Patent Description:
Fluid connectors are often installed throughout vehicles to provide fluid communication between components and different areas. One particular use of fluid connectors is in drainage assemblies, for example located within a sunroof recess of a vehicle to prevent the accumulation of fluid.

Such fluid connectors are typically connected to a hole in a vehicle body panel and a hose or conduit is then connected to the fluid connector. The hole is located within a low point of a recess to facilitate the drainage of fluid.

Fluid connectors are often connected to vehicle body panels by welding or brazing. Such methods of installation are time consuming and complex, adding to the overall cost of vehicle manufacture. It is most often the case that such fluid connectors must be installed manually to the vehicle body structure.

In some cases, the fluid connectors include a plurality of parts, for example, a first, housing part arranged to be connected to the vehicle body panel and a second, connector part arranged to be connected to the first, housing part. A hose or conduit must then be connected to the second, connector part. It has been found that such multi-part connectors add weight, cost and complexity to the fluid connector. Further, as a result of the method of attachment and/or the complexity of the fluid connector itself, the assembly process cost is increased and fluid-tightness/fluid-proofing/impermeability or integrity of seal of the joint/connection between the fluid connector and vehicle body panel is often compromised.

It is therefore an object of embodiments of the invention to at least mitigate one or more of the problems of the prior art.

<CIT> discloses a water drainage pipe designed as a die-cast piece that is connected to a metal frame of a vehicle sunroof by caulking one end of the water drainage pipe which is inserted through the frame opening, and introducing an adhesive between the outer circumference of the water drainage pipe and the inner circumference of the frame opening.

<CIT> discloses a bulkhead fitting in which breakaway torque required to rotate the fitting body relative to a bulkhead after assembly of the fitting body and nut is significantly greater than the body and nut assembly torque.

<CIT> discloses a water pipe connecting member and a method of mounting such member through a wall. The connection element, formed by a plate and first and second parts, is preassembled forming a unitary assembly before it is introduced into the wall.

Aspects of the invention relate to a fluid drain connector, a vehicle body panel, a vehicle drain assembly, a vehicle and to a method, as defined in the appended claims.

According to an aspect of the invention, there is provided a fluid drain connector for a vehicle, the fluid drain connector comprising a flange portion having a clinching element to a first side thereof and a hose connector extending from a second side thereof, the fluid drain connector having a generally tubular body, wherein the clinching element comprises a deformable region arranged to plastically deform outwardly under the influence of force so as to clinch a portion of a vehicle body panel between the flange portion and clinching element; wherein the fluid drain connector comprises one or more anti-rotation lock features on an external surface of the clinching element or on a panel facing side of the flange, the one or more anti-rotation lock features arranged to engage a vehicle body panel.

In this context, clinching is a forming process whereby the flange of the drain connector is held against one side of the body panel with the clinching element protruding through the opening in the body panel, either the clinching element, the body panel or both are plastically formed in order to retain the drain connector to the body panel. A first method of clinching is as follows; while the flange is held in place, a force is applied to plastically deform the clinching element outwardly. This results in the clinching element forming a second flange on the opposite side of the body panel from the first flange and the body panel is clinched between the two flanges. By clinching in this manner the extension of the clinching element through the body panel after forming is minimised. It is also possible to simultaneously form the body panel or preform the body panel into a chamfered aperture so that the finished fluid drain connector is flush with the surface of the body panel opposite to the first flange. This has the technical advantage that a drain can be provided to remove water from a horizontal surface without pooling. Such a horizontal surface may be present in the surround to a sunroof aperture.

Providing a fluid drain connector having a clinching element allows for quick and effective attachment to a vehicle panel. Such attachment can be affected concurrently with stamping or pressing of the vehicle panel. Further, the clinching element can provide a fluid-tight seal between the fluid drain connector and vehicle body panel. This can be achieved without any additional components or materials, for example washers or sealing compounds, the effect of which is an improvement in the simplicity and reliability of the fluid drain connector.

The hose connector may comprise a spigot. The hose connector may comprise a push-fit connector, for example a male or female push-fit connector. The hose connector may comprise a hose-tail type connector. The hose connector may comprise a flared end or tapered end.

Advantageously, a push fit connector allows for easy installation of a hose or other conduit on the fluid drain connector. Combined with the clinching element described above, such features act in concert to allow for a reliable fluid assembly, for example a drain assembly, due to the absence of multiple components.

The flared or tapered end may comprise a first tapered surface. The first tapered surface may taper in the direction of the flange. The flared or tapered end may comprise a second tapered surface. The second tapered surface may extend from the first tapered surface. The second tapered surface may taper in the opposite direction to that of the first tapered surface. The first tapered surface may have a shallower taper profile than the second tapered surface.

Additionally or alternatively, the hose connector, push-fit connector or hose-tail connector may comprise one or more barbs. The hose connector may comprise a spigot.

The clinching element may comprise a clinch ring. The clinch ring may be arranged to be inserted into or within a hole or opening of a vehicle body panel. The clinch ring, or at least a portion thereof, may be arranged to be deformed or clinched towards the flange, for example such that a portion of the vehicle body panel is captivated therebetween.

Captivating a portion of vehicle body panel between the clinch ring and flange may provide a water-tight or fluid-tight seal therebetween, without requiring any further components or materials, thereby improving the simplicity and reliability of the fluid drain connector when installed in a fluid assembly or an area requiring efficient and effective drainage.

The clinching element or clinch ring may be arranged to engage behind the rim of the opening in the vehicle body panel. The clinching element or clinch ring may be arranged to provide a watertight fit or seal between the fluid drain connector and the vehicle body panel.

In this context a clinch ring is a feature of the clinching element to provide a second method of clinching the drain tube to the body panel. The clinch ring may be a serrated diameter or a plain diameter forming a step between the clinching element and the flange. It is normally associated with an undercut formed in the outer diameter of the clinching element. During assembly the clinching element is inserted through the vehicle body aperture and the clinch ring comes into contact with the body panel. Application of a force pushes the clinch ring into the body material and plastically deforms a small amount of the body material into the undercut until the flange makes contact with the body surface. The formed body material connects the drain connector to the body panel in a similar manner to a self-clinching nut. This method of clinching is appropriate for a soft body material and if the clinching element is sufficiently short that it does not extend beyond the body panel surface then the drain tube has the technical benefit of providing a drain tube connector for a horizontal body panel which does not allow pooling of fluid above the body surface.

In embodiments, the clinch ring comprises press-in element, for example arranged to deform under the influence of a pressing force. Such a feature allows for the installation of the fluid drain connector concurrently with the stamping or pressing of a vehicle body panel.

The fluid drain connector may comprise a tubular shaft. The tubular shaft may extend between the hose connector and flange. In embodiments, the hose connector is formed on an end, for example a free end, of the tubular shaft. The tubular shaft may comprise a substantially constant or uniform wall thickness along at least a portion of its length. The wall thickness of the tubular shaft may be greater than a wall thickness of the clinch ring.

In embodiments, the one or more anti-rotation lock features comprise substantially axially or longitudinally extending ribs or notches. The ribs or notches may be arranged to engage inside the rim of an opening in a vehicle body panel. The external surface of the clinch ring may comprise six anti-rotation lock features, for example evenly distributed therearound. One or more, for example each, of the anti-rotation lock features may comprise serrations or teeth.

One or more anti-rotation lock features may be located on a panel facing side of the flange. The one or more anti-rotation lock features may be arranged to engage a vehicle body panel, for example behind a rim of an opening therein.

The one or more anti-rotation lock features may comprise substantially radially extending ribs or notches. The ribs or notches may be arranged to engage behind the rim of an opening in a vehicle panel. The panel facing side of the flange may comprise six anti-rotation lock features, for example evenly distributed therearound. One or more of the anti-rotation lock features may comprise a rib tapered away from a longitudinal axis of the fluid drain connector. One or more, for example each, of the anti-rotation lock features may comprise serrations or teeth.

In embodiments, the anti-rotation lock features on the clinch ring may be located intermediate, for example circumferentially intermediate, of the anti-rotation lock features of the panel facing side of the flange.

In embodiments, the one or more anti-rotation lock features may comprise one or more ribs or notches for engaging a cooperating portion of a vehicle body panel. The one or more ribs or notches may be arranged so as to resist relative rotation between the fluid drain connector and vehicle body panel.

At least a portion of a panel facing side of the flange may comprise an annular recess. The annular recess may circumscribe, surround and/or be adjacent the clinching element. The annular recess may describe an undercut. The annular recess may be located at a join or joint between the flange and the clinching element. The clinching element may be arranged to deform part of the vehicle body panel into the undercut.

An undercut allows for a flush finish on a side of the vehicle panel to which the fluid drain connector is connected. A flush finish is advantageous in terms of packaging requirements, the fluid drain connector requiring less space on one side of the vehicle body panel when secured thereto. Further, a flush finish also allows substantially all fluid that accumulates in the vicinity of the fluid drain connector to drain therethrough.

In embodiments, the fluid drain connector or generally tubular body is integrally formed. In embodiments, the flange portion, clinching element and hose connector are integrally formed.

Forming elements of the fluid drain connector integrally provides a fluid drain connector in which a reliable seal can be provided, both between the fluid drain connector and a vehicle body panel and between the fluid drain connector and a hose, without the need for additional components or materials, for example washers, clamps or sealing compounds.

The fluid drain connector may comprise or be formed from metal, for example aluminium or steel.

In some embodiments, the clinching element comprises a self-clinch fastener or self-clinch element.

In embodiments, the generally tubular body may comprise a pair of concentric tubes. The clinching element may comprise a rivet-nut or rivet-nut type feature. The internal bore may comprise a thread, for example for engagement with a tool for deforming the clinching element.

The hose connector or a flared or tapered end thereof may have a length between <NUM> and <NUM>, for example between <NUM> and <NUM> or <NUM>.

The first tapered surface may have an axial extent or length (hereinafter length) of between <NUM> and <NUM>. The second tapered surface may have a length of between <NUM> and <NUM>. The first tapered surface may have a length of <NUM> and the second tapered surface may have a length of <NUM>.

The first tapered surface and second tapered surface may have a maximum outer diameter of between <NUM> and <NUM>, for example between <NUM> and <NUM>. The first tapered surface and second tapered surface may have a maximum outer diameter of <NUM>.

In embodiments, an internal bore or interior surface of the generally tubular body may be smooth or absent any surface features. The internal bore of the generally tubular body may be between <NUM> and <NUM>, for example between <NUM> and <NUM>, between <NUM> and <NUM>.

In embodiments, the clinch ring may have an axial extent or length, e.g. a wall height, of between <NUM> and <NUM>. The wall height may be between <NUM> and <NUM>, for example between <NUM> and <NUM>.

The clinch ring may have a wall thickness of between <NUM> and <NUM>, for example between <NUM> and <NUM>.

The clinch ring may have an outer diameter between <NUM> and <NUM>, for example between <NUM> and <NUM>, between <NUM> and <NUM>. The clinch ring may have an outer diameter between <NUM> and <NUM>.

The fluid drain connector may comprise a fillet between the tubular shaft and flange. The fillet may have a radius of between <NUM> and <NUM>, for example between <NUM> and <NUM>. The fillet may have a radius of <NUM>.

The wall thickness of the tubular shaft may be between <NUM> and <NUM>, for example between <NUM> and <NUM>, between <NUM> and <NUM> or <NUM> and <NUM>.

The tubular shaft may have a length between <NUM> and <NUM>, for example between <NUM> and <NUM>, between <NUM> and <NUM> or between <NUM> and <NUM>.

The tubular shaft may have an outer diameter between <NUM> and <NUM>, for example between <NUM> and <NUM>.

The hose connector may have an opening which is between <NUM> and <NUM> in diameter.

In embodiments, a panel facing side of the flange may be tapered towards a longitudinal axis of the generally tubular body, so as to describe the undercut. The flange may have an outer diameter between <NUM> and <NUM>, for example between <NUM> and <NUM>. The flange may have an outer diameter between <NUM> and <NUM>.

The flange may comprise a rim having a depth between <NUM> and <NUM>, for example between <NUM> and <NUM>. The rim may have a depth between <NUM> and <NUM>.

According to a further aspect of the invention, there is provided a vehicle body panel comprising a fluid drain connector as described above.

In embodiments, the clinching element lies substantially flush with a surface of the vehicle body panel when the fluid drain connector is attached thereto.

In embodiments, the fluid drain connector and vehicle body panel form or describe a fluid-tight or water-tight seal therebetween. The fluid drain connector and vehicle body panel may form or describe an impervious or impermeable joint/connection/seal therebetween.

According to another aspect of the invention, there is provided a vehicle comprising a fluid drain connector as described above or a vehicle body panel as described above.

According to yet another aspect of the invention there is provided a vehicle drain assembly comprising one or more fluid drain connectors as described above.

According to another aspect of the invention, there is provided a method of attaching a fluid drain connector to a vehicle body panel, the fluid drain connector comprising a flange portion having a clinching element to a first side thereof and a hose connector extending from a second side thereof, the fluid drain connector having a generally tubular body, wherein the clinching element comprises a deformable region arranged to plastically deform outwardly under the influence of force so as to clinch a portion of a vehicle body panel between the flange portion and clinching element, characterised in that the fluid drain connector comprises one or more anti-rotation lock features on an external surface of the clinching element or on a panel facing side of the flange, the one or more anti-rotation lock features arranged to engage a vehicle body panel; the method comprising inserting the clinching element through an opening in the vehicle body panel, applying a pressing force to the fluid drain connector so as to plastically deform the clinching element towards the flange such that a portion of the vehicle body panel is captivated between the flange and the clinching element.

The method may comprise stamping or pressing the vehicle body panel and applying a pressing force to the fluid drain connector concurrently.

Deforming the clinching element may comprise at least partially embedding the clinching element within the vehicle body panel such that the clinching element lies substantially flush with a surface of the vehicle body panel.

In the above aspects and embodiments, the term clinching element may be alternatively referred to as a clinching fastener.

Within the scope of this invention it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination within the scope of the claims. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination within the scope of the claims, unless such features are incompatible.

Referring now to <FIG>, there is shown a fluid drain connector <NUM>, the fluid drain connector <NUM> being a fluid drain connector for a vehicle V (<FIG>) in this embodiment.

The fluid drain connector <NUM> incudes a generally tubular body with a bore B extending therealong. The body of the fluid drain connector <NUM> has a flange <NUM>, a clinching element <NUM> extending from a first, panel facing, side <NUM> of the flange <NUM>, a tubular shaft <NUM> extending from a second side <NUM> of the flange <NUM> and a hose connector <NUM> formed on an end of the tubular shaft <NUM> and arranged to connection of a hose (not shown). The flange <NUM>, clinching element <NUM>, tubular shaft <NUM> and hose connector <NUM> are integrally formed.

The flange <NUM> is located between, and interconnects, the clinching element <NUM> and tubular shaft <NUM>. The first side <NUM> includes an annular recess <NUM> describing an undercut and a planar, annular abutment surface <NUM> circumscribing the annular recess <NUM>, for abutment against a vehicle body panel. The annular recess <NUM> is adjacent to and circumscribes the clinching element <NUM>. The second side <NUM> describes a bracing surface <NUM> for bracing against a pressing tool, supporting surface or die. The bracing surface <NUM> is a planar surface in this embodiment.

The first side <NUM> of the flange <NUM> is also provided with anti-rotation lock features evenly distributed circumferentially therearound. The anti-rotation lock features are in the form of six radially extending ribs <NUM> in this embodiment. Each of the radially extending ribs <NUM> extends from the clinching element <NUM> towards an outer rim <NUM> of the flange <NUM>. In the present embodiment, the ribs <NUM> are tapered, such that they narrow progressively from the recess <NUM> toward the rim <NUM>, i.e. taper away from a longitudinal axis L of the fluid drain connector <NUM>. The upper and lower outer edges of the rim <NUM> each have a chamfered edge <NUM> in this embodiment. The flange <NUM> has an outer diameter D1 and the rim <NUM> has a depth T1 in this embodiment.

The clinching element <NUM> comprises a wall <NUM> describing a ring in the form of a clinch ring in this embodiment. The clinch ring is arranged to be inserted into an opening in a vehicle body panel (not shown) and deformed outwardly, toward the flange <NUM>, so as to captivate a portion of the vehicle body panel (not shown) between the flange <NUM>, in particular the first side <NUM> thereof, and the clinching element <NUM>. The clinching element <NUM> is arranged to provide a fluid tight seal between a vehicle body panel (not shown) and the fluid drain connector <NUM>.

The wall <NUM> extends from the first side <NUM> of the flange <NUM> towards a free end <NUM>. The wall <NUM> has an outer diameter D2, a wall thickness T2 and a wall height H. In the present embodiment, the wall height H is described between the outer abutment surface <NUM> of the flange <NUM> and the free end <NUM>.

The external surface of the wall <NUM> is provided with anti-rotation lock features <NUM> evenly distributed circumferentially therearound. The anti-rotation lock features <NUM> are in the form of six longitudinally extending ribs <NUM> in this embodiment, extending along the longitudinal axis L of the fluid drain connector <NUM> and arranged to engage inside the rim of an opening in a vehicle body panel (not shown). Each of the longitudinally extending ribs <NUM> extends from the first side <NUM> of the flange <NUM> to the free end <NUM> of the wall <NUM>. In the present embodiment, each of the longitudinally extending ribs <NUM> is located circumferentially intermediate the radially extending ribs <NUM>.

The tubular shaft <NUM> has a length L1, and a smooth outer surface <NUM> of uniform outer diameter D3. The tubular shaft <NUM> has a uniform wall thickness T3 along length L1 and a smooth internal bore <NUM>, i.e. absent surface features.

The tubular shaft <NUM> connects flange <NUM> via a fillet <NUM> that leads to a base ring <NUM>. The base ring <NUM> has a greater outer diameter D4 and greater wall thickness T4 than the tubular shaft <NUM>. The base ring <NUM> provides for a degree of structural rigidity at the connection between the flange <NUM> and tubular shaft <NUM>. The length L1 of the tubular shaft <NUM> is measured between the fillet <NUM> and hose connector <NUM>.

In the present embodiment, outer diameter D3 of the tubular shaft <NUM> is equal to the outer diameter D2 described by the wall <NUM> of the clinching element <NUM>. The wall thickness T3 of the tubular shaft <NUM> is equal to the wall thickness T2 of the wall <NUM>.

Although the wall thickness T2 of the clinching element <NUM> is described as being equal to the wall thickness T3 of the tubular shaft <NUM>, this need not be the case. Instead, the wall thickness T3 of the tubular shaft <NUM> may be greater than the wall thickness T2 of the clinching element <NUM>. Such a feature may provide a degree of structural rigidity to the tubular shaft <NUM>, for example when the wall <NUM> of the clinching fastener <NUM> is being deformed.

The hose connector <NUM> is formed on an end of the tubular shaft <NUM> opposite the flange <NUM>. The hose connector <NUM> is a push-fit connector in the form of a flared end in this embodiment. The flared end is described by a first tapered surface <NUM> tapering in the direction of the flange <NUM>. The hose connector <NUM> is also provided with a second tapered surface <NUM>, having an opposing taper to that of the first tapered surface <NUM> and extending therefrom.

The first tapered surface <NUM> has an outer diameter D5 at a first end, equal to diameters D2 & D3. The first tapered surface <NUM> provides an enlargement to the outer diameter of the hose connector <NUM> to diameter D6 at a second end. The first tapered surface <NUM> has longitudinal extent L2 described between the first end and second end.

The second tapered surface <NUM> has an outer diameter D6 at a first end, the first end being the second end of the first tapered surface <NUM>. The second tapered surface <NUM> meets the outer surface <NUM> of the tubular shaft <NUM> at a second end. The second tapered surface <NUM> provides a reduction to the outer diameter of the hose connector <NUM> from D6 to D3. The second tapered surface <NUM> has longitudinal extent L3 described between its first and second end. The longitudinal extent L3 is shorter than longitudinal extent L2 of the first tapered surface <NUM>. Therefore, the first tapered surface <NUM> has an opposing and shallower taper profile than the second tapered surface <NUM>.

By virtue of the enlargement to the outer diameter of the hose connector <NUM>, the first tapered surface <NUM> is arranged to provide an interference fit between the hose connector <NUM> and a hose (not shown) connected thereto.

In the present embodiment, each of the flange <NUM>, clinching element <NUM>, tubular shaft <NUM> and hose connector <NUM> describe an internal bore. Each respective internal bore is of equal diameter and together describe bore B extending along the fluid drain connector <NUM>.

In use, the clinching element <NUM>, in particular the wall <NUM>, is inserted into an opening in a vehicle body panel (not shown) until the outer abutment surface <NUM> of the flange <NUM> abuts the vehicle body panel (not shown) about the opening, for example behind a rim of the opening.

The wall height H must be chosen such that, with the outer abutment surface <NUM> abutting the vehicle body panel (not shown), a portion of the wall <NUM> protrudes from the opening. Such an arrangement allows for engagement of the wall <NUM> with a portion of a pressing tool (not shown).

In the present embodiment, the second side <NUM> of the flange <NUM> is brought into engagement with a pressing tool (not shown) and the clinching element <NUM>, or more specifically the free end <NUM> of the wall <NUM>, is aligned with a die (not shown). A pressing force is applied to the fluid drain connector <NUM> via the second side <NUM> of the flange <NUM>. The pressing force and the shape of the die act in concert to deform the wall <NUM> towards the first side <NUM> of the flange <NUM>.

The arrangement allows a pressing force to be applied to the fluid drain connector <NUM> concurrently with stamping of a vehicle body panel (not shown), for example such that a vehicle body panel (not shown) is stamped and the fluid drain connector <NUM> attached to the vehicle body panel (not shown) during the same process step.

By virtue of the deformation, a portion of the vehicle body panel (not shown) is captivated between the first side <NUM> of the flange <NUM> the wall <NUM> so as to attach the fluid drain connector <NUM> thereto. A fluid-tight, water-tight, impervious or impermeable seal is provided between the clinching element <NUM> and the vehicle body panel (not shown).

The portion of vehicle body panel (not shown) captivated between clinching element <NUM> and first side <NUM> of the flange <NUM> is deformed into the annular recess <NUM>. The annular recess <NUM> helps provide a flush finish on the side of the vehicle body panel (not shown) opposite that adjacent the abutment surface <NUM>.

Further, the application of the pressing force results in the longitudinally extending ribs <NUM> engaging inside the rim of the opening and the radially extending ribs <NUM> engaging the vehicle body panel (not shown) behind the opening. Such engagement inhibits rotation of the fluid drain connector <NUM> relative to the vehicle body panel (not shown).

Additionally, although the diameter of the internal bore described by of each flange <NUM>, clinching element <NUM>, tubular shaft <NUM> and hose connector <NUM> is described as being equal, this need not be the case. One or more of the flange <NUM>, clinching element <NUM>, tubular shaft <NUM> and hose connector <NUM> may have a different diameter internal bore so as to describe an internal step within bore B. For example, there may be a step in the bore B described between the flange <NUM> and tubular shaft <NUM>.

Although the fluid drain connector <NUM> is described as having anti-rotation lock features in the form of six radially extending ribs <NUM> and six longitudinally extending ribs <NUM>, this need not be the case. The fluid drain connector <NUM> may be provided with any suitable number of radially extending ribs and/or longitudinally extending ribs. The fluid drain connector <NUM> may be provided with only radially extending ribs or only longitudinally extending ribs.

Claim 1:
A fluid drain connector (<NUM>) for a vehicle, the fluid drain connector (<NUM>) comprising a flange (<NUM>) portion having a clinching element (<NUM>) to a first side thereof and a hose connector (<NUM>) extending from a second side thereof, the fluid drain connector (<NUM>) having a generally tubular body, wherein the clinching element (<NUM>) comprises a deformable region arranged to plastically deform outwardly under the influence of force so as to clinch a portion of a vehicle body panel between the flange (<NUM>) portion and clinching element (<NUM>);
wherein the fluid drain connector (<NUM>) comprises one or more anti-rotation lock features (<NUM>, <NUM>) on an external surface of the clinching element (<NUM>) or on a panel facing side of the flange (<NUM>), the one or more anti-rotation lock features (<NUM>, <NUM>) arranged to engage a vehicle body panel.