the nominal port diameter. The header module  760  may, however, be provided with a different number n of fluid-flow ports  762  on the multiple port mounting surfaces  764   c ,  764   d . In that case, the width W 2  of the header module  760  would be less than or equal to n times dd. The dimension dd may be less than EE provided that the width W of the flanged connector  30  attached thereto is less than the dimension dd.  
         [0140]    [0140]FIG. 22 e  illustrates a further embodiment of the block, fluid-flow connector for connecting two or more flanged connectors  30  (such as described above). FIG. 22 e  illustrates a junction module  780  to which multiple connectors can be attached to multiple, independent (unconnected) fluid-flow ports  782   a - d . The junction module  780  has a plurality of mounting surfaces  784   a - d . Independent fluid flow channels  782   a - d  extend from one mounting surface to each of the other mounting surfaces. The channels have ports on each of the mounting surfaces, respectively. The fluid-flow ports have a nominal diameter D 1  at the mounting surfaces. A plurality of threaded bores  786  are located on each mounting surface proximate each fluid-flow port. In the embodiment illustrated in FIG. 22 e , each mounting surface has a width W 2  equal to four times dd. In this embodiment, the dimension dd is preferably equal to the dimension O specified in SAE standard J518 corresponding to the nominal port diameter D1. However, the width W 1  and the height H are each less than FF, preferably less than or equal to the minimum pad width EE, specified in SAE standard J518.  
         [0141]    FIGS.  23 - 25  illustrate stackable, one-piece, Elbow  420 , Tee  460  and Cross  500 , fluid flow connectors for connecting one or more flanged connectors (such as described above) to a port face. The stackable block connectors  424   c / 464   c / 504   c  have at least one flange mounting surface, a port face mounting surface  424   a / 464   a / 504   a , and a stacking surface  464   b / 504   b  opposite the port face mounting surface. An additional block connector can be fastened to or “stacked” on the stacking surface  464   b / 504   b  of the Tee and Cross connectors after the first block connector has been fastened to the port face. Each surface of the block connector has a width W and a height H. In the embodiments illustrated in FIGS.  23 - 25 , the width W of the mounting surfaces is less than FF, preferably less than or equal to the minimum pad width EE, corresponding to the nominal port diameter D1.  
         [0142]    A fluid-flow channel  422 / 462 / 502  extends from the port face mounting surface  424   a / 464   a / 504   a  to each of the mounting surfaces  424   c / 464   c / 504   c ,  504   d . The fluid flow channel also extends to the stacking surface  464   b / 504   b  of the Cross and Tee connectors. The channel has ports on each surface. The fluid-flow ports have a nominal diameter D 1  at the port face mounting surface and at each of the mounting surfaces.  
         [0143]    A plurality of threaded fastening bores  426 / 466 / 506  are located on each mounting surface for fastening a flanged connector to the mounting surface. A plurality of threaded fastening bores  466 / 506  are also located on the stacking surface of the Cross and Tee connectors for fastening or stacking another block connector or the stacking surface.  
         [0144]    In contrast with the connectors  400 / 440 / 480  described above, the connectors  420 / 460 / 500  have a designated port face mounting surface  424   a / 464   a / 504   a  having an annular recess  423 / 463 / 503  formed therein designed to receive an “O” ring which seals the block connector on a desired port face  24 . The connector  420 / 460 / 500  has a pair of through bores  427 / 467 / 507  extending from the stacking surface to the port face mounting surface. The through bores are diagonally located on opposed sides of the central port. The bores  427 / 467 / 507  have a counterbore  429 / 469 / 509  on the stacking surface  424   b / 464   b / 504   b . When fastening bolts are inserted through the bores  427 / 467 / 507 , the bolt heads fit within the counterbores  429 / 469 / 509 . A two-bolt flanged connector  30  or modular connector such as described above can then be fastened to or “stacked” on the stacking surface  464   b / 504   b  by inserting socket head bolts into the threaded bores  426 / 466 / 506 . Two-bolt flanged connectors  30  can also be mounted on the mounting surfaces  464   c / 504   c , 504   d  of the Tee and Cross connectors, respectively, which also have threaded bores  466 / 506  diagonally located on opposed sides of the each port.  
         [0145]    FIGS.  23 - 25  illustrate that the port face mounting surface in these embodiments is wider than the dimension EE. Otherwise, the threaded bores  426 / 466 / 506  and the through bores  427 / 467 / 507  would intersect and interfere with one another. However, the mounting surfaces  424   c / 464   c / 504   c , 504   d  which are perpendicular to the port face mounting surface  424   a / 464   a / 504   a  have a width less than the recommended pad width FF established in SAE standard J518. Preferably, the width of the mounting surfaces  424   c / 464   c / 504   c , 504   d  is equal to EE, the minimum pad width specified in SAE standard J518 corresponding to the nominal diameter D1. The mounting surface width may be less than EE provided the width of the mating flange connector  30  is less than the width of the mounting surface, thereby maintaining a widthwise differential between the mounting surface and the flange connector.  
         [0146]    [0146]FIG. 25 a  illustrates a further embodiment of a stackable, fluid-flow connector for connecting one or more flanged connectors  30  (such as described above) to a port face. The block connector  790  has a construction similar to the above-described stackable connectors  420 / 460 / 500 . However, the connector  790  has a top mounting surface  794   d.    
         [0147]    [0147]FIG. 25 a  shows the dimensions of the connector relative to the dimensions EE and O. FIG. 25 a  shows that the width of the port face mounting surfaces  794   a  and the stacking surface  794   b  must be wider than EE so that the threaded fastening bores  796  and the through bores  797  do not intersect and interfere with one another.  
         [0148]    [0148]FIG. 25 b  illustrates a further embodiment of the block, fluid-flow connector for connecting two or more flanged connectors  130  (such as described above). FIG. 25 b  shows a “stackable” header module  800  on which multiple four-bolt connectors  130  can be fastened and interconnected with a common fluid-flow channel. The header module  800  has a port face mounting surface  804   a , a stacking surface  804   c , and a mounting surface  804   b . An additional block connector can be fastened to or “stacked” on the stacking surface  804   c . Each surface of the block has a width W and a height H.  
         [0149]    A common fluid-flow channel  802  extends from the port face mounting surface  804   a  to the stacking surface  804   c  and multiple ports on the mounting surface  804   b . The fluid-flow ports have a nominal diameter D1 at the port face mounting surface  804   a , the mounting surface  804   b , and the stacking surface  804   c.    
         [0150]    A plurality of threaded fastening bores  806  are located on each surface proximate each port. In the embodiment illustrated in FIG. 25 b , the port face mounting surface has a width W 1  which is greater than the dimension EE so that the threaded fastening bores  806  and the through bores  807  do not intersect and interfere with one another. The mounting surface  804   b  has a width W 2  which is less than or equal to two times dd. In this embodiment, the dimension dd is less than FF, and preferably less than or equal to the dimension EE corresponding to the nominal diameter D1.  
         [0151]    The two-bolt block connectors are illustrated and described above as “right-hand” connectors since the two threaded fastening bores, e.g.  406 ,  446 ,  726 , are located in the upper right corner and lower left corner of each mounting surface. However, it should be appreciated that the connector  30  can be “left-handed” with fastening bores in the upper left and lower right corners.  
         [0152]    FIGS.  26 - 28  illustrate Elbow  410 , Tee  450 , and Cross  490  modular connectors designed to connect with the flanged four-bolt connectors  130  described above. The Elbow connector  410  has a single-piece, block construction with a central channel  412  extending therethrough. The central channel extends inwardly from a first mounting surface  414   a , bends 90-degrees, and exits through a second mounting surface  414   b . The channel has ports on each mounting surface. The connector  410  has two pair of threaded bores  416  diagonally located on opposed sides of the each port  412 . The Tee  450  and Cross  490  connectors have a construction similar to the Elbow connector  410  but have additional mounting surfaces and a differently shaped fluid-flow channel. Flanged four-bolt connectors  130  can be mounted on the mounting surfaces  414   a , 414   b / 454   a , 454   b , 454   c / 494   a , 494   b , 494   c , 494   d  of the Elbow  410 , Tee  450 , and Cross  490  connectors, respectively, by inserting socket head bolts through the connector tabs  134  and into the threaded bores  416 ,  456 ,  496 .  
         [0153]    FIGS.  26 - 28  illustrate that the width of at least one mounting surface  414   a / 454   a / 494   a , 494   d  is less than the recommended pad width FF established in SAE standard J518. Preferably, the width of the mounting surfaces  414   a / 454   a / 494   a , 494   d  is equal to EE, the minimum pad width specified in SAE standard J518 corresponding to the nominal diameter of the central port. The mounting surface width may be less than EE provided the width of the mating flanged connector  130  is less then the width of the mounting surface, thereby maintaining a widthwise differential between the mounting surface and the flange connector.  
         [0154]    FIGS.  26 - 28  also illustrate that the other mounting surfaces  414   b / 454   b , 454   c / 494   d , 494   c  are wider than the dimension EE. Otherwise, the threaded bores  416 / 456 / 496  would intersect and interfere with one another. Therefore, additional widthwise material must be provided to prevent interference.  
         [0155]    FIGS.  29 - 31  illustrate Elbow  430 , Tee  470 , and Cross  510  modular connectors which can be “stacked” and connected to one or more four-bolt connectors  130  described above. In contrast with the connectors  410 / 450 / 490  described above, the connectors  430 / 470 / 510  have a designated port face mounting surface  434   a / 474   a / 514   a  having an annular recess  433 / 473 / 513  formed therein designed to receive an “O” ring which seals the block connector on a desired port face  24 .  
         [0156]    The connectors  430 / 470 / 510  have two pairs of through bores  437 / 477 / 517  diagonally located on opposed sides of the port  432 / 472 / 512 . A four-bolt flanged connector  130  or additional block connector can be fastened to or “stacked” on the stacking surface  474   b / 514   b  by inserting fastening bolts through the through bores  477 / 517 , and into threaded bores on a desired port face  24 . Four-bolt flanged connectors  130  can also be mounted on the mounting surfaces  434   c / 474   c / 514   c , 514   d  which have threaded bores  436 / 476 / 516  diagonally located on opposite sides of the port  432 / 472 / 512 .  
         [0157]    FIGS.  29 - 31  illustrate that the width W 2  of the mounting surfaces  434   c / 474   c / 514   c , 514   d  is less than the recommended pad width FF established in SAE standard J518. Preferably, the width of the mounting surfaces  434   c / 474   c / 514   c , 514   d  is equal to EE but may be less than EE provided the width of the mating flange connector  130  is less than the width W 2  of the mounting surface. FIGS.  29 - 31  also illustrate that the port face mounting surface  434   a / 474   a / 514   a  is wider than the dimension EE. Otherwise, the through bores  437 / 477 / 517  and the threaded bores  436 / 476 / 516  would intersect and interfere with one another.  
         [0158]    [0158]FIGS. 32 and 33 illustrate adapters in accordance with an embodiment of the invention. The adapters  520 / 540  are used to retain two-bolt or four-bolt sandwich modules and provide a two-bolt flange port for adding new components to the fluid-flow circuit. The adapters  520 / 540  are also used to adapt to the alternate two-port tapped locations.  
         [0159]    The adapters  520 / 540  have a single-piece, block construction with a central port  522 / 542  extending therethrough. The central port  522 / 542  extends through the adapter from a port face mounting surface  524   a / 544   a  to a mounting surface  524   b / 544   b . Each adapter  520 / 540  has a pair of threaded bores  526 / 546  diagonally located on opposed sides of the central port.  
         [0160]    The adapters also include a pair of through bores  527 / 547  diagonally located on opposed sides of the central port and extending entirely through the adapters  520 / 540 . One end of the aperture has an enlarged-diameter counterbore  527   a / 547   a  formed in one of the port face mounting surfaces  524   b / 544   b.    
         [0161]    FIGS.  34 - 44  illustrate further connectors in accordance with the present invention. FIGS.  34 - 35  illustrate a 180-degree flow turn around flanged modular connector  560 . FIGS.  36 - 37  illustrate a 180-degree flow turn around block modular connector  580 .  
         [0162]    The one-piece, 180-degree flow turn around connectors  560 / 580  have a single port face mounting surface  564 / 584  having a width W and a height H. Input and output fluid-ports are located on the port face mounting surface and a 180-degree fluid-flow channel  562 / 582  connects the input and output ports. The ports have a nominal diameter D 1  at the port face mounting surface.  
         [0163]    The flanged connector  560  has a height H which is slightly larger than O. The block connector  580  has a height H which is less than or equal to O.  
         [0164]    Each connector  560 / 580  has a pair of through bores  567 / 587  diagonally located on opposed sides of the input port and output port. The through bores  567 / 587  receive bolts for mounting the connectors  560 / 580  to a port face.  
         [0165]    FIGS.  34 - 37  illustrate that the width W of the 180-degree flow turn around connectors  560 / 580  is less than twice the dimension FF, preferably less than twice the minimum pad width EE of SAE standard J518 described in detail above. The port centers are separated by the dimension dd. The dimension dd is less than FF, and preferably equal to EE. The dimension dd may also be less than EE provided the width W of the connector attached thereto is less than the dimension dd. For example, the turn around connectors  560 / 580  can be mounted on two adjacently-connected (stacked) block connectors such as described above having the pad width EE or on a block connector having an enlarged width and multiple fluid-flow ports (described below).  
         [0166]    FIGS.  38 - 39  illustrate an offset flow modular block connector  600  in accordance with an embodiment of the invention. The offset flow connector  600  has a single-piece, block construction similar to the turn around block connector  580  described above except that the central channel extends inwardly from a first port face mounting surface  604   a  and exits through a second port face mounting surface  604   b . While the overall width W of the connector  580  is greater than 2 times EE, the connector  580  can be connected to two fluid flow ports  6  separated by the port dimension dd. The dimension dd is less than FF, and preferably equal to EE. The dimension dd may also be less than EE provided the width W of the flanged connector attached thereto is less than the dimension dd.  
         [0167]    FIGS.  40 - 41  illustrate an in-line divide flow/combine flow modular connector  620 . The connector  620  has a single-piece, block construction with a central channel  622  extending inwardly from an input port face mounting surface  624   a , dividing internally into two separate channels which exit on an opposed port face mounting surface  624   b . The connector  620  has a pair of through bores  627  diagonally located on opposed sides of each port on the exit port face mounting surface  624   b . The through bores  627  receive connecting bolts for mounting the connector to a port face, flange connector, or block connector. The connector  620  also has a pair of threaded bores  626  diagonally located on opposed sides of the port on the input port face mounting surface  624   a.    
         [0168]    The width W of the connector is preferably equal to, but may be less than, 2⅓ times EE. The ports on the output port face  624   b  are separated by the distance dd which is preferably equal to, but may be less than, 1⅓ EE.  
         [0169]    FIGS.  42 - 44  illustrate a right angle divide flow/combine flow modular connector  640 . The connector  640  has a single-piece, block construction with a central channel extending inwardly from a first port face mounting surface  644   a , dividing internally into two separate channels which exit on a second port face mounting surface  644   b . The connector  640  has a pair of through bores  647  diagonally located on opposed sides of each port on the exit port face mounting surface  644   b . The apertures receive connecting bolts for mounting the connector  640  to a port face. The connector  640  also has a pair of threaded bores  646  diagonally located on opposed sides of the port on the input port face mounting surface  644   a.    
         [0170]    FIGS.  42 - 44  illustrate that the width of the first port face mounting surface  644   a  of the connector  640  is less than FF, preferably less than or equal to the minimum pad width EE of SAE standard J 518  described in detail above. FIGS.  42 - 44  also illustrate that the distance between the ports centers on the second port face mounting surface is equal to dd. The dimension dd is preferably equal to or less than EE. For example, the connector  640  can be mounted on two adjacently-connected (stacked) block connectors such as described above having the minimum pad width EE.  
         [0171]    Except in FIG. 45, the modular connectors are illustrated and described wherein all the fluid-flow channels have a constant diameter along its length and the ports have the same nominal diameter D1. However, it should be appreciated to one of ordinary skill in the art that the modular connectors may have a converging or diverging fluid flow channel and a plurality of ports having different nominal diameters. In such a case, the height H of the connector is determined by the diameter of the largest port in the connector. The width W 1  and W 2  of the connector are determined by the port diameter, or combination of port diameters, on the respective mounting surfaces. Typically, the width W 1  is determined by the largest port diameter.  
         [0172]    The embodiments shown in FIGS.  34 - 44  can be made to accept a four-bolt flanged connector  130  by adding additional threaded fastening bores. In such embodiments, the dimensions shown in FIGS.  34 - 44  would be the same except for the embodiment shown in FIGS. 40 and 41. A four-bolt in-line divide flow/combine flow modular connector would have a width W less than or equal to 3 times EE and the dimension dd would be equal to 2 times EE.  
         [0173]    [0173]FIG. 45 illustrates a modular block connector  900  having multiple interconnected fluid-flow channels  902  having different diameters. The connector  900  has a single-piece, block construction with a fluid-flow channel extending inwardly from a first port face mounting surface  904   a  to a second port face mounting surface  904   b  having multiple ports thereon. FIG. 45 illustrates how several two-bolt and four-bolt flange connectors having different sizes can be fastened to and nested on the second port face mounting surface  904   b . FIG. 45 illustrates various dimensions between port centers corresponding to various sizes specified in SAE standard J518. The four digit code underneath the various dimensions represents the pressure series and size of the port as designated in SAE standard J518.  
         [0174]    The flanged and block connectors described above are combined to form a compact fluid flow system. The fasteners employed in connecting either the flanged connectors or modular block connectors described above should have a minimum tensile yield of 155,000 p.s.i. which is higher than the Grade 5 minimum allowed by SAE standard J518.