U.S. patent application number 09/827797 was filed with the patent office on 2002-02-21 for gasket tab retainer.
This patent application is currently assigned to Dana Corporation. Invention is credited to Belter, Jerome G..
Application Number | 20020020969 09/827797 |
Document ID | / |
Family ID | 26907157 |
Filed Date | 2002-02-21 |
United States Patent
Application |
20020020969 |
Kind Code |
A1 |
Belter, Jerome G. |
February 21, 2002 |
Gasket tab retainer
Abstract
A gasket for sealing between a flange and a mating surface
includes a metal layer having at least two integral tabs formed as
a continuation of said metal layer. The flange includes at least
two apertures that are correspondingly sized and positioned to
receive the tabs. In a first embodiment, each tab is formed on the
outer periphery of the metal layer and comprises two contoured,
resilient legs separated to form a vertical slot between the legs,
and a contoured tip located at a distal end of each tab leg. In a
second embodiment, each tab includes a serrated resilient edge that
promotes tab insertion, but digs into an inner periphery of the
aperture upon attempted tab removal. In a third embodiment, each
tab is formed on an inner periphery of two mounting apertures
formed in the metal layer.
Inventors: |
Belter, Jerome G.; (Mt.
Prospect, IL) |
Correspondence
Address: |
RADER, FISHMAN & GRAUER PLLC
39533 WOODWARD AVENUE
SUITE 140
BLOOMFIELD HILLS
MI
48304-0610
US
|
Assignee: |
Dana Corporation
|
Family ID: |
26907157 |
Appl. No.: |
09/827797 |
Filed: |
April 6, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09827797 |
Apr 6, 2001 |
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09218490 |
Dec 22, 1998 |
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6318731 |
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60212453 |
Jun 19, 2000 |
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Current U.S.
Class: |
277/591 |
Current CPC
Class: |
F16J 2015/0868 20130101;
F16J 15/0831 20130101; F16J 15/0818 20130101; F16J 15/061
20130101 |
Class at
Publication: |
277/591 |
International
Class: |
F02F 011/00 |
Claims
What is claimed is:
1. An exhaust manifold gasket for sealing between an exhaust header
and a mating flange, said gasket comprising: at least two metal
layers having a length and a width defining at least two mounting
apertures, said length greater than said width, said layers
constituting at least a part of the gasket and including at least
one hole formed therein corresponding to a hole in the mating
flange; and at least two integral tabs formed on at least one of
said layers, each of said tabs formed as a continuation of said
layer on an inner periphery of each of said mounting apertures,
said tabs bent generally perpendicular to said layer, each of said
tabs received in an aperture formed on the mating flange.
2. An exhaust manifold gasket as recited in claim 1, wherein said
tabs are positioned generally vertical to said width of the
gasket.
3. An exhaust manifold gasket as recited in claim 1, wherein said
tabs are formed from two contoured tab legs that are separated to
form a slot therebetween.
4. An exhaust manifold gasket as recited in claim 3, wherein each
tab leg further includes a contoured tip located at a distal end
thereof.
5. An exhaust manifold gasket as recited in claim 4, wherein said
contoured tip of each said tab leg includes a laterally outwardly
sloped portion along an outside edge of said tab leg.
6. An exhaust manifold gasket as recited in claim 5, wherein each
said sloped portion terminates in a contoured, laterally outwardly
extending protrusion.
7. An exhaust manifold gasket as recited in claim 1, wherein an
outermost periphery of said tabs in an uncompressed state is
greater in dimension than a corresponding inner periphery of said
apertures such that an interference fit is created by said tabs and
said apertures.
8. An exhaust manifold gasket as recited in claim 7, wherein said
outermost periphery of said tabs includes a serrated edge, said
edge oriented to promote tab insertion, but digging into said inner
periphery upon attempted tab removal.
9. An exhaust manifold gasket as recited in claim 1, wherein the
metal layers are stainless steel.
10. A sealing assembly, comprising: a flange to be sealingly
engaged against a mating surface, said flange and said mating
surface including at least one first hole formed therein to be
sealed, said flange further defining at least two apertures formed
on said flange; a metal layer constituting at least part of a
gasket, said metal layer having a length and a width such that said
length is greater than said width and defining at least two
mounting apertures, said layer including at least one second hole
corresponding to said first hole; and at least two integral tabs,
each of said tabs formed as a continuation of said layer on an
inner periphery of each of said mounting apertures, said tabs bent
generally perpendicularly to said layer and received in said
apertures.
11. A sealing assembly as recited in claim 10, wherein an outermost
periphery of said tabs in an uncompressed state is greater in
dimension than a corresponding inner periphery of said apertures
such that an interference fit is created by said tabs and said
apertures.
12. A sealing assembly as recited in claim 11, wherein said
outermost periphery of said tabs includes a serrated edge, said
edge oriented to promote tab insertion, but digging into said inner
periphery of said apertures upon attempted tab removal.
13. A sealing assembly as recited in claim 10, wherein each of said
tabs is formed from two contoured tab legs that are separated to
form a slot therebetween.
14. A sealing assembly as recited in claim 13, wherein each tab leg
further includes a contoured tip located at a distal end of each
tab leg.
15. A sealing assembly as recited in claim 14, wherein said
contoured tip of each said tab leg includes an outwardly sloped
portion.
16. A sealing assembly as recited in claim 15, wherein each of said
sloped portions terminates in a contoured, outwardly extending
protrusion.
17. A sealing assembly as recited in claim 10, wherein the metal
layers are stainless steel.
Description
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
Provisional Application No. 60/212,453, filed Jun. 19, 2000, which
is a continuation-in-part of co-pending U.S. application Ser. No.
09/218,490, filed Dec. 22, 1998, the disclosures of which are
incorporated by reference herein in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a gasket tab retainer. More
particularly, the present invention relates to a multiple layer
steel laminate gasket including at least two integral tabs formed
in a metal layer of the gasket to locate and retain the gasket on a
mating flange.
BACKGROUND OF THE INVENTION
[0003] Gaskets are often used as seal between mating metal
surfaces. One common application involves the placement of a gasket
between a head and an exhaust manifold of an internal combustion
engine. Another application involves gasket placement between the
exhaust manifold and an exhaust pipe flange. Gaskets for either
application can be considered high temperature gaskets and more
particularly exhaust manifold gaskets since they provide an exhaust
seal which prevents the byproducts of combustion exiting the engine
from escaping into the engine compartment of a vehicle.
[0004] Exhaust manifold gaskets are typically installed by placing
the gasket between an exhaust manifold and its mating component and
aligning bolt holes or apertures formed in the gasket with
corresponding holes formed in the manifold and mating component.
Typically, a threaded fastener passes through the manifold and
gasket and engages a corresponding threaded aperture formed in the
mating component. Some maneuvering of the manifold and gasket
relative to the mating component may be required to align the holes
therein with the corresponding threaded apertures of the mating
component before the fasteners can be inserted. However, during the
assembly process, the gasket may slip from its desired position or
drop off the end of the inserted fastener before it can be fixed in
place between the exhaust manifold and its mating component.
[0005] Attempts have been made to retain a gasket against a mating
component prior to and during assembly by providing separate clips
for attaching the gasket to a gasket attaching portion of an engine
part. Using such clips, a gasket is placed adjacent the mating
component, and the separate clip is attached to the mating
component such that the gasket is secured in place between the clip
and the mating component. The separate clips typically include one
end for contacting the gasket about an outer periphery thereof
while a second end is attached to an outer periphery of a mating
component or to an outer periphery of a connecting portion between
mating components. Use of such separate clips does not eliminate
the problems involved in the assembly process whereby a gasket may
slip from its desired position. The clip attached to an outer
periphery of the mating component may be jostled or become
otherwise dislodged by contacting adjacent parts. Further, separate
clips may become dislodged during sub-assembly handling and
shipping of mating components, allowing the gasket to slip or drop.
As a result, the gasket sealing portion may become offset or
misaligned from the holes to be sealed before assembly, again
requiring some maneuvering of the manifold and gasket relative to
the mating component during assembly in order to achieve a tight
seal. Assembly of a gasket to a mating flange using separate clips
is also a complex operation, requiring multiple parts and means to
hold the gasket adjacent the mating flange while the clips are
attached. Finally, because such clips are designed to interact with
an outer periphery of a gasket, the gasket itself must cover the
full radial extent of a mating surface.
SUMMARY OF THE INVENTION
[0006] An exhaust manifold gasket for sealing between an exhaust
header and a mating flange is provided that includes integral tabs
formed on an outer periphery of the gasket to locate and retain the
gasket on the mating flange. In accordance with the present
invention, at least two tabs are integrally formed on an outer
periphery of a metal layer of a multiple layer steel laminate
gasket for attaching the gasket to a first mating flange. After the
gasket is attached, the first mating flange to which the gasket is
attached by the tabs is easily fixed to a second mating flange
without supporting the gasket between the flanges.
[0007] The gasket of the present invention includes a metal layer
having a length and a width, wherein the length is greater than the
width. The metal layer constitutes at least a part of the gasket,
and includes at least one hole formed therein corresponding to an
exhaust gas flow hole in the first mating flange. A first outer
periphery is defined by a radially outer edge of the first mating
flange, while the gasket length and width defines a second outer
periphery. The second outer periphery fits entirely within the
first outer periphery. At least two tabs are integrally formed
along the width of the layer, and are bent generally perpendicular
relative to the rest of the gasket. The two tabs prevent the gasket
from rotating relative to the mating flange after the gasket has
been installed. The first mating flange further includes at least
two apertures located within the first outer periphery that are
sized and positioned to receive the tabs.
[0008] In one preferred embodiment, each tab comprises two
contoured, resilient legs separated to form a vertical slot between
the legs. Each tab leg further includes a contoured tip located at
a distal end of each tab leg. The contoured tip includes a sloped
portion that slopes laterally outwardly from the distal end of each
tab leg along an outside edge of each tab leg. The sloped portion
terminates in a laterally outwardly extending protrusion that
creates an interference fit when inserted into the aperture. The
vertical slot between the legs allows each leg to deform to adjust
for aperture size tolerance.
[0009] Because the apertures are formed inside the configuration of
the mating component, i.e. within the first outer periphery, a
gasket formed according to the present invention uses less
material, thereby reducing cost. The resilient tab legs deform when
inserted into the corresponding apertures, such that insertion of
the legs into corresponding apertures positively locates the gasket
in place against the mating flange. Thus, the configuration of the
resilient legs produces a tight interference fit within the
apertures. The gasket is therefore held tightly in place by the tab
legs. The tab legs are also positioned vertical to the width of the
gasket, allowing for adjustment of the gasket relative to the
mating flange to account for linear tolerances of the apertures and
for gasket tolerances. Finally, the tabs are integral to a metal
layer that comprises at least a portion of a gasket, so that
manufacture is easily accomplished. Moreover, no separate clips are
needed to positively locate the gasket adjacent a mating
flange.
[0010] In a second preferred embodiment, each tab comprises a
serrated side edge. The edge is oriented such that the tab may be
easily inserted into a mating aperture. However, the edge digs into
the inner periphery of the mating aperture upon attempted removal
of the tab.
[0011] In accordance with a third embodiment, a two layer laminate
gasket is disclosed having at least two mounting apertures. The
gasket includes at least two tabs; each tab being integrally formed
on an inner periphery of an aperture. The geometry and function of
the tabs are substantially similar to those disclosed in the first
two embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The features and inventive aspects of the present invention
will become more apparent upon reading the following detailed
description, claims, and drawings, of which the following is a
brief description:
[0013] FIG. 1 is a top view showing a component such as an engine
manifold with a flange according to the present invention.
[0014] FIG. 2 is a top view showing a gasket according to the
present invention placed adjacent the mating flange of the
component illustrated in FIG. 1.
[0015] FIG. 3 is a side view of a tab retainer as it is inserted
into an aperture according to lines 3-3 of FIG. 2.
[0016] FIG. 4 is a side view of a second embodiment of a tab
retainer.
[0017] FIG. 5 is a bottom view of a third embodiment of a gasket
according to the present invention.
[0018] FIG. 6 is a side view of a tab retainer as it is inserted
into an aperture according to lines 6-6 of FIG. 5.
[0019] FIG. 7 is a side view of the gasket according to lines 7-7
of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] In FIG. 2, a gasket 20 is shown installed adjacent a first
mating flange 22 on an exhaust manifold 23, the manifold being
illustrated in FIG. 1. The gasket 20 includes a plurality of bolt
holes 24 and exhaust gas flow holes 26 that correspond to similar
holes in the first mating flange 22. The mating flange 22 defines a
first outer periphery 28, and the gasket 20 defines a second outer
periphery 30. As can be seen in FIG. 2, the first outer periphery
28 fully encloses the second outer periphery 30. As a result, the
gasket 20 covers less than the full extent of the mating flange 22.
Because of the arrangement of the flow holes 26, the length L of
the gasket 20 is greater than the width W of the gasket.
[0021] Because seals on the exhaust manifold must withstand high
temperatures, the gasket 20 is typically formed from metal, and
usually includes multiple metal layers. Typically, the metal layers
are made from resilient steel, and all layers of the gasket 20 are
sized and shaped to fit and seal a corresponding mating surface.
The outermost (i.e. top and bottom) layers (not shown) of the
gasket 20 may further include embossments, folds or any other
surface feature designed to improve fit, wear and sealing ability
of the gasket.
[0022] According to the present invention, at least one layer of
the gasket 20 includes at least two integral tabs 32 formed along
the second outer periphery 30. The two tabs 32 are spaced from each
other to prevent rotation of the gasket relative to the first
mating flange 22 once the gasket 20 is installed. The first mating
flange 22 includes at least two apertures 34 located within the
first outer periphery that are sized and positioned to receive the
tabs 32. Preferably, the tabs 32 are formed along the outer
periphery of the gasket 20 parallel to the width W of the gasket
20, thereby allowing the tabs 32 to flex within the apertures 34
and account for linear tolerances of the apertures and for gasket
tolerances. Moreover, because the apertures 34 are located within
the first outer periphery of the first mating flange 22, the gasket
itself does not cover the entire surface of the first mating flange
22. Instead, the gasket 20 is smaller than the first mating flange
22, thereby requiring less material for fabrication.
[0023] Prior to assembly of the gasket 20 against the first mating
flange 22, the tabs 32 are bent generally perpendicular relative to
the gasket 20. The gasket 20 is then placed adjacent the first
mating flange 22 so that the tabs 32 align with and are inserted
into the apertures 34. The tabs 32 are sized to frictionally engage
the inner surface 36 of the apertures 34 and to thereby retain the
gasket 20 in place against the first mating flange 22. Thus, an
outermost periphery of tabs 32 in an uncompressed state is greater
in dimension than a corresponding inner surface of the apertures
34.
[0024] The tabs 32 may be formed into any geometric shape that is
convenient to manufacture and that achieves a tight interference
fit within appropriately sized apertures 34. Most preferably, as
seen in FIG.3, the tabs 32 are formed from two contoured legs 38
that are separated to form a slot 40 between the tab legs 38. Each
tab leg 38 further includes a contoured tip 42 located at a distal
end 44 of each tab leg 38.
[0025] The contoured tip 42 of each tab leg is preferably formed
into a sloped portion 46 that slopes laterally outwardly from the
distal end 44 along an outside edge 48 of each tab leg 38. Each
sloped portion 46 terminates in a contoured, laterally outwardly
extending protrusion 50. Thus, a protrusion 50 is located at either
side of the tab 32. As the tab 32 is inserted into the aperture 34,
a portion the sloped portion 46 contacts the inner surface 36 of
the aperture 34, forcing the tab leg 38 to gradually compress
laterally inwardly as it is inserted. Thus, the sloped portion 46
aids in pre-loading the tab legs 38 while making insertion into
aperture 34 easier. The protrusion 50 is sized to create an
interference fit when placed in contact with the inner surface 36
of the aperture 34, but is small enough to be easily inserted
within the aperture 34.
[0026] As noted above, the tab legs 38 are separated to form a slot
40 between the tab legs. Formation of the slot 40 allows the slight
inward deformation of each resilient tab leg 38 as it is inserted
into the aperture 34. The slot 40 also allows each tab leg 38 to
deform independently of the other tab leg, so that the tab legs 38
in combination are able to self adjust to the actual diameter of
the aperture 34. The size of the slot 40 also allows the tab legs
38 to adjust for minor variations in the location of the apertures,
thus providing a suitable tolerance.
[0027] In assembling a gasket 20 to a first mating flange 22, the
tabs 32 are bent generally perpendicular relative to the gasket 20,
so that the tabs 32 are positioned generally vertical to the width
of the gasket. As applied to the preferred embodiment, the tab legs
38 are thus positioned vertical to the width of the gasket. The
gasket 20 is then placed adjacent the first mating flange 22 so
that the tabs 32, including the tab legs 38, align with and are
inserted into the apertures 34. As the tabs 32 are inserted into
the apertures 34, the sloped portion 46 first contacts the inner
surface 36 of aperture 34. As the tabs 32 are further inserted into
the aperture 34, the tab legs 38 are independently forced to deform
slightly inwardly. When the tab legs 38 have been fully inserted
into the aperture 34, only the protrusions 50 contact the inner
surface 36 of the aperture 34. The resilient tabs maintain a
slightly laterally inwardly deformed position, thereby applying a
force laterally outwardly against the inner surface 36 of the
aperture 34. The outward force applied through the protrusions 46
is sufficient to cause a tight interference fit of the tabs 32
within the aperture 34 such that the entire gasket 20 is maintained
in position adjacent the first mating flange 22. The first mating
flange 22 may then await assembly or shipment to a location for
assembly at a later time without the gasket 20 becoming dislodged
from it.
[0028] Because the apertures 34 are formed inside the configuration
of the mating component, i.e. within the first outer periphery, a
gasket 20 formed according to the present invention uses less
material, thereby reducing cost. The resilient tab legs 38 deform
independently when inserted into the corresponding apertures 34
such that insertion of the legs 38 into corresponding apertures 34
positively locates the gasket 20 in place against the mating flange
22. The combination of the tab legs 38, the slot 40 and the
protrusions tabs 32, when placed into frictional engagement with
the inner surface 36 of the apertures 34, effectively retains the
gasket 20 in place against the first mating flange 22. Thus, the
configuration of the resilient legs 38 produces a tight
interference fit within the apertures 34. The gasket 20 is
therefore held tightly in place by the tab legs 38. Because the tab
legs 38 are also positioned vertical to the width of the gasket,
the tab legs 38 may deform to allow for adjustment of the gasket
relative to the mating flange, thereby accounting for linear
tolerances of the apertures and for overall gasket tolerances. And
finally, because the tabs 32 are formed as part of a metal layer of
the gasket 20, both manufacture and assembly are simplified because
no separate clips are required to attach the gasket 20 to the first
mating flange 22.
[0029] A second preferred embodiment of a tab 32' is illustrated in
FIG. 4. Tab 32' comprises a serrated side edge 52 terminating at a
plurality of resilient points 54. Each point 54 extends upwardly
and is angled with respect to an adjacent valley 56 such that tab
32 may be easily inserted into mating aperture 34 as the points 54
bend inwardly. However, each point 54 digs into the inner periphery
36 of the mating aperture 34 upon attempted removal of tab 32'.
[0030] A third alternative embodiment of the invention is disclosed
in FIGS. 5, 6 and 7, showing a two-layer exhaust manifold gasket
120. While a two-layer design is illustrated, a three or more layer
design is also within the scope of the invention. Gasket 120
includes a plurality of bolt holes 124 and gas flow holes 126 that
correspond to similar holes in a mating component. Like the first
two embodiments, the layers of gasket 120 may further include
embossments, folds or other sealing features. Because seals on the
gasket must withstand high temperature and resist chemical attack,
gasket 120 is preferably formed of a metal, and more preferably
stainless steel. When formed from stainless steel, however,
modifications to the production tooling may be required in view of
the material characteristics.
[0031] According to the third embodiment, at least one metal layer
of the gasket 120 includes at least two integral tabs 132. Each tab
132 is formed as a continuation of the metal layer along an inner
periphery 130 of a mounting aperture 131. Permitting the tab to be
formed as a continuation of a metal layer allows the shape of the
tab to be formed in the same manufacturing operation. For example,
mounting apertures 131, tabs 132, bolt holes 124 and gas flow holes
126 may be formed in the same stamping operation. As with the
embodiments discussed above, tabs 132 are bent generally
perpendicular relative to gasket 120 so that tabs 132 are
positioned generally vertical to the width of gasket 120.
Additionally, tabs 132 are spaced apart to prevent rotation of
gasket 120 once it is installed. The geometric shape of tabs 132 is
preferably substantially similar to tabs 32 in the first embodiment
or, alternatively, may be formed substantially similar to tabs 32'
in the second embodiment. However, it is within the scope of this
embodiment that tabs 132 may be formed into any geometric shape
that is convenient to manufacture and that achieves a tight
interference fit within a mating aperture 134. The assembly of
gasket 120 on a mating flange is substantially similar to the first
embodiment as described above. Moreover, as with the earlier
embodiments, tab legs 138 may deform to allow for adjustment of the
gasket relative to the mating flange.
[0032] Accordingly, the present invention provides a gasket design
that incorporates integral tabs formed as a continuation of a
gasket layer to locate and retain the gasket on an engine
component. The use of integral tabs eliminates the need to use
clips to attach the gasket to the gasket-attaching portion of the
component. While the use of integral tabs has been described in
relation to an exhaust gasket, it is recognized that the present
invention may be incorporated into other engine gaskets, such as a
head gasket, to retain the gasket in place prior to assembly of the
mating component.
[0033] Although certain preferred embodiments of the present
invention have been described, the invention is not limited to the
illustrations described and shown herein, which are deemed to be
merely illustrative of the best modes of carrying out the
invention. A person of ordinary skill in the art will realize that
certain modifications and variations will come within the teachings
of this invention and that such variations and modifications are
within its spirit and the scope as defined by the claims.
* * * * *