Flash trap

Abstract

A manifold assembly for an automobile cooling system includes a crossover tube and a crossover tube cover welded in an opening of the crossover tube A flash trap is provided adjacent the region of the weld joint to receive and capture weld flash migrating inwardly in the crossover tube.

Claims

1. A welded assembly, comprising: a first component including an opening arranged at a first end thereof, the opening defining a stepped profile and including a first weld joint surface and an inner surface; and a second component received within the opening and including a second weld joint surface and a flash trap formed in the second weld joint surface, wherein the second weld joint surface at least partially overlaps axially with the first weld joint surface, and wherein a weld joint region is arranged within a gap formed laterally between the first weld joint surface and the second weld joint surface, and wherein the flash trap forms a recess that extends laterally into the second weld joint surface and is arranged inwardly from the first end of the opening between the weld joint region and a lip of the second component.

2. The welded assembly of claim 1, wherein the first weld joint surface extends into the opening from the first end to a junction between the first weld joint surface and the inner surface, and the inner surface extends into the opening from the junction between the first weld joint surface and the inner surface to a laterally inwardly extending stop surface.

3. The welded assembly of claim 2, wherein the inner surface is disposed laterally inward relative to the first weld joint surface.

4. The welded assembly of claim 1, wherein the flash trap defines a generally U-shaped recess that extends continuously around a periphery of the second component.

5. The welded assembly of claim 1, wherein the flash trap, the lip, and the inner surface define an enclosed pocket.

6. The welded assembly of claim 1, wherein a diameter defined by the lip is less than a diameter defined by the second weld joint surface.

7. The welded assembly of claim 1, wherein the lip is arranged inwardly from the first end of the opening relative to the flash trap.

8. The welded assembly of claim 1, wherein the flash trap is arranged axially between the lip and the second weld joint surface.

9. A crossover tube assembly for an automobile cooling system; comprising: a crossover tube having an opening arranged at a first end thereof, wherein the opening includes a first weld joint surface extending inwardly into the opening from the first end; and a crossover tube cover disposed in the opening and including a second weld joint surface, wherein the second weld joint surface at least partially overlaps axially with the first weld joint surface, and wherein a weld joint region is arranged within a gap formed laterally between the first weld joint surface and the second weld joint surface, and wherein the second weld joint surface includes a depression extending laterally into the second weld joint surface and arranged inwardly from the first end of the opening relative to the weld joint region.

10. The crossover tube assembly of claim 9, wherein the opening defines a stepped profile and includes an inner surface.

11. The crossover tube assembly of claim 10, wherein the inner surface is disposed laterally inward relative to the first weld joint surface.

12. The crossover tube assembly of claim 11, wherein the first weld joint surface extends into the opening from the first end to a junction between the first weld joint surface and the inner surface, and the inner surface extends into the opening from the junction between the first weld joint surface and the inner surface to a laterally inwardly extending stop surface.

13. The crossover tube assembly of claim 9, wherein the depression defines generally U-shaped depression that extends continuously around a periphery of the crossover tube cover.

14. The crossover tube assembly of claim 9, wherein the crossover tube cover includes a lip arranged inwardly from the first end of the opening relative to the depression.

15. The crossover tube assembly of claim 14, wherein the depression, the lip, and the inner surface define an enclosed pocket.

16. The crossover tube assembly of claim 15, wherein a diameter defined by the lip is less than a diameter defined by the second weld joint surface.

17. A crossover tube assembly for an automobile cooling system, comprising: a crossover tube including an opening arranged at a first end thereof, the opening defining a stepped profile and including a first weld joint surface and an inner surface; and a crossover tube cover received within the opening and including a second weld joint surface and a flash trap formed in the second weld joint surface, wherein the second weld joint surface at least partially overlaps axially with the first weld joint surface, and wherein a weld joint region is arranged within a gap formed laterally between the first weld joint surface and the second weld joint surface, and wherein the flash trap forms a depression that extends laterally into the second weld joint surface and is arranged inwardly from the first end of the opening relative to the weld joint region.

18. The crossover tube assembly of claim 17, wherein the crossover tube cover includes a lip arranged inwardly from the first end of the opening relative to the flash trap.

19. The crossover tube assembly of claim 18, wherein the flash trap, the lip, and the inner surface define an enclosed pocket.

20. The crossover tube assembly of claim 17, wherein the flash trap defines generally U-shaped depression that extends continuously around a periphery of the crossover tube cover.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a manifold from an automobile cooling system, the manifold including a crossover tube assembly having a cover welded to a crossover tube, in which a flash trap as disclosed herein is used;

(2) FIG. 2 is a perspective view of the assembled crossover tube before overmolding;

(3) FIG. 3 is a plan view of the crossover tube assembly shown in FIG. 2;

(4) FIG. 4 is a cross-sectional view of the crossover tube assembly shown in FIGS. 2 and 3, the view being taken along line 4-4 of FIG. 3;

(5) FIG. 5 is an enlarged view of a portion of the crossover tube assembly shown in FIG. 4;

(6) FIG. 6 is an elevational view of the crossover tube;

(7) FIG. 7 is a an elevational view of the crossover tube cover; and

(8) FIG. 8 is a cross-sectional view similar to FIG. 5, but illustrating weld flash captured in the weld trap.

(9) Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of including, comprising and variations thereof is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(10) Referring now more specifically to the drawings and to FIG. 1 and FIG. 2 in particular, an automotive cooling system manifold assembly 10 is shown, which includes a crossover tube assembly 12 having a manifold 14 overmolded thereon. Crossover tube assembly 12 includes a crossover tube 16 and crossover tube cover 18 welded to one another. Crossover tube cover 18 defines a flash trap 20 (FIG. 5) as disclosed herein.

(11) It should be understood that manifold assembly 10 is merely an exemplary embodiment in which a flash trap as described herein can be used advantageously. Other types of manifold assemblies with crossover tube assemblies of other types therein also can employ the use of the present flash trap. Further, while a flash trap is described herein with respect to a manifold assembly in an automobile cooling system, it should be understood that the flash trap hereof also can be used in other types of assemblies and for welded joints established in structures and assemblies other than manifold assemblies in automobile cooling systems.

(12) Crossover tube 16 is a generally elongated tubular body having fluid line connection fittings 22, 24, 26 for establishing fluid flow connections within an automobile cooling fluid circuit. Further, at one end thereof, crossover tube 16 defines an opening 28. An inner surface of opening 28 defines a first weld joint surface 30 surrounding opening 28. Inwardly of first weld joint surface 30, opening 28 further defines a shoulder 32 and an inner surface 34. Opening 28 is slightly narrower at inner surface 34 than at first weld joint surface 30. In other words, the opening 28 defines a stepped profiled with the inner surface 34 disposed laterally inward relative to the first weld joint surface 30. The fist weld joint surface 30 extends into the opening 287 from the end of the crossover tube 16 to a junction between the first weld joint surface 30 and the inner surface 34, and the inner surface 34 extends into the opening 28 from the junction between the first weld joint surface 30 and the inner surface 34 to a laterally extending (e.g., up and down from the perspective of FIGS. 4, 5, and 8)stop surface.

(13) Crossover tube cover 18 is sized and configured to fit closely within open and 28. An edge of crossover tube cover 18 defines a second weld joint surface 36 surrounding crossover tube cover 18. In the assembled configuration of crossover tube assembly 12, crossover tube cover 18 fits closely within opening 28, and first weld joint surface 30 and second weld joint surface 36 confront one another to define a weld joint region 38. That is, the second weld joint surface 36 at least partially overlaps axially (e.g., along a longitudinal centerline defined along the opening 28) with the first weld joint surface 30, and the weld joint region 38 is arranged within a gap formed laterally between the first weld joint surface 30 and the second weld joint surface 36.

(14) Flash trap 20 is a depression, hollow or valley adjacent second weld joint surface 36 on crossover tube cover 18. In the exemplary embodiment, flash trap 20 surrounds crossover tube cover 18 at the outer edge thereof. Accordingly, in the assembled configuration of crossover tube cover 18 within opening 28, flash trap 20 coextends with weld joint region 38.

(15) Inwardly of flash trap 20, crossover tube cover 18 defines a lip 40 of slightly smaller diameter than a diameter defined by second weld joint surface 36. That is, the flash trap 20 is arranged inwardly from the end of the opening 28 between the weld joint region 38 and the lip 40 of the cross tube cover 18. The flash trap 20 is arranged inwardly from the end of the opening 28 relative to the weld joint region 38. Inner surface 34 extends over flash trap 20 and closely confronts lip 40, so that inner surface 34 and lip 40 together with flash trap 20 define an enclosed pocket or region in which weld flash can be received, captured and prevented from migrating more deeply into crossover tube 16.

(16) During assembly of crossover tube assembly 12, crossover tube cover 18 is placed in opening 28 so that first weld joint surface 30 and second weld joint surface 36 overlie one another. Inner surface 34 and lip 40 closely confront. A welding process is initiated externally and directed inwardly, so that a weld joint 42 is established within weld joint region 38. As melt, or weld flash, is generated between first weld joint surface 30 and second weld joint surface 36, the weld flash is forced toward the interior of the crossover tube 16. As the weld flash migrates inwardly, the weld flash flows into flash trap 20 and is captured in the flash trap. Further migration of weld flash into crossover tube 16 is inhibited, and the weld flash is held away from an area where it could be dislodged during vehicle use, and then circulated by the coolant flowing through the system.

(17) The condition of weld flash having been captured and retained is shown in FIG. 8, wherein a volume of weld flash 44 is shown within flash trap 20. It should be understood that weld flash migrating beyond weld joint 42 may be sporadic and intermittent, and that weld flash may be present in flash trap 20 only at discrete and isolated locations. In some assemblies, no weld flash may be present in flash trap 20. However, flash trap 20 should define a volume sufficient for receiving a maximum amount of weld flash that would be created in a typical assembly and welding process.

(18) Further variations and modifications of the foregoing are within the scope of the present invention. It is understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.

(19) Various features of the invention are set forth in the following claims.