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 having a first weld joint surface; a second component having a second weld joint surface; said first weld joint surface and said second weld joint surface confronting one another in a weld joint region; a weld joint formed in said weld joint region; and a flash trap formed in at least one of said first component and said second component adjacent the weld joint surface thereof.

2. The welded assembly of claim 1, said flash trap being a depression.

3. The welded assembly of claim 1, said flash trap coextending with said weld joint region.

4. The welded assembly of claim 3, the other of said first component and said second component having a surface overlying said depression.

5. The welded assembly of claim 4, said first component and said second component having confronting surfaces adjacent said flash trap on a side of said flash trap opposite from said weld joint region.

6. The welded assembly of claim 5, said flash trap being a depression in said at least one surface.

7. The welded assembly of claim 1, the other of said first component and said second component having a surface overlying said flash trap.

8. The welded assembly of claim 1, said first component and said second component having confronting surfaces adjacent said flash trap on a side of said flash trap opposite from said weld joint region.

9. The welded assembly of claim 8, the other of said first component and said second component having a surface overlying said flash trap.

10. The welded assembly of claim 9, including weld flash in said flash trap.

11. The welded assembly of claim 1, including weld flash in said flash trap.

12. A crossover tube assembly for an automobile cooling system; comprising: a crossover tube having an opening; a crossover tube cover disposed in said opening; confronting surfaces of said crossover tube and said crossover tube cover defining a weld joint region; and a depression in at least one of said crossover tube and said crossover tube cover defining a flash trap adjacent said weld joint region.

13. The crossover tube assembly of claim 12, said depression defined as a continuous channel in the periphery of said crossover tube cover.

14. The crossover tube assembly of claim 12, said crossover tube cover and said crossover tube having confronting surfaces adjacent said depression along an opposite side of said depression from said weld joint region.

15. The crossover tube assembly of claim 14, said flash trap coextending with said weld joint region

6. The crossover tube assembly of claim 15, said depression defined as a continuous channel in the periphery of said crossover tube cover.

17. The crossover tube assembly of claim 12, said flash trap coextending with said weld joint region.

18. A crossover tube assembly for an automobile cooling system; comprising: a crossover tube having an opening; a crossover tube cover disposed in said opening; a weld joint formed between said crossover tube and said crossover tube cover; and a flash trap in at least one of said crossover tube and said crossover tube cover inwardly in said crossover tube from said weld joint.

19. The crossover tube assembly of claim of claim 18, said flash trap being a continuous groove in an outer edge surface of said crossover tube cover.

20. The crossover tube assembly of claim 19, including weld flash disposed in said flash trap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] 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;

[0014] FIG. 2 is a perspective view of the assembled crossover tube before overmolding;

[0015] FIG. 3 is a plan view of the crossover tube assembly shown in FIG. 2;

[0016] 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;

[0017] FIG. 5 is an enlarged view of a portion of the crossover tube assembly shown in FIG. 4;

[0018] FIG. 6 is an elevational view of the crossover tube;

[0019] FIG. 7 is a an elevational view of the crossover tube cover, and

[0020] FIG. 8 is a cross-sectional view similar to FIG. 5, but illustrating weld flash captured in the weld trap.

[0021] 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

[0022] 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.

[0023] 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.

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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. 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.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] Various features of the invention are set forth in the following claims.