Pipe joints or couplings – Deformed
Reexamination Certificate
2001-05-17
2003-09-23
Browne, Lynne H. (Department: 3679)
Pipe joints or couplings
Deformed
C285S020000, C285S382400, C285S382500, C091S37600A
Reexamination Certificate
active
06623048
ABSTRACT:
TECHNICAL FIELD
This invention relates generally to the field of vacuum brake boosters for cars or light trucks, and in particular, to an apparatus and method of attaching a tube member to a housing of a vacuum brake booster.
BACKGROUND OF THE INVENTION
Vacuum brake boosters are typically used in automobiles and light trucks. They typically include a housing that includes a front side and a rear side. The rear side is attached to the firewall of the vehicle, while the front side provides an attachment for a master-cylinder.
Screws or tie-rods are commonly used to attach the booster to the firewall. They are typically crimped or welded to the inner side of the rear shell of the booster housing. The booster is presented to the firewall, and the screws or tie-rods (there are usually 4 screws or 2 tie-rods) are inserted through holes in the firewall. An operator then positions nuts on the other side of the wall (i.e. the driver's compartment) and installs them on the screws or tie-rods. Although this is a widely used process, it involves two operators, one on each side of the firewall, and results in increased costs.
Another process for attaching a booster to a firewall of a housing involves only one operator. This process uses rigid tubular members that extend through the front side of the housing, through the interior of the booster and through the rear of the housing. Fastening bolts can then be inserted into the tubular members to allow the booster to be attached to the firewall. In this scenario, the nut is typically welded onto the firewall.
Various attempts have been made to attach such tubular members to the housing of vacuum brake boosters. An example of a conventional arrangement is described in EP 0 623 081 and shown generally in FIG.
10
. As shown in
FIG. 10
, at least four parts are required, namely, a tubular member
100
, a fitting
102
, a nut
104
and a seal
106
. One end
108
of tubular member
100
is connected and sealed to the front side
110
of a housing
112
via fitting
102
by slightly deforming the metal structure of fitting
102
. That is, end
108
of tubular member
100
is crimped against fitting
102
, which itself is crimped against the front side
110
of housing
112
. The nut
104
and seal
106
are positioned adjacent an inner surface
114
of a back side
116
of housing
112
. Nut
104
and seal
106
facilitate the connection and sealing of a second end
118
of the tubular member
100
to the back side
116
of housing
112
. The seal is typically obtained by applying glue to a portion of a thread
109
, which constitutes an additional step in the process and results in additional costs.
There are several disadvantages to this arrangement, including the large number of parts required (i.e. fitting
102
, nut
104
, seal
106
, and tubular member
100
). In addition to the steps required for sealing, the large number of parts increases the costs associated with the vacuum brake booster. Moreover, the installation of these parts is a labor intensive and time-consuming process, which also increases the costs associated with installing the booster.
Another example of a conventional apparatus is shown in FIG.
11
. As shown in
FIG. 11
, a tubular member
200
consists of a first tube portion
202
and a second tube portion
204
. The first tube portion
202
is linked mechanically to a rear housing
206
and the second tube portion
204
is linked mechanically to a front housing
208
. A bolt
210
may extend through tubular member
200
from the front housing
208
to the rear housing
206
. A flange
212
positioned adjacent to an end of bolt
210
prevents the master-cylinder from compressing the booster. EP 0 331 535, for example, discloses a similar arrangement for providing a tubular member in a vacuum brake booster.
There are also several disadvantages to this arrangement. For example, it is very impractical and difficult to manufacture and assemble the first and second tube portions
202
,
204
so that they are a part of the housings
206
,
208
, respectively. This arrangement is also likely to require additional parts. The large number of parts required and the complexity of the interconnections between parts result in increased costs.
In addition to the above, attempts have been made to install metal tubes, studs, etc. onto a planar metal sheet by deforming the metal tube. Although this method of fastening materials together is well known, and is used in many other applications, it has not yet been applied to the manufacture and installation of vacuum brake boosters. In particular, this technique has not yet been utilized to address the problems associated with attaching tube member to a housing of a vacuum brake booster.
Accordingly, it would be desirable to have an apparatus and method of attaching a tube member to a housing of a vacuum brake booster that overcomes the disadvantages described.
SUMMARY OF THE INVENTION
One aspect of the invention provides a connector apparatus for attaching to a housing of a vacuum brake booster. A tube member includes a body portion, an outer surface, a first end, and a second end. A first collar portion is formed between the first end and the body portion and extends outward from the outer surface. A lip portion is formed at the first end and extends outward from the outer surface. The first collar portion and the lip portion define a recess to receive a first housing member. The first collar portion may preferably be adjacent to the first end of the tube member. The first collar portion may preferably include a body portion that extends outward from the outer surface in a direction towards the first end. The first collar portion may preferably have a conical shape. The tube member may further include a second collar portion spaced apart from the first collar portion. The second collar portion may preferably extend outward from the outer surface and may define a contact surface for contacting an inner surface of a second housing member. The second collar portion may preferably extend outward substantially perpendicular from the outer surface of the tube member.
Another aspect of the invention provides a method of attaching a tube member to a housing of a vacuum brake booster. A first housing member including an inner surface, an outer surface, and an opening formed therein is provided. A tube member including an outer surface, a first end, a first portion, and a body portion is also provided. The first portion of the tube member is positioned between the first end and the body portion. The first end of the tube member is inserted through the opening in the first housing member. A force is applied to the first end of the tube member. The first portion is deformed to create a first collar portion extending outward from the outer surface. The first collar portion is contacted against the inner surface of the first housing member. A second force is applied to the first end of the tube member. An end portion of the first portion is deformed to create a lip portion extending outward from the outer surface. The lip portion is contacted against the outer surface of the first housing member to create a seal between the first housing member and the tube member. The first collar portion may preferably be located adjacent to the first end of the tube member and may preferably include a body portion that extends outward from the outer surface in a direction towards the first housing member. The first collar portion may preferably have a conical shape. The first portion may preferably include a first wall thickness and the body portion may preferably include a second wall thickness, the first wall thickness being less than the second wall thickness. The first housing member may preferably include a flange portion, and the first collar portion may be contacted against the flange portion. The lip portion may preferably be contacted against the flange portion. The flange portion may preferably be angled with respect to the first housing member, and the first housing member may preferably be a planar
Castel Philippe Georges
Fanelli Michael William
Browne Lynne H.
Delphi Technologies Inc.
Hewitt James M.
Sigler Robert M.
LandOfFree
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