U.S. patent application number 13/301912 was filed with the patent office on 2012-06-07 for exhaust manifold gasket.
This patent application is currently assigned to Dana Automotive Systems Group, LLC. Invention is credited to David J. Schweiger.
Application Number | 20120139188 13/301912 |
Document ID | / |
Family ID | 46161484 |
Filed Date | 2012-06-07 |
United States Patent
Application |
20120139188 |
Kind Code |
A1 |
Schweiger; David J. |
June 7, 2012 |
Exhaust Manifold Gasket
Abstract
An exhaust manifold gasket assembly having at least two layers
and a series of tabs and slots. The gasket has a first outer layer
with an outer surface, an inner surface, two bolt hole flanges, and
a central aperture. The surfaces are bounded by an outer perimeter
portion, with foldable tabs. A first inner layer and a second inner
layer each with an outer surface, an inner surface, two bolt hole
flanges, a central aperture, and internal slots. The surfaces are
bounded by an outer perimeter portion with locator tabs. Each inner
layer has a bead circumferentially extending around the central
aperture. A second outer layer may be provided having an outer
surface, an inner surface, two bolt hole flanges, a central
aperture, and internal slots. The surfaces are bounded by an outer
perimeter portion.
Inventors: |
Schweiger; David J.;
(Pewaukee, WI) |
Assignee: |
Dana Automotive Systems Group,
LLC
Maumee
OH
|
Family ID: |
46161484 |
Appl. No.: |
13/301912 |
Filed: |
November 22, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61458852 |
Dec 2, 2010 |
|
|
|
Current U.S.
Class: |
277/594 |
Current CPC
Class: |
F01N 13/10 20130101;
F16J 2015/0843 20130101; F16J 2015/085 20130101; F01N 13/1827
20130101; F16J 15/0831 20130101; F16J 15/0825 20130101 |
Class at
Publication: |
277/594 |
International
Class: |
F02F 11/00 20060101
F02F011/00 |
Claims
1. An exhaust manifold gasket, comprising: a first outer layer
comprising an outer surface, an inner surface, two bolt hole
flanges with bolt holes therethrough, and a central aperture
between said flanges, said surfaces bounded by an outer perimeter
portion, wherein at least two tabs are nested within said outer
perimeter portion and wherein a cut-out is adjacent each side of
said foldable tab; and a first inner layer and a second inner layer
each comprising an outer surface, an inner surface, two bolt hole
flanges with bolt holes therethrough, and a central aperture
between said flanges, and at least two internal slots, said
surfaces bounded by an outer perimeter portion, wherein at least
two locator tabs extend from said perimeter portion of each of said
first inner layer and said second inner layer, and a bead
circumferentially extending about said central aperture inboard
said outer perimeter portion of said first inner layer and said
second inner layer; and a second outer layer comprising an outer
surface, an inner surface, two bolt hole flanges with bolt holes
therethrough, a central aperture between said flanges, and at least
two internal slots, said surfaces bounded by an outer perimeter
portion.
2. An exhaust manifold gasket according to claim 1, wherein said
internal slots on each of said first inner layer and said second
inner layer are aligned with one another.
3. An exhaust manifold gasket according to claim 1, wherein said
foldable tabs on said first outer layer are aligned with said
internal slots on each of said first inner layer, second inner
layers and said second outer layer.
4. An exhaust manifold gasket according to claim 1, wherein said
locator tabs on each of said first inner layer and said second
inner layer are opposite and diagonal from each other.
5. An exhaust manifold gasket according to claim 1, wherein said
central apertures of all said layers are aligned with one another
and have a complimentary shape to one another.
6. An exhaust manifold gasket according to claim 1, wherein said
beads of said inner layers are radially aligned with one
another.
7. An exhaust manifold gasket according to claim 1, wherein said
inner and outer surfaces of said outer layers are planar and
parallel and define between them a substantially constant
thickness.
8. An exhaust manifold gasket according to claim 1, wherein four
foldable tabs extend from said outer perimeter portion of said
first outer layer.
9. An exhaust manifold gasket according to claim 1, wherein two
locator tabs extend from said outer perimeter portion of each of
said first inner layer and said second inner layer.
10. An exhaust manifold gasket according to claim 1, wherein said
inner surface of said first inner layer is directly adjacent said
inner surface of said first outer layer.
11. An exhaust manifold gasket according to claim 1, wherein said
outer surface of said second inner layer is directly adjacent said
inner surface of said second outer layer.
12. An exhaust manifold gasket according to claim 1, wherein said
outer surface of said first inner layer is directly adjacent said
inner surface of said second inner layer.
13. An exhaust manifold gasket according to claim 1, wherein said
foldable tabs on said first outer layer fold to a 90 degree angle
and align with said internal slots on each of said first inner
layer, said second inner layer and said second outer layer.
14. An exhaust manifold gasket, comprising: a first layer
comprising an outer surface, an inner surface, two bolt hole
flanges with bolt holes therethrough, and a central aperture
between said flanges, said surfaces bounded by an outer perimeter
portion, wherein at least two tabs are nested within said outer
perimeter portion and wherein a cut-out is adjacent each side of
said foldable tab; and a second layer comprising an outer surface,
an inner surface, two bolt hole flanges with bolt holes
therethrough, and a central aperture between said flanges, and at
least two internal slots, said surfaces bounded by an outer
perimeter portion, wherein at least two locator tabs extend from
said perimeter portion, and a bead circumferentially extending
about said central aperture inboard said outer perimeter
portion.
15. An exhaust manifold gasket according to claim 14, wherein said
foldable tabs on said first layer are aligned with said internal
slots on said second layer.
16. An exhaust manifold gasket according to claim 14, wherein said
locator tabs on said second layer are opposite and diagonal from
each other.
17. An exhaust manifold gasket according to claim 14, wherein said
central apertures of said layers are aligned with one another and
have a complimentary shape to one another.
18. An exhaust manifold gasket according to claim 14, wherein four
foldable tabs extend from said outer perimeter portion of said
first layer.
19. An exhaust manifold gasket according to claim 14, wherein two
locator tabs extend from said outer perimeter portion of said
second layer.
20. An exhaust manifold gasket according to claim 14, wherein said
foldable tabs on said first layer fold to a 90 degree angle and
align with said internal slots on said second layer.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a non-provisional application filed off
of U.S. patent application Ser. No. 61/458,852 filed on Dec. 2,
2010, which is incorporated by reference in its entirety herein.
This non-provisional application is being filed during the pendency
of U.S. patent application Ser. No. 61/458,852.
FIELD OF THE INVENTION
[0002] The present invention relates to an exhaust manifold gasket
for use in internal combustion engines.
BACKGROUND OF THE INVENTION
[0003] Gaskets essentially are used to seal and prevent leakage
between two parts. Exhaust manifold gaskets for internal combustion
engines seal any gaps and prevent leakage when the mating surfaces
of the cylinder head and the exhaust manifold are bolded together.
The gaskets may be made of layers and one or more of the layers may
include a bead. Sealing the joined area between the parts can be
difficult because the cylinder head, manifold and gasket all move
due to pressure and temperature fluctuations. There are also
problems due to thermal expansion and thermal contraction, which
occurs when the temperature varies in the cylinder head and the
manifold.
[0004] Thermal motion, resulting from hot exhaust gases, increasing
combustion pressure and steep thermal swings, and sheer stresses
are created in the joined area between the cylinder head and the
exhaust manifold increasing the risk of horizontal motion and
shifting of the gasket layers, such as in a multi-layer steel (MLS)
gasket. When this occurs, the layers shift and the mechanical beads
in the gasket layers can become misaligned. This reduces the
sharing capabilities of the beads located on the various layers,
and the misaligned beads may induce unusual stress
concentrations.
[0005] There are also multiple openings in the head and the
manifold for exhaust gases and bolts holes. The areas around these
openings are known to be put under additional stresses and leakage
is common due to movement and misalignment of the gasket
layers.
[0006] Traditionally, the various gasket layers are aligned and
held in place during gasket assembly by welding, eyeleting or
form-locking. The eyeleting and form-locking methods both add
thickness to the gasket and therefore must be located outside of
the joined area, which is not ideal. While welding does not
necessarily add thickness to the gasket, the weld spots may crack
and/or break due to horizontal hardware motion which allows the
gasket layers to shift.
[0007] In view of the foregoing disadvantages of the prior art, it
would be advantageous for a MLS gasket to be able to prevent or
resist horizontal motion and misalignment of the layers to the
extent that it negatively affects performance of the gasket.
SUMMARY OF THE INVENTION
[0008] The present invention is directed toward an exhaust manifold
gasket assembly having at least two or more layers, and utilizing a
series of tabs and slots to maintain alignment of the layers. The
exhaust manifold gasket assembly has a first outer layer comprising
an outer surface, an inner surface, two bolt hole flanges with bolt
holes therethrough, and a central aperture between the flanges. The
surfaces are bounded by an outer perimeter portion. At least two
foldable tabs are nested within the outer perimeter portion with a
cut-out on each side of the foldable tab. A first inner layer and a
second inner layer each comprise an outer surface, an inner
surface, two bolt hole flanges with bolt holes therethrough, and a
central aperture between the flanges, and at least two internal
slots. The surfaces are bounded by an outer perimeter portion,
wherein at least one locator tab is located. Each of the inner
layers also has a bead circumferentially extending about the
central aperture inboard the outer perimeter portion of each of the
inner layers. A second outer layer may be provided and comprises an
outer surface, an inner surface, two bolt hole flanges with bolt
holes therethrough, a central aperture between the flanges, and at
least two internal slots. The surfaces are bounded by an outer
perimeter portion.
[0009] In accordance with the present invention, it has been
discovered that once the layers are assembled together, horizontal
movement between the layers is significantly decreased, and the
beads located on the inner layers remain aligned reducing unusual
stress concentrations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The above, as well as other advantages of the present
invention, will become readily apparent to those skilled in the art
from the following detailed description when considered in the
light of the accompanying drawings in which:
[0011] FIG. 1 is a partial perspective exploded view of the present
invention with an exhaust manifold gasket, an exhaust manifold and
cylinder block;
[0012] FIG. 2 is a top view of the assembled exhaust manifold
gasket in FIG. 1;
[0013] FIG. 3 is a cross-sectional view of a portion of the
embodiment of FIG. 2 along line 3-3;
[0014] FIG. 4 is a cross-sectional view of a portion of the
embodiment of FIG. 2 along line 4-4;
[0015] FIG. 5 is a cross-sectional view of a portion of the
embodiment of FIG. 2 along line 5-5;
[0016] FIG. 6 is a perspective assembled view of the embodiment of
FIG. 2;
[0017] FIG. 7 is a perspective exploded view of the layers of the
embodiment of FIG. 2;
[0018] FIG. 8 is a top view of a layer of the embodiment of FIG.
2;
[0019] FIG. 9 is a top view of a layer of the embodiment of FIG.
2;
[0020] FIG. 10 is a top view of a layer of the embodiment of FIG.
2;
[0021] FIG. 11 is a top view of a layer of the embodiment of FIG.
2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] 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 devices and processes illustrated in the attached
drawings, and described in the following specification are simply
exemplary embodiments of the inventive concepts defined in the
appended claims. Hence, specific dimensions, directions or other
physical characteristics relating to the embodiments disclosed are
not to be considered as limiting, unless the claims expressly state
otherwise.
[0023] As shown in FIG. 1, an exhaust manifold gasket assembly 10
is positioned between a cylinder head 12 and an exhaust manifold
14, so as to create an air tight seal between the two parts when
they are bolted together. Both the cylinder head 12 and the exhaust
manifold 14 are parts of an internal combustion engine (not shown.)
The cylinder head 12 sits on top of a cylinder block (not shown.)
It closes in the top of the cylinder, to form a combustion chamber.
The exhaust manifold 14 collects exhaust gases from the cylinder
combustion chamber, and delivers the gases to an exhaust pipe. Both
the cylinder head 12 and the exhaust manifold 14 have bolt
apertures 12a, 12b, 14a, 14b, which align with each, and each has a
flat surface 16, 18 for receiving an exhaust manifold gasket
assembly between them, as shown in the figure.
[0024] Exhaust manifold gasket assemblies are manufactured in
accordance with the various shapes of cylinder heads and exhaust
manifolds, and include numerous openings, such as exhaust gasket
openings and bolt holes. FIG. 1 depicts one embodiment of an
exhaust manifold gasket assembly 10; however, other shapes, sizes
and designs are permissible. Various sealing means are provided in
the gasket assembly for sealing around the respective openings.
[0025] The embodiment of the exhaust manifold gasket assembly 10,
as depicted in FIGS. 2-11, comprises a first outer layer 20, a
second outer layer 128, a first inner layer 66, and a second inner
layer 96. It is also within the scope of the invention for there to
be more or fewer layers. The two outer layers 20, 128 and the two
inner layers 66, 96 may be made of a metallic material, such as
steel.
[0026] As shown in FIGS. 6, 7 and 8, the first outer layer 20
comprises an outer surface 22, an inner surface 24, two bolt hole
flanges 26, 28 with bolt holes 30, 32 therethrough, and a central
aperture 34 between the flanges 26, 28.
[0027] The surfaces 22, 24 of the first outer layer 20 are bounded
by an outer perimeter portion 36, wherein unitary foldable tabs 38,
40, 42, 44 are nested within the outer perimeter portion 36. A
rectangular shaped cut-out 46, 48, 50, 52, 54, 56, 58, 60 is
adjacent each side of each foldable tab 38, 40, 42, 44, and an
outer edge 62 of each of the foldable tabs 38, 40, 42, 44 is
substantially even with an outer edge 64 of the outer perimeter
portion 36. While as depicted in FIGS. 7 and 8 four foldable tabs
are shown, it is within the scope of the invention for there to be
more or fewer tabs. The foldable tabs 38, 40, 42, 44 are generally
located toward the narrow ends of the oval outer perimeter portion
36 between the bolt hole flanges 26, 28 and the central aperture
34. The rectangular shaped cut-outs 46, 48, 50, 52, 54, 56, 58, 60
extend inward from the outer perimeter portion 36, and are parallel
and coplanar to the inner surface 24 and outer surface 22. As
depicted in FIG. 8 there are eight cut-outs 46, 48, 50, 52, 54, 56,
58, 60 one on either side of each foldable tab 38, 40, 42, 44.
[0028] As depicted in FIGS. 7, 9 and 10, the first inner layer 66
and the second inner layer 96 each comprise an outer surface 68,
98, an inner surface 70, 100, two bolt hole flanges 72, 74, 102,
104 with bolt holes 76, 78, 106, 108 therethrough, a central
aperture 80, 110 between the flanges 72, 74, 102, 104, and at least
two internal slots 81, 82, 84, 86, 112, 114, 116, 118.
[0029] The surfaces 68, 70, 98, 100 of each of the inner layers 66,
96 are bounded by an outer perimeter portion 88, 120. The outer
perimeter portion 88, 120 is generally oval in shape and includes
locator tabs 90, 92, 122, 124. As shown in FIGS. 9 and 10, the
locator tabs 90, 92, 122, 124 extend unitarily outward from the
outer perimeter portion 88, 120. Locator tabs are generally
utilized during assembly of the gasket between two parts to ensure
that it is in the correct position to obtain optimum sealing
capabilities. While as depicted in the figures two locator tabs 90,
92, 122, 124 are shown on each of the inner layers 66, 96, it is
also within the scope of the invention for there to be more or
fewer locator tabs. As depicted in the figures, the locator tabs
90, 92, 122, 124 on each of the inner layers 66, 96 are located on
opposite sides, diagonally across from each other. The locator tabs
90, 92, 122, 124 are generally located toward the narrow ends of
the oval outer perimeter portion 88, 120 between the bolt hole
flanges 72, 74, 102, 104 and the central aperture 80, 110.
[0030] As shown in FIGS. 4 and 7, the internal slots 81, 82, 84,
86, 112, 114, 116, 118 on each of the first and second inner layers
66, 96 are aligned with one another. The internal slots 81, 82, 84,
86, 112, 114, 116, 118 are located inboard of the outer perimeter
portion 88, 120, and generally located toward the narrow ends of
the oval outer perimeter portion 88, 120 between the bolt hole
flanges 72, 74, 102, 104 and the central aperture 80, 110. The
internal slots 81, 82, 84, 86, 112, 114, 116, 118 are oriented
parallel with and adjacent the outer perimeter portion 88, 120. The
width of each internal slot 81, 82, 84, 86, 112, 114, 116, 118 is
less than the length.
[0031] As depicted in FIGS. 2 and 3, the first inner layer 66 and
the second inner layer 96 each comprise a bead 94, 126 which
circumferentially extends about the central aperture 80, 110 and is
inboard of the outer perimeter portion 88, 120. The two inner
layers 66, 96 are a mirror image of one another, as shown in FIGS.
9 and 10.
[0032] As depicted in FIGS. 7 and 11, the second outer layer 128
comprises an outer surface 130, an inner surface 132, two bolt hole
flanges 134, 136 with bolt holes 138, 140 therethrough, a central
aperture 142 between the flanges 134, 136, and at least two
internal slots 144, 146, 148, 150. The surfaces are bounded by an
outer perimeter portion 152, which is generally oval in shape.
[0033] The internal slots 144, 146, 148, 150 are located inboard of
the outer perimeter portion 152, and generally located toward the
narrow ends of the oval outer perimeter portion 151 between the
bolt hole flanges 134, 136 and the central aperture 142. The
internal slots 144, 146, 148, 150 are oriented parallel with and
adjacent the outer perimeter portion 152. The width of each
internal slot is less than the length. As depicted in FIG. 7, the
internal slots 144, 146, 148, 150 on the second outer layer 128 are
also aligned with the internal slots 81, 82, 84, 86, 112, 114, 116,
118 on each of the first and second inner layers 66, 96. As shown
in FIG. 3, the inner surface 24, 132 and the outer surface 22, 130
of each of the outer layers 20, 128 are planar and parallel to one
another, and define between them a substantially constant
thickness.
[0034] As shown in FIGS. 2, 6 and 7, the central aperture 34, 80,
110, 142 on all the layers 20, 66, 96, 128 are aligned with one
another and have a complimentary shape when the layers 20, 66, 96,
128 are placed together for assembly. When all the layers 20, 66,
96, 128 are aligned, the beads 94, 126 of the inner layers 66, 96
are also radially aligned with one another. Once the layers 20, 66,
96, 128 are placed together they may be welded to hold them
together, although with this embodiment welding is not
necessary.
[0035] It can be appreciated from FIGS. 2, 6 and 7 that the
foldable tabs 38, 40, 42, 44 on the first outer layer 20 align with
and fit into the internal slots 81, 82, 84, 86, 112, 114, 116, 118,
144, 146, 148, 150 in each of the first and second inner layers 66,
96 and the second outer layer 128.
[0036] As can also be depicted from FIGS. 5, 6 and 7 when the
layers 20, 66, 96, 128 are assembled, the inner surface 70 of the
first inner layer 66 is directly adjacent the inner surface 24 of
the first outer layer 20, and the outer surface 98 of the second
inner layer 96 is directly adjacent the inner surface 132 of the
second outer layer 128. The outer surface 68 of the first inner
layer 66 is directly adjacent the inner surface 100 of the second
inner layer 96 when assembled.
[0037] As depicted in FIGS. 4 and 5, in their original position the
foldable tabs 38, 40, 42, 44 on the first outer layer 20 are
parallel and coplanar to the inner surface 24 and outer surface 22.
For assembly, the foldable tabs 38, 40, 42, 44 are folded at a 90
degree so that they are transverse to the inner and outer surfaces
24, 22 of the first outer layer 20. The remaining layers 66, 96,
128 are stacked onto the first outer layer 20, so that the foldable
tabs 38, 40, 42, 44 extend through the internal slots 81, 82, 84,
86, 112, 114, 116, 118, 144, 146, 148, 150 of each of the layers
66, 96, 128. The foldable tabs 38, 40, 42, 44 are then folded
again, so that they are parallel and non-planar to the inner and
outer surfaces 24, 22 of the first outer layer 20, as depicted in
FIG. 4. This configuration ensures that the layers 20, 66, 96, 128
remain in alignment and in direct contact with each other.
[0038] The use of the series of foldable tabs and internal slots in
the various gasket layers that align during assembly eliminates the
ability of the layers to slide independently if the welds or other
means of attachment that may have been used fails. The foldable
tabs act as limiters to the horizontal movement of the layers
within the joint. This combination of tabs and slots does not add
additional thickness to the gasket in the region between the joint.
The ability to locate these features within the joint eliminates
the horizontal motion from "unfolding" the tabs that are acting as
the motion limiters.
* * * * *