Attachment of connector bushings to tubular electric heating elements

1. A method of attaching a connector bushing to an end of a tubular electric heating element comprising:

providing an elongated sleeve-like bushing having a bore extending along the longitudinal axis thereof; said bushing being of a deformable, crimpable metal;

inserting an end portion of a tubular metal electric heating element into said bore such that said end portion extends along and within said bore, said bore and said element having diameters selected such that a close sliding fit exists between them;

positioning a portion of the bushing together with the element end portion located therein into a crimping machine having a plurality of radially arranged jaws in such manner that said jaws surround said bushing portion;

activating said crimping machine to cause said jaws to advance radially toward and to engage said bushing portion all around the circumference thereof with sufficient force to radially deform and crimp the metal of said bushing portion into a direct force fit engagement to provide a fluid tight seal with the heating element end portion.

2. The method of claim 1 wherein the jaws of said crimping machine apply sufficient force that the bore of said portion of the bushing is permanently reduced to a diameter slightly less than the original outside diameter of the element which existed prior to the activation of the crimping machine thereby to assist in providing a fluid-tight joint between the bushing and the element which is capable of strongly resisting relative axial displacement therebetween.

3. The method of claim 1 wherein the jaws of said crimping machine act with sufficient force as to radially deform and crimp the metal of said bushing portion into an interference fit with said heating element wherein the bore diameter of the radially deformed portion of the bushing and the outside diameter of the element end portion are permanently reduced in a crimping zone to a common value which is less than the element diameter which existed prior to the crimping step, said crimping zone being spaced from a free end of said end portion of the element.

4. The method of claim 3 wherein said bushing has a pair of cylindrical sections disposed on opposing sides of a larger diameter intermediate portion which acts as a mechanical shoulder for fastening purposes, a first one of said cylindrical sections being threaded for fastening purposes and the other one of said sections comprising said portion of the bushing which is engaged and deformed by the jaws of the crimping machine.

5. The method of claim 3 wherein said connector bushing is made of free machining brass.

6. The combination of a tubular metal electric heating element and a connector bushing which is mounted on an end portion of said element;

said bushing being of an elongated sleeve-like configuration and having a bore extending along the longitudinal axis thereof and being made of a deformable, crimpable metal;

said end portion of the element extending along and within the bore of the bushing; and

a portion of said bushing having been radially deformed and crimped into a direct force fit engagement to provide a fluid tight seal all around the heating element end portion.

7. The heating element connector bushing combination of claim 6 wherein said heating element is of circular cross-section and of preselected diameter throughout its length except at a location where said bushing is in said force fit engagement with said element, with the bore of said bushing portion and the outside diameter of said heating element at said location having a common diameter less than said preselected diameter to provide a fluid-tight joint, said location being spaced inwardly from an outer free end of said end portion of the element.

8. The combination of claim 6 wherein said bushing portion is in an interference fit with said heating element with the bore of the radially deformed portion of the bushing and the outside diameter of the element end portion engaged thereby having a common value which is less than the diameter of those portions of the element not engaged by said bushing.

9. The combination according to claim 7 wherein said bushing comprises a pair of generally cylindrical sections located to opposing sides of a centrally located diametrically larger shoulder portion.

10. The combination according to claim 8 wherein said bushing comprises a pair of generally cylindrical sections located to opposing sides of a centrally located diametrically larger shoulder portion.

11. The combination according to claim 9 wherein one said cylindrical section is threaded for fastening purposes with the other generally cylindrical section comprises said bushing portion which has been radially deformed and crimped.

12. The combination according to claim 10 wherein one said cylindrical section is threaded for fastening purposes with the other generally cylindrical section comprises said bushing portion which has been radially deformed and crimped.