U.S. patent application number 13/304712 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 | 20120139189 13/304712 |
Document ID | / |
Family ID | 46161484 |
Filed Date | 2012-06-07 |
United States Patent
Application |
20120139189 |
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 recesses. The gasket has a first outer
layer with an outer surface, an inner surface, two bolt hole
flanges, a central aperture, and internal square cut-outs. 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 pairs of internal slits. The surfaces are surfaces
bounded by an outer perimeter portion, with locator tabs. Each
inner layer has a bead circumferentially 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 square cut-outs. The surfaces are bounded by
an outer perimeter portion, with recesses.
Inventors: |
Schweiger; David J.;
(Pewaukee, WI) |
Assignee: |
Dana Automotive Systems Group,
LLC
Maumee
OH
|
Family ID: |
46161484 |
Appl. No.: |
13/304712 |
Filed: |
November 28, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61458852 |
Dec 2, 2010 |
|
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|
Current U.S.
Class: |
277/594 |
Current CPC
Class: |
F01N 13/1827 20130101;
F16J 15/0825 20130101; F16J 15/0831 20130101; F01N 13/10 20130101;
F16J 2015/0843 20130101; F16J 2015/085 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, a central aperture between
said flanges, and at least two internal square cut-outs, said
surfaces bounded by an outer perimeter portion, wherein at least
two foldable tabs extend from said outer perimeter portion; 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, a central aperture between said flanges, and at least
two pair of internal slits, said surfaces bounded by an outer
perimeter portion, wherein at least two locator tabs extend from
said outer 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 square cut-outs,
said surfaces bounded by an outer perimeter portion, wherein at
least two recesses extend inward from said outer perimeter portion
outboard of each of said internal square cut-outs.
2. An exhaust manifold gasket according to claim 1, wherein said
foldable tabs on said first outer layer are aligned with said
recesses on said second outer layer.
3. An exhaust manifold gasket according to claim 1, wherein said
pairs of internal slits on each of said first inner layer and said
second inner layer are aligned with one another.
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
internal square cut-outs on each of said first outer layer and said
second outer layer are aligned with one another.
6. An exhaust manifold gasket according to claim 1, wherein said
central apertures of all said layer are aligned with one another
and have a complimentary shape to one another.
7. An exhaust manifold gasket according to claim 1, wherein said
beads of said inner layers are radially aligned with one
another.
8. An exhaust manifold gasket according to claim 1, wherein said
inner and outer surfaces on each of said outer layers are planar
and parallel and define between them a substantially constant
thickness.
9. An exhaust manifold gasket according to claim 1, wherein four
foldable tabs extend from said outer perimeter portion of said
first outer layer.
10. 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.
11. 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.
12. 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.
13. 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.
14. An exhaust manifold gasket according to claim 1, wherein said
foldable tabs on said first outer layer are folded into a C-shape
and enclose around said outer perimeter portion of each of said
first inner layer, said second inner layer and said second outer
layer.
15. An exhaust manifold gasket, comprising: a first 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 square cut-outs, said
surfaces bounded by an outer perimeter portion, wherein at least
two foldable tabs extend from said outer perimeter portion; and a
second 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 pair of internal slits, said
surfaces bounded by an outer perimeter portion, wherein two locator
tabs extend from said outer perimeter portion, and a bead
circumferentially extending about said central aperture inboard
said outer perimeter portion.
16. An exhaust manifold gasket according to claim 15, wherein said
internal square cut-outs on said first layer are aligned with said
pairs of internal slits on said second layer.
17. An exhaust manifold gasket according to claim 15, wherein said
locator tabs on said second layer are opposite and diagonal from
each other.
18. An exhaust manifold gasket according to claim 15, wherein said
central apertures of said both layers are aligned with one another
and have a complimentary shape to one another.
19. An exhaust manifold gasket according to claim 15, wherein four
foldable tabs extend from said outer perimeter portion of said
first layer.
20. An exhaust manifold gasket according to claim 15, wherein said
foldable tabs on said first outer layer are folded into a C-shape
and enclose around said outer perimeter portion of 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 bolted 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, 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 cylinder 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, recesses, square cut-outs and pairs of slits 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,
a central aperture between the flanges, and at least two internal
square cut-outs. The surfaces are bounded by an outer perimeter
portion, wherein at least two foldable tabs extend from the outer
perimeter portion. 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, a central aperture between
the flanges, and at least two pair of internal slits. 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
square cut-outs. The surfaces are bounded by an outer perimeter
portion, wherein at least two recesses are located.
[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 head;
[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 other, 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 118, a first inner layer 54 and a second inner
layer 86. It is also within the scope of the invention for there to
be more or fewer layers. The two outer layers 20, 118 and the two
inner layers 54, 86 may each 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, a central
aperture 34 between the flanges 26, 28, and at least two internal
square cut-outs. While as depicted in the figures four internal
square cut-outs 36, 38, 40, 42 are shown, it is also within the
scope of the invention for there to be more or fewer internal
square cut-outs.
[0027] The surfaces 22, 24 of the first outer layer 20 are bounded
by an outer perimeter portion 44, wherein foldable tabs 46, 48, 50,
52 are formed from the outer perimeter portion 44. The foldable
tabs 46, 48, 50, 52 extend unitarily outward from the outer
perimeter portion 44. While as depicted in FIGS. 7 and 8 four
foldable tabs 46, 48, 50, 52 are shown, it is also within the scope
of the invention for there to be more or fewer tabs. The foldable
tabs 46, 48, 50, 52 and internal square cut-outs 36, 38, 40, 42 are
generally located toward the narrow ends of the oval outer
perimeter portion 44 between the bolt hole flanges 26, 28 and the
central aperture 34.
[0028] The internal square cut-outs 36, 38, 40, 42 are oriented
parallel with and adjacent the outer perimeter portion 44. The
internal square cut-outs 36, 38, 40, 42 insure that there are only
four layers overlapping at any one point. This feature ensures that
when the gasket is installed, the total gasket thickness is never
greater than the original number of layers in the gasket assembly,
as depicted in FIG. 4. The foldable tabs 46, 48, 50, 52 are located
outboard of the internal square cut-outs 36, 38, 40, 42 and are
slightly narrower in width than the internal square cut-outs 36,
38, 40, 42. The foldable tabs 46, 48, 50, 52 also have a length
longer than the thickness of the first outer layer 20.
[0029] As depicted in FIGS. 7, 9 and 10, the first inner layer 54
and the second inner layer 86 each comprise an outer surface 56,
88, an inner surface 58, 90, two bolt hole flanges 60, 62, 92, 94
with bolt holes 64, 66, 96, 98 therethrough, a central aperture 68,
100 between the flanges 60, 62, 92, 94, and at least two pair of
internal slits 70, 72, 74, 76, 102, 104, 106, 108.
[0030] The surfaces 56, 58, 88, 90 of each of the inner layers 54,
86 are bounded by an outer perimeter portion 78, 110. The outer
perimeter portion 78, 110 is generally oval in shape and includes
locator tabs 80, 82, 112, 114. As shown in FIGS. 9 and 10, the
locator tabs 80, 82, 112, 114 extend unitarily outward from the
outer perimeter portion 78, 110. Locator tabs 80, 82, 112, 114 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 80, 82, 112, 114 are shown on each of the inner layers 54, 86,
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
80, 82, 112, 114 on each of the inner layers 54, 86 are located on
opposite sides, diagonally across from each other. The locator tabs
80, 82, 112, 114 are generally located toward the narrow ends of
the oval outer perimeter portion 78, 110 between the bolt hole
flanges 60, 62, 92, 94 and central aperture 68, 100.
[0031] As shown in FIGS. 4 and 7, the pairs of internal slits 70,
72, 74, 76, 102, 104, 106, 108 on each of the first and second
inner layers 54, 86 are aligned with one another. The pairs of
internal slits 70, 72, 74, 76, 102, 104, 106, 108 are located
parallel to and internally inboard of the outer perimeter portion
78, 110, and generally located toward the narrow ends of the oval
outer perimeter portion 78, 110 between the bolt hole flanges 60,
62, 92, 94 and central aperture 68, 100. The individual slits in
each pair 70, 72, 74, 76, 102, 104, 106, 108 are the same and
parallel one another. One slit in each pair 70, 72, 74, 76, 102,
104, 106, 108 is adjacent the outer perimeter portion 78, 110. The
two inner layers 54, 86 are a mirror image of one another, shown in
FIGS. 9 and 10.
[0032] The first inner layer 54 and the second inner layer 86 each
also comprise a bead 84, 116 which circumferentially extends about
the central aperture 68, 100 and is inboard of the outer perimeter
portion 78, 110, as depicted in FIGS. 2 and 3.
[0033] As depicted in FIGS. 7 and 11, the second outer layer 118
comprises an outer surface 120, an inner surface 122, two bolt hole
flanges 124, 126 with bolt holes 128, 130 therethrough, a central
aperture 132 between the flanges 124, 126, and at least two
internal square cut-outs. While as depicted in the figures four
internal square cut-outs 134, 136, 138, 140 are shown, it is also
within the scope of the invention for there to be more or fewer
internal square cut-outs.
[0034] The surfaces 120, 122 of the second outer layer 118 are
bounded by an outer perimeter portion 142. The outer perimeter
portion 142 is generally oval in shape and includes recesses 144,
146, 148, 150. As depicted in the figures, the recesses 144, 146,
148, 150 extend inward from the outer perimeter portion 142. While
as depicted in the figures four recesses 144, 146, 148, 150 are
shown, it is also within the scope of the invention for there to be
more or fewer recesses.
[0035] The recesses 144, 146, 148, 150 and internal square cut-outs
134, 136, 138, 140, as depicted in FIGS. 7 and 11, are generally
located toward the narrow ends of the oval outer perimeter portion
142 between the bolt hold flanges 124, 126 and the central aperture
132. The internal square cut-outs 134, 136, 138, 140 are oriented
parallel with and adjacent the outer perimeter portion 142. The
internal square cut-outs 134, 136, 138, 140 insure that there are
only four layers overlapping at any one point. This feature ensures
that when the gasket is installed, the total gasket thickness is
never greater than the original number of layers in the gasket
assembly, as depicted in FIG. 4. The recesses 144, 146, 148, 150
are parallel with and located outboard of the internal square
cut-outs 134, 136, 138, 140 and are substantially the same width as
the internal square cut-outs 134, 136, 138, 140.
[0036] As shown in FIGS. 3 and 5, the inner surfaces 24, 122 and
the outer surfaces 22, 120 of each of the outer layers 20, 118 are
planar and parallel to one another, and define between them a
substantially constant thickness.
[0037] As shown in FIGS. 6 and 7, the central aperture 34, 68, 100,
132 in all the layers 20, 54, 86, 118 are aligned with one another
and have a complimentary shape when the layers 20, 54, 86, 118 are
placed together for assembly. When all the layers 20, 54, 86, 118
are aligned, the beads 84, 116 of each of the inner layers 54, 86
are also radially aligned with one another. Once the layers 20, 54,
86, 118 are placed together they may be welded to hold them
together, although with this embodiment welding is not
necessary.
[0038] It can be appreciated from FIGS. 2, 6 and 7 that the
foldable tabs 46, 48, 50, 52, internal square cut-outs 36, 38, 40,
42, 134, 136, 138, 140 and recesses 144, 146, 148, 150 of the outer
layers 20, 118 are in alignment with one another, and the pairs of
internal slits 70, 72, 74, 76, 102, 104, 106, 108 of the inner
layers 54, 86 are in alignment with one another. For example, the
foldable tabs 46, 48, 50, 52 on the first outer layer 20 align with
and engage the recesses 144, 146, 148, 150 on the second outer
layer 118.
[0039] As can also be appreciated from FIGS. 5, 6 and 7 when the
layers 20, 54, 86, 118 are assembled, the inner surface 58 of the
first inner layer 54 is directly adjacent the inner surface 24 of
the first outer layer 20, and the outer surface 88 of the second
inner layer 86 is directly adjacent the inner surface 122 of the
second outer layer 118. The outer surface 56 of the first inner
layer 54 is directly adjacent the inner surface 90 of the second
inner layer 86 when assembled.
[0040] Ultimately when the layers 20, 54, 86, 118 are assembled, as
depicted in FIGS. 4 and 6, the foldable tabs 46, 48, 50, 52 on the
first outer layer 20 are folded into a C-shape which encloses
around the outer perimeter portion 78, 110, 142 of each of the
first inner layer 54, second inner layer 86 and the second outer
layer 118. The internal square cut-outs 36, 38, 40, 42, 134, 136,
138, 140 on each of the outer layers 20, 118 insure that there are
only four layers overlapping at any one point. This feature ensures
that when the gasket is installed, the total gasket thickness is
never greater than the original number of layers in the gasket
assembly, as depicted in FIG. 4. This configuration ensures that
the layers remain in alignment and in direct contact with each
other.
[0041] The use of the series of foldable tabs, recesses, and square
cut-outs and pairs of slits in the various gasket layers that align
during layer assembly eliminates the ability of the layers to slide
indecently 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 recesses 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.
* * * * *