End Forming Tool for Forming a Protrusion on a Tube

This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 63/710,375, filed Oct. 22, 2024, and U.S. Provisional Patent Application No. 63/575,138, filed on Apr. 5, 2024, which applications are incorporated herein by reference in their entireties.

The present disclosure relates to tools, and more particularly, to a tool used to end form or change the shape of a tube.

End forming is a process that is used to change the geometry of a tube, typically at or near the end of the material. The process dates back many decades: once done with castings, manufacturers have now transitioned to custom, machine-forming for cost efficiency. The most requested types of end forming include beading, expanding, flanging, flaring, grooving, knurling, reducing and thickening. These operations can be done on a variety of part specifications and materials, including copper, aluminum, brass, steel and stainless steel.

Beading is the most popular type of end forming. This process is commonly used for automotive and heavy truck applications where multiple tubes must be connected to join systems or assemblies. This could be a small component such as a fuel pump, or something larger like an engine block. While the automotive industry has been a key driver for end forming, other industries also rely on this technique. For example, residential and commercial water companies rely on end forming for tubing used to transport water and waste. Refrigeration is also an area where end forming is used to create piping for radiators. Additionally, this process is requested by recreation companies (e.g., all-terrain vehicles (ATVs), boats, motorcycles, and side-by-sides), food equipment companies, the aerospace industry, and large-scale furniture makers.

There are two primary machine types used in end forming. For lower volumes, a segmented machine, or sizer, is used. For larger volumes and tighter tolerances, spin-forming machines and progressive ram forming processes are performed to meet the critical dimension. However, current tube end forming machines are very large and immovable, and as such prevent end forming from being performed onsite. Additionally, current tube end forming processes are time consuming.

The present disclosure is directed to one or more exemplary embodiments of an end forming tool assembly.

In an exemplary embodiment, the end forming tool assembly comprises a body including a through-hole extending in a first axial direction, a plunger slidingly engaged with the first hole, a clamp, a first arm pivotably connected to the body, the first arm operatively arranged to engage the clamp, and a die connected to the plunger, and wherein when the plunger is displaced in the first axial direction the first arm applies a force to the clamp.

In an exemplary embodiment, as the plunger is displaced in the first axial direction, the first arm is displaced in a first radial direction. In an exemplary embodiment, the clamp is fixedly secured to the first arm. In an exemplary embodiment, the die is removably connected to the plunger. In an exemplary embodiment, the plunger comprises a first end and a second end, the first end comprising a hole, and the die comprises a protrusion operatively arranged to engage the hole to connect the die to the plunger. In an exemplary embodiment, the end forming tool assembly further comprises a biasing member operatively arranged to apply a radially inward force to the clamp.

In an exemplary embodiment, the plunger comprises a first end engaged with the die, a second end, and at least one leg extending from the second end and including a slot. In an exemplary embodiment, the at least one leg comprises a first leg and a second leg spaced apart from the first leg along the second end. In an exemplary embodiment, the body comprises a flange, the first leg is arranged on a first side of the flange, and the second leg is arranged on a second side of the flange. In an exemplary embodiment, the plunger further comprises a wedging member, and when the plunger is displaced in the first axial direction the wedging member displaces the first arm in a first circumferential direction with respect to the body.

In an exemplary embodiment, the end forming tool assembly further comprises a biasing element arranged around the die and operatively arranged to engage the plunger. In an exemplary embodiment, the end forming tool assembly further comprises a second arm pivotably connected to the body and operatively arranged to engage the clamp, wherein the first arm engages a first side of the clamp and the second arm engages a second side of the clamp, opposite the first side of the clamp.

The present disclosure is directed to one or more exemplary embodiments of a tool for end forming a tube.

In an exemplary embodiment, the tool comprises a body including a first end, a second end, a through-hole extending from the first end to the second end in a first axial direction, and a flange extending in the first axial direction from the second end, a plunger slidingly engaged with the first hole, a clamp including a first portion and a second portion, a first arm pivotably connected to the body, the first arm including a first proximal end and a first distal end arranged to engage the first portion, and a second arm pivotably connected to the body, the second arm including a second proximal end and a second distal end arranged to engage the second portion, wherein when the plunger is displaced in the second axial direction, opposite the first axial direction, the first arm and the second arm apply a radially inward force to the clamp.

In an exemplary embodiment, the tool further comprises a die connected to the plunger. In an exemplary embodiment, the plunger comprises a third end engaged with the die, a fourth end, and at least one leg extending from the fourth end and including a slot. In an exemplary embodiment, the third end comprises a hole, the die comprises a protrusion, and the protrusion engages the hole to connect the die to the plunger. In an exemplary embodiment, the at least one leg comprises a first leg and a second leg spaced apart from the first leg along the second end. In an exemplary embodiment, the first leg is arranged on a first side of the flange, and the second leg is arranged on a second side of the flange.

In an exemplary embodiment, the plunger further comprises a wedging member, and when the plunger is displaced in the first axial direction the wedging member displaces the first arm in a first circumferential direction with respect to the body and the second arm in a second circumferential direction with respect to the body. In an exemplary embodiment, the tool further comprises a biasing member operatively arranged to bias the first portion and the second portion radially inward.

The present disclosure is directed to one or more exemplary embodiments of an end forming tool assembly.

In an exemplary embodiment, the end forming tool assembly comprises a body including a bracket assembly comprising at least one wall including a first hole, and a first flange including a second hole, a clamp arranged in the bracket assembly, a first arm pivotably connected to the body, the first arm operatively arranged to engage the clamp, a link including a base, and a first leg extending from the base and arranged to engage the first arm, and a die connected to the link, wherein when the link is displaced in a first axial direction the first arm applies a force to the clamp.

In an exemplary embodiment, as the link is displaced in the first axial direction, the first arm is displaced in a first radial direction. In an exemplary embodiment, the first arm extends through the first hole to engage the clamp. In an exemplary embodiment, the first leg is translatably connected to the first arm. In an exemplary embodiment, the first arm comprises a curvilinear slot and the first leg is engaged with the slot via a pin. In an exemplary embodiment, the clamp is removably connected to the bracket assembly. In an exemplary embodiment, the die is removably connected to the link. In an exemplary embodiment, the link comprises a third hole and a second flange extending radially into the third hole, the die comprises a groove, and the second flange is operatively arranged to engage the groove.

In an exemplary embodiment, the end forming tool assembly further comprises a plunger connected to the link, wherein the plunger extends through a second flange in the body. In an exemplary embodiment, the plunger is removably connected to the link via a retainer. In an exemplary embodiment, the end forming tool assembly further comprises a plate removably connected to the body, the plate operatively arranged to engage a tube. In an exemplary embodiment, the end forming tool assembly further comprising a clip removably connected to the body, the clip operatively arranged to engage the clamp within the bracket assembly.

In an exemplary embodiment, the second hole extends in the first axial direction and the first hole extends in a radial direction, wherein the radial direction is arranged substantially perpendicular to the first axial direction. In an exemplary embodiment, the end forming tool assembly further comprises a second arm pivotably connected to the body and operatively arranged to engage the clamp, wherein the first arm engages a first side of the clamp and the second arm engages a second side of the clamp, opposite the first side of the clamp. In an exemplary embodiment, the link further comprises a second leg extending from the base and arranged to engage the second arm, and when the link is displaced in a first axial direction the first arm and the second arm squeeze the clamp.

The present disclosure is directed to one or more exemplary embodiments of a tool for end forming a tube.

In an exemplary embodiment, the tool comprises a body including a bracket assembly comprising a first wall including a first hole, and a second wall including a second hole, a clamp removably arranged in the bracket assembly, a first arm pivotably connected to the body and operatively arranged to engage the clamp, a second arm pivotably connected to the body and operatively arranged to engage the clamp, a link including a base, a first leg extending from the base and arranged to engage the first arm, and a second leg extending from the base and arranged to engage the second arm, and a die removably connected to the link, wherein when the link is displaced in a first axial direction the first arm and the second arm apply a radially inward force to the clamp.

In an exemplary embodiment, the first arm extends through the first hole to engage a first side of the clamp, and the second arm extends through the second hole to engage a second side of the clamp, opposite the first side of the clamp. In an exemplary embodiment, the first leg is slidably connected to the first arm. In an exemplary embodiment, the first leg is slidably connected to the first arm, and the second leg is slidably connected to the second arm. In an exemplary embodiment, the link comprises a third hole including a flange, the die comprises an annular groove, and the flange engages the groove to connect the die to the link. In an exemplary embodiment, the tool further comprises an actuator operatively arranged to displace the link in a first axial direction with respect to the body.

According to aspects illustrated herein, there is provided a portable end forming tool assembly for a tube that can be used on a job site in any industry, for example, the industrial and commercial tube forming, heating, ventilation, and air conditioning (HVAC), plumbing, and automotive, industries. In an exemplary embodiment, the end forming tool assembly is operatively arranged to form a bead, shoulder, and/or radially outward extending protrusion on the tube.

In an exemplary embodiment, the end forming tool assembly comprises a mechanism to hold a tube in place and form the required feature thereon (e.g., bead, shoulder, radially outward facing protrusion, etc.). The end forming tool assembly utilizes linear motion to capture and clamp the tube and then form the required features. The end forming tool assembly utilizes one power source to clamp and form the tube. In an exemplary embodiment, the end forming tool assembly utilizes a cam mechanism/method to end form a tube that eliminates brazing when connecting and installing HVAC and plumbing fluid transfer lines.

In an exemplary embodiment, the end forming tool assembly: 1) eliminates the need for brazing with a flame-less connection process; 2) eliminates the need to pre-form tubes (since the end forming tool assembly allows tubes to be end formed on a job site; 3) reduces the potential of cracked braze joints within the indoor unit (IDU) and outdoor unit (ODU) or wherever a braze joint is located while torquing the flare nut solution as well as the other torque required fittings; 4) reduces time per job with quick connection system because of the bead/shoulder/protrusion creation; 5) reduces damage to O-rings with radiused nose on tube end form as well as eliminates the heat damage caused by braze operations; 6) creates interface of a formed tube to HVAC and plumbing connectors without brazing or flaring; 7) creates a consistent sealing surface to seal within a fitting; 8) reduces the potential for contamination in the tube systems that can damage mating equipment; and 9) reduces the manual strain since no pumping or tightening is required.

These and other objects, features, and advantages of the present disclosure will become readily apparent upon a review of the following detailed description of the disclosure, in view of the drawings and appended claims.

It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific assemblies and systems illustrated in the attached drawings and described in the following specification are simply exemplary embodiments of the inventive concepts defined herein. Hence, specific dimensions, directions, or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless expressly stated otherwise. Also, although they may not be, like elements in various embodiments described herein may be commonly referred to with like reference numerals within this section of the application.

Furthermore, it is understood that this disclosure is not limited to the particular methodology, materials and modifications described and as such may, of course, vary. It is also understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the claims.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure pertains. It should be understood that any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the example embodiments.

Where used herein, the terms “first,” “second,” and so on, do not necessarily denote any ordinal, sequential, or priority relation, but are simply used to more clearly distinguish one element or set of elements from another, unless specified otherwise.

Where used herein, the term “about” when applied to a value is intended to mean within the tolerance range of the equipment used to produce the value, or, in some examples, is intended to mean plus or minus 10%, or plus or minus 5%, or plus or minus 1%, unless otherwise expressly specified.

It should be appreciated that the term “substantially” is synonymous with terms such as “nearly,” “very nearly,” “about,” “approximately,” “around,” “bordering on,” “close to,” “essentially,” “in the neighborhood of,” “in the vicinity of,” etc., and such terms may be used interchangeably as appearing in the specification and claims. It should be appreciated that the term “proximate” is synonymous with terms such as “nearby,” “close,” “adjacent,” “neighboring,” “immediate,” “adjoining,” etc., and such terms may be used interchangeably as appearing in the specification and claims. The term “substantially” is intended to mean values within ten percent of the specified value.

Where used herein, the term “exemplary” is intended to mean “an example of,” “serving as an example,” or “illustrative,” and does not denote any preference or requirement with respect to a disclosed aspect or embodiment.

It should be understood that use of “or” in the present application is with respect to a “non-exclusive” arrangement, unless stated otherwise. For example, when saying that “item x is A or B,” it is understood that this can mean one of the following: (1) item x is only one or the other of A and B; (2) item x is both A and B. Alternately stated, the word “or” is not used to define an “exclusive or” arrangement. For example, an “exclusive or” arrangement for the statement “item x is A or B” would require that x can be only one of A and B. Furthermore, as used herein, “and/or” is intended to mean a grammatical conjunction used to indicate that one or more of the elements or conditions recited may be included or occur. For example, a device comprising a first element, a second element and/or a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or a device comprising a second element and a third element.

Moreover, as used herein, the phrases “comprises at least one of” and “comprising at least one of” in combination with a system or element is intended to mean that the system or element includes one or more of the elements listed after the phrase. For example, a device comprising at least one of: a first element; a second element; and a third element, is intended to be construed as any one of the following structural arrangements: a device comprising a first element; a device comprising a second element; a device comprising a third element; a device comprising a first element and a second element; a device comprising a first element and a third element; a device comprising a first element, a second element and a third element; or a device comprising a second element and a third element. A similar interpretation is intended when the phrase “used in at least one of:” is used herein.

It should be appreciated that the term “tube” as used herein is synonymous with hose, pipe, channel, conduit, tube end form, or any other suitable pipe flow used in hydraulics and fluid mechanics. It should further be appreciated that the term “tube” can mean a rigid or flexible conduit of any material suitable for containing and allowing the flow of a gas or a liquid.

By “non-rotatably connected” elements, it is meant that the elements are connected so that whenever one of the elements rotate, all the elements rotate, and relative rotation between the elements is not possible. Radial and/or axial movement of non-rotatably connected elements with respect to each other is possible, but not required. By “rotatably connected” elements, it is mean that the elements are rotatable with respect to each other.

Adverting now to the figures,is a front perspective view of end forming tool assembly, in a non-engaged state.is a front perspective view of end forming tool assembly.is a rear perspective view of end forming tool assembly.is a front perspective exploded view of end forming tool assembly.is a rear perspective exploded view of end forming tool assembly.is a cross-sectional view of end forming tool assemblytaken generally along line-in.is a cross-sectional view of end forming tool assemblytaken generally along line-in.is a cross-sectional view of end forming tool assemblytaken generally along line-in.

End forming tool assemblygenerally comprises body, link, at least one arm, for example, armsA-B, clamp, and die. In an exemplary embodiment, end forming tool assemblyfurther comprises plunger. In an exemplary embodiment, end forming tool assemblyfurther comprises actuator. End forming tool assemblyis operatively arranged to end form tube. Prior to end forming, tubecomprises end, end, and radially outward facing surface.

Bodygenerally comprises a plate including end, end, and bracket assembly. In an exemplary embodiment, bracket assemblyis arranged proximate endand generally comprises at least one protrusion or wall, for example, wallA and wallB. WallA comprises holeA extending generally in a radial direction therethrough. HoleA is operatively arranged to allow armA to engage clamp, as will be described in greater detail below. WallB comprises holeB extending generally in a radial direction therethrough. HoleB is operatively arranged to allow armB to engage clamp, as will be described in greater detail below.

In an exemplary embodiment, bodyfurther comprises flangearranged at or proximate to end. Flangecomprises holeextending in an axial direction therethrough. Holeis operatively arranged to engage tube, namely, such that tubecan pass through flangein an axial direction. In an exemplary embodiment, bodyfurther comprises flangearranged proximate to end. Flangecomprises holeextending in an axial direction therethrough. Holeis operatively arranged to allow plungerto extend axially therethrough to connect to link, as will be described in greater detail below.

In an exemplary embodiment, bodyfurther comprises holeand plate or tube holder. Plateis operatively arranged to be removably engaged with bodyvia hole. As best shown in, plateis removably engaged with holeto engage tube. Platecomprises bottom surfaceand top surface. Top surfaceis arranged to engage end. In an exemplary embodiment, bottom surfaceengages protrusions extending inward from wallsA-B. In an exemplary embodiment, platefurther comprises protrusionextending from bottom surfacein axial direction AD. Protrusionis operatively arranged to engage bodyto prevent over insertion of platein hole. In the disengaged state, plateholds tubein place. Platealso provides an indicator of how far tubeneeds to be inserted into hole, in axial direction AD. Prior to engaging end forming tool assembly, plateis removed to allow dieto engage endof tube, as will be described in greater detail below.

In an exemplary embodiment, bodyfurther comprises at least one hole, for example, holeA and holeB, and clip. Clipcomprises at least one arm, for example armsA-B, operatively arranged to extend through holesA-B and engage clamp. ArmsA-B may be clastic and comprise inward extending protrusions arranged thereon. As best shown in, armsA-B engage outward facing surfacesA-B of clampto hold clampin position within bracket assembly, prior to engaging end forming tool assembly. Clipis removably connectable to body.

ArmA is rotatably connected to body, for example, via pinA. ArmA comprises holeA arranged to engage pinA, slotA, and engaging surfaceA. In an exemplary embodiment, and as best shown in, slotA is at least partially curvilinear and is operatively arranged to engage pinA. As pinA is displaced in slotA, engaging surfaceA of armA is displaced radially, for example, in radial direction RDand radial direction RD, to engage and disengage clamp, respectively. In an exemplary embodiment, armA further comprises engaging memberA displaceably and/or removably connected to engaging surfaceA. Engaging memberA is engaged with holeA and is adjustable, for example, via a threaded connection therein. Engaging memberA may be adjusted to increase or decrease the force with which armA engages clamp portionA.

ArmB is rotatably connected to body, for example, via pinB. ArmB comprises holeB arranged to engage pinB, slotB, and engaging surfaceB. In an exemplary embodiment, and as best shown in, slotB is at least partially curvilinear and is operatively arranged to engage pinB. As pinB is displaced in slotB, engaging surfaceB of armB is displaced radially, for example, in radial direction RDand radial direction RD, to engage and disengage clamp, respectively. In an exemplary embodiment, armB further comprises engaging memberB displaceably and/or removably connected to engaging surfaceB. Engaging memberB is engaged with holeB and is adjustable, for example, via a threaded connection therein. Engaging memberB may be adjusted to increase or decrease the force with which armB engages clamp portionB.

In an exemplary embodiment, end forming tool assemblyfurther comprises a linkage removably connectable to body, the linkage comprising one or more elements, for example, armand leg. Legis operatively arranged to be connected to body. For example, legis removably connectable to flange. Armis connected to legand is operatively arranged to maintain armsA-B on body, for example, via pinsA-B. In an exemplary embodiment, legcomprises holeA including a female component that engages a male connecting component of protrusionon body. As shown, protrusionextends from flange, for example, in an axial direction.

Clampcomprises portionA and portionB. PortionsA-B are configured to be arranged radially around tubeand squeezed against radially outward facing surfaceduring engagement of end forming tool assembly. Clampis removably arranged in bracket assembly. PortionA comprises inward facing surfaceA, spaceA, and outward facing surfaceA. Inward facing surfaceA comprises a plurality of teeth or threading arranged to engage radially outward facing surface. SpaceA is arranged to engage die. ArmA engages outward facing surfaceA to apply radially inward force on portionA. PortionB comprises inward facing surfaceB, spaceB, and outward facing surfaceB. Inward facing surfaceB comprises a plurality of teeth or threading arranged to engage radially outward facing surface. SpaceB is arranged to engage die. ArmB engages outward facing surfaceB to apply radially inward force on portionB.

As best shown in, endof tubeis spaced apart in axial direction ADfrom inward facing surfacesA-B. Specifically, endis arranged in or extends through spacesA-B. ArmsA-B and/or engaging membersA-B extend through holesA-B and engage outward facing surfacesA-B to squeeze portionsA-B around tube, respectively. Dieis displaced in axial direction ADinto spacesA-B to engage endof tube. It should be appreciated that the outer diameter of dieis less than or equal to the inner diameter formed by spacesA-B. When dieis forced into enda radially outward extending protrusion is formed on tube.

Link or bodycomprises baseand at least one leg extending axially therefrom, for example, legA and legB. LegB is spaced apart from legA, for example, in radial direction RD. In an exemplary embodiment, legA comprises two portions that are spaced apart and engage opposite sides of armA. LegA comprises holeA and pinA extends through legA and slotA of armA. In an exemplary embodiment, legB comprises two portions that are spaced apart and engage opposite sides of armB. LegB comprises holeB and pinB extends through legB and slotB of armB.

Linkis arranged to be connected to plunger. In an exemplary embodiment, plungergenerally comprises end, end, and groovearranged proximate to end. Endis arranged to engage linkand endis arranged to engage actuator. In an exemplary embodiment, and as best shown in, linkcomprises holeextending into basein axial direction ADfrom the bottom thereof. Linkmay further comprise hole. In an exemplary embodiment, holeextends into basein a direction perpendicular to axial direction AD. Endof plungeris engaged with holesuch that grooveis aligned with hole. Retaineris then inserted into holeand engages groove, for example via two legs, to connect plungerto link. Retainercan be removed from holeto disconnect linkfrom plunger.