Abstract
Gaskets and methods for manufacturing a gasket for sealing a gap in a housing, such as a battery housing, which gap extends at least partially around an interior of the housing, said gasket comprising at least one sealing layer. The sealing layer comprises at least two segments which are arranged adjacent to each other in the longitudinal direction of the sealing layer and are joined to each other at a joining region. The two segments have, at the joining region, intermeshing engagement elements joined to each other, and one or both of the segments has/have, at the joining region a positioning hole and a through-opening which are arranged behind the engagement element from the point of view of the respective other segment.
Claims
1. A gasket for sealing a gap extending at least partially around an interior of a housing, said gasket comprising at least one sealing layer, wherein the sealing layer comprises at least two segments which are arranged adjacent to each other in the longitudinal direction of the sealing layer and are joined to each other at a joining region, wherein the two segments have, at the joining region, intermeshing engagement elements joined to each other, and at least one segment has, at the joining region, a positioning hole and a through-opening which are arranged behind the engagement element from the point of view of a respective other segment.
2. The gasket according to claim 1, wherein the positioning hole is arranged in front of or behind the through-opening from the point of view of the adjacent segment.
3. The gasket according to claim 1, wherein the two segments are compressed together at the joining region.
4. The gasket according to claim 1, wherein an edge of one engagement element of one segment has a recess and an edge of another adjacent engagement element has a protrusion complementary to the recess.
5. The gasket according to claim 1, wherein the engagement elements form a dovetail-type joint.
6. The gasket according to claim 1, wherein a segment having a dovetail-type protrusion is compressed in a first compression region at a head end and/or at flanks of the dovetail-type protrusion, and/or a segment having a dovetail-type recess is compressed in second compression regions on both sides of a transition from the dovetail-type protrusion into a corresponding segment.
7. The gasket according to claim 1, wherein a centroid of the first compression region and centroids of the second compression regions are arranged at a distance of at least 1 mm from each other in the longitudinal direction of the gasket.
8. A method of manufacturing a gasket according to claim 1, wherein the two segments are compressed together in the region of the joining region.
9. The method according to claim 8, wherein the areas around the through-openings are fixed from at least one side along the circumferential edge of the through-opening.
10. The method according to claim 8, wherein the segments may be placed into an injection-molding die, and the two segments may be caulked together by the injection-molding die, and an elastomer may be injected onto at least parts of the edge regions of the gasket.
Description
BRIEF DESCRIPTION OF THE FIGURES
[0032] FIG. 1 shows a carrier layer of a gasket according to the present disclosure.
[0033] FIG. 2 shows the carrier layer of the gasket of FIG. 1 in a clinched position, according to the present disclosure.
[0034] FIG. 3 shows a first cross section of the gasket of FIG. 1, according to the present disclosure.
[0035] FIG. 4 shows a second cross section of the gasket of FIG. 1, according to the present disclosure.
[0036] FIG. 5 shows a third cross section of the gasket of FIG. 1, according to the present disclosure.
[0037] FIG. 6 shows a fourth cross section of the gasket of FIG. 1, according to the present disclosure.
[0038] FIG. 7A shows a first portion of the gasket of FIG. 1 including a stamping die in an open position, according to the present disclosure.
[0039] FIG. 7B shows the first portion of FIG. 7A including the stamping die in a closed position, according to the present disclosure.
[0040] FIG. 8A shows a second portion of the gasket of FIG. 1 including the stamping die in an open position, according to the present disclosure.
[0041] FIG. 8B shows the second portion of FIG. 8A including the stamping die in a closed position, according to the present disclosure.
[0042] FIG. 9A shows a third portion of the gasket of FIG. 1 including the stamping die in an open position, according to the present disclosure.
[0043] FIG. 9B shows the third portion of FIG. 9A including the stamping die in a closed position, according to the present disclosure.
[0044] FIG. 10 shows a fourth portion of the gasket of FIG. 1 including the stamping die in a closed position, according to the present disclosure.
[0045] FIG. 11 shows a carrier layer of a gasket that includes two gasket sections, according to the present disclosure.
[0046] FIG. 12 shows the carrier layer of the gasket of FIG. 11 in a clinched and stamped position, according to the present disclosure.
DETAILED DESCRIPTION
[0047] FIG. 1 shows a carrier layer 30 of a gasket 1 according to the present disclosure in plan view and in the region of two segments 10 and 20 which are joined to each other, but which have not yet been clinched together. Each of these segments comprises substantially of a metal layer. The metal layers of the two segments 10 and 20 are joined to each other in a joining region 2. The first segment 10 has a positioning opening 12, a through-opening 13 and, adjacent thereto, engagement elements 11a, 11b and 11c which are arranged at the peripheral edge 15 of the segment 10 and adjacent to the segment 20. In a corresponding manner, the segment 20 has a positioning opening 22, a through-opening 23, and engagement elements 21a, 21b and 21c arranged at the peripheral edge 25 of the segment 20 and adjacent to the segment 10, the outer contour of these engagement elements being complementary to the outer contour of the engagement elements 11a, 11b and 11c. In this example, the engagement elements are designed either as dovetail-type protrusions (namely elements 11a, 11c and 21b) or as dovetail-type recesses (elements 11b, 21a, 21c).
[0048] When the segments 10 and 20 are joined to each other by the engagement elements, as shown in FIG. 1, the protrusion 11a engages in the recess 21a and forms an undercut between the segment 10 and the segment 20 in the layer plane of the segments 10 and 20. The protrusion 21b engages in the recess 11b and forms a corresponding undercut between the segment 10 and the segment 20. The protrusion 11c engages in the recess 21c and likewise forms a corresponding undercut between the segment 10 and the segment 20.
[0049] The through-opening 13 is arranged between the positioning opening 12 and the end of the segment 10 that is formed by the engagement elements 11a, 11b and 11c. In a manner symmetrical thereto, the through-opening 23 is arranged between the positioning hole 22 and the engagement elements 21a, 21b and 21c.
[0050] While FIG. 1 shows a carrier layer 30 in the region around a joining region 2 between two segments 10 and 20 in the non-clinched state, FIG. 2 shows this gasket 1 according to the present disclosure in the same region in a state in which the two segments 10 and 20 are clinched together and thus joined to each other in the joining region 2. In addition, the elastomer injections 16a and 16b are now located on the outer edge of the carrier layer 30; these extend over the two segments. The clinching of the two segments 10 and 20 takes place at compression points 17a, 17b, 27a and 27b, which are respectively arranged in the recesses 11c, 11 a and 21b. The position of these clinching points is selected such that the two clinching points 27a and 27b are located next to each other transversely to the direction of extension of the gasket 1. The clinching points 17a and 17b are likewise located next to each other transversely to the direction of extension of the gasket 1, but are offset with respect to the clinching points 27a and 27b in the longitudinal direction of the gasket 1 and also transversely to the direction of extension of the gasket 1. This offset has the effect of minimizing the warpage of the joining region 2 that occurs as a result of material being displaced during the clinching of the points 17a, 17b, 27a and 27b. Nevertheless, the warpage of the segments 10 and 20 would still be considerable—such as at the positioning holes 12 and 22—and would lead to tilting or jamming of the positioning holes—if the through-opening 13 and the through-opening 23 were not arranged between these clinching points 17a, 17b, 27a, 27b, on the one hand, and the respectively adjacent positioning hole 12, 22, on the other hand, as per the present disclosure. When clinching the two segments 10 and 20 in a die, the segment 10 can now additionally be fixed, e.g. compacted, from both sides at the through-opening 13, e.g. at its peripheral edge, by means of holding punches which are placed onto the circumferential edge of the though-opening 13 from both sides of the segment 10 and fix the latter. In the same way, when clinching the two segments 10 and 20 in a die, the segment 20 can additionally be fixed from both sides at the through-opening 23 by means of holding punches which are placed onto the circumferential edge of the through-opening 23 from both sides of the segment 20 and fix the latter. Since the holding punches have to press against the gasket at the same time as the clinching punches, they penetrate deep into the carrier layer 30. As a result, however, the circumferential edge of the through-openings 13 and/or 23 is in turn compressed. This results in a form fit, which additionally holds the layer in position. However, the material that is compressed here can flow into the respective through-opening 13 or 23. The through-openings 13 and 23 thus serve as cutouts in the segments 10 and 20 for receiving material that is displaced by holding punches, e.g. as so-called “sacrificial holes”. Thus, the present disclosure proposes a fixing of the gasket between engagement elements and positioning hole and a sacrificial hole for receiving the material displaced in the process.
[0051] The holding punches prevent significant warpage from occurring at the positioning holes 12 and 22 as a result of the joining region 2 being clinched. The use of holding punches does not for its part produce any additional warpage, or only negligible warpage, at the positioning holes 12 and 22 since the holding punches press against the circumferential edge of the through-opening 13 and 23, but the through-openings 13 and 23 receive most or all of the material that is displaced by the holding punches.
[0052] The position of the positioning holes 12 and 22 is therefore not significantly affected, or is not affected at all, by the clinching of the two segments 10 and 20 at the joining region 2 and by the holding punches at the through-openings 13 and 23. The gasket 1 according to the present disclosure is therefore very dimensionally stable even in the joining region and in the region of the positioning holes 12 and 22 and is not jammed by positioning pins in the die or on a housing. It can therefore easily be removed from the die used for the joining process, and can also be applied with dimensional accuracy to a housing, for example a housing of a battery box.
[0053] In addition, the segment 10 is also compressed along its outer edge 15 having the edge sections 15a, 15b, so that depressions 17d, 17e are formed on the outer edge 15 in the layer of the segment 10. In a corresponding manner, the segment 20 is also compressed along its outer edge having the edge sections 25a, 25b, so that depressions 27d and 27e are formed on the outer edge in the layer of the segment 20. Elastomeric sealing lips 16a, 16b are injected onto these depressions.
[0054] The embossed contours produced during clinching of adjacent gasket segments, whether in the area of the joint, in the region of the sacrificial hole or along the outer edge of the segments, are easy to recognize because in these areas, on the one hand, the thickness of the metallic layer of the respective segment is reduced (see, for example, depressions 17d, 17e or recesses 17c, 27c) and, on the other hand, the microstructure of the metallic layer has been changed by the clinching process.
[0055] FIG. 3 shows a cross-section through the gasket 1 along the line A-A in FIG. 2. This cross-section extends transversely through the compression regions 27a and 27b in the protrusion 21b that serve to join the two segments 10 and 20, said compression regions being elongated in the longitudinal direction of the gasket 1.
[0056] FIG. 4 shows a cross-section along the line B-B in FIG. 2. This cross-section passes through the compression regions 17a, 17b in the protrusions 11a, 11c.
[0057] FIG. 5 shows a cross-section along the line C-C in FIG. 2. This cross-section passes through the through-opening 23. The edge of the through-opening 23 is likewise compressed here, resulting in depressions 27c. The material that is displaced in the regions 27c as a result of the compression can migrate into the through-opening 23 and therefore does not cause any warpage at the positioning hole 22. The fixing of the edge of the through-opening 23 also protects the positioning hole 22 against warpage caused by the clinching of the joining region 2.
[0058] FIG. 6 shows a cross-section along the line D-D in FIG. 2. This cross-section extends centrally through the gasket 1 in the longitudinal direction. The through-opening 13 in the segment 10 is compressed along its circumferential edge in the form of a circumferential depression 17c, and the through-opening 23 in the segment 20 is compressed along its circumferential edge in the form of the circumferential depression 27c. The material that is compressed out of the depressions 17c and 27c can flow into the respective through-opening 13 or 23. This prevents warpage from occurring at the positioning holes 12 and 22, or has the effect that any warpage that does occur there is minor and insignificant.
[0059] FIGS. 7A and 7B, 8A and 8B, 9A and 9B, and 10 show the gasket 1 according to FIGS. 1 and 2 in the sections A-A, B-B, C-C and D-D, respectively, in the state in which no clinching has yet taken place and the stamping die is still open, and in the state in which clinching has taken place and the stamping die is closed.
[0060] FIG. 7A shows the section along the line A-A from FIG. 2 with a stamping die comprising of an upper stamping die plate 3 and a lower stamping die plate 4, wherein the stamping die is not yet closed and consequently the segments 10 and 20 are not yet joined to each other.
[0061] The upper stamping die plate 3 (in FIG. 7A) has stamping elements 5a and 5b, by which the second segment 20 can be compressed in compression regions 27a and 27b. The lower stamping die plate 4 (in FIG. 7A) also has corresponding stamping elements 6a and 6b, which during the stamping process are arranged opposite the stamping elements 5a and 5b, respectively, so that the compression regions 27a and 27b can be compressed between the elements 5a and 6a and between the elements 5b and 6b, respectively. By compressing the compression regions 27a and 27b, as shown with the stamping die closed in FIG. 7B, the second segment 20 is clinched between the adjacent regions of the first segment 10.
[0062] Furthermore, the upper stamping die plate 3 has two stamping elements 5a′ and 5b′, and the lower stamping die plate 4 has the stamping elements 6a′ and 6b′ at corresponding positions. In the closed state of the stamping die, which is shown in FIG. 7B, the stamping elements 5a′ and 6a′ compress the edge region of the first segment 10 in order to flatten the outer peripheral edge 15b. An elastomer can then be injected in this region in the form of an elastomer seal (not shown here).
[0063] In a corresponding manner, the stamping elements 5b′ and 6b′ compress the opposite edge 15a of the first element 10 in order likewise to thin the first element 10 for the injection of an elastomer seal (not shown here).
[0064] FIG. 8A shows the section B-B from FIG. 2. In this section, the upper stamping die plate 3 has stamping elements 5c and 5d in addition to the stamping elements 5a′ and 5b′. The lower stamping die plate 4 has stamping elements 6c and 6d in addition to the stamping elements 6a′ and 6b′. By means of the stamping elements 5c and 6c and 5d and 6d, the first segment 10 can be compressed in the compression regions 17a, 17b and thus the first segment 10 can be clinched to the adjacent second segment 20 in order to produce a stable form fit and friction fit between the segments 10 and 20. FIG. 8B shows the same section as in FIG. 8A, but with the stamping die comprising the stamping die plates 3 and 4 now closed.
[0065] FIGS. 9A and 9B show a section along the line C-C in FIG. 2. In addition to the stamping elements 5a′, 5b′, the upper stamping die plate 3 has a further stamping element 7b, by which the second segment 20 can be compressed in the region of the through-opening 23. In this section, the stamping die plate 4 likewise has the stamping elements 6a′ and 6b′ as well as a further stamping element 8b, by which, together with the aforementioned stamping element 7b of the stamping die plate 3, the circumferential edge of the through-opening 23 can be compressed.
[0066] FIG. 9A shows a state in which the stamping die is not closed, while FIG. 9B shows a state in which the stamping die is closed. As a result of the circumferential edge of the through-opening 23 being compressed by the stamping elements 7b and 8b, the second segment 20 is fixed at the through-opening 23 and prevents any warpage of the second segment 20 at this point as the joining region 2 is compressed in the regions 17a, 17b, 27a and 27b. The material that is displaced as a result of the compression of the segment 20 by the stamping elements 7b and 8b can migrate into the through-opening 23 as a sacrificial hole, thereby avoiding or at least considerably reducing any further warpage of the segment 20 caused by this compression.
[0067] FIG. 10 shows a section along the line D-D in FIG. 2, in which the stamping die comprising the upper stamping die plate 3 and the lower stamping die plate 4 is closed, e.g. in the compressed state. Arranged in each of the positioning holes (fitting holes) 12 and 22 is a respective positioning pin 9a and 9b, by which the segments of the gasket 1 are held in position during the compression. These positioning holes can also subsequently be used to accurately position the gasket 1 at its intended location.
[0068] Since both the first segment 10 and the second segment 20 are simultaneously fixed at the through-openings 13 and 23 during the compression of the joining region 2, warpage caused by the stamping of the joining region 2 has no effect or only a minor effect on the regions around the through-openings 13 and 23 and for instance on the regions of the segments 10 and 20 that are located behind the through-openings 13 and 23 from the point of view of the respective other segment. This prevents any warpage of the positioning holes 22 and 12 and any jamming or tilting of the positioning pins 9b, 9a in the positioning holes 22 and 12.
[0069] In the present example, the positioning holes 12 and 22 are arranged in each case behind, such as in a straight line behind, the adjacent through-openings 13 and 23 from the point of view of the respective other segment, as seen from the joining region. However, it is also possible for them to be arranged to the side of or in front of the through-openings 13 and 23, without entirely losing the described technical effects.
[0070] FIG. 11 shows the carrier layer of a gasket with two gasket segments 10 and 20, which are connected to each other in a joining region 2. FIG. 11 is an illustration of another example corresponding to the illustration in FIG. 1. The gasket segments 10 and 20 are constructed like the gasket segments 10 and 20 in FIG. 1 and differ from them in the shape of the engagement elements. While the engagement elements 11a, 11b, 21a, 21b, 21c, 11c in FIG. 1 are formed in a dove-tailed shape, the engagement elements 11a and 21a in FIG. 11 are formed in such a way that they engage laterally behind one another and produce a form fit in the direction of the longitudinal axis of the segments 10 and 20. For this purpose, the engagement elements are S-shaped, each of the engagement elements 11a and 21a extending longitudinally from their respective segment at one segment edge and having a projection at their end in the direction of the other edge, so that the two engagement elements 11a and 21a have an approximately S-shaped course, engage in the free spaces formed by the respective other engagement element and undercut one another.
[0071] FIG. 12 shows the same carrier layer as in FIG. 11, but after clinching and stamping of the two segments 10 and 20 in the joint region 2 at the through-holes 13 and 23 and at the outer edge of the segments 10 and 20. The clinched regions in which the layer thickness is reduced are designated by the reference signs 17a, 17c, 17d, 17e and 27a, 27c, 27d, 27e. In contrast to the illustration in FIG. 2, the embodiment of segments 10 and 20 in the joint region 2 are only clinched together along the two adjacent outer edges of the engagement elements 11a, 11b and 21a, 21b.
[0072] FIGS. 1-12 are shown approximately to scale. FIGS. 1-12 show example configurations with relative positioning of the various components. If shown directly contacting each other, or directly coupled, then such elements may be referred to as directly contacting or directly coupled, respectively, at least in one example. Similarly, elements shown contiguous or adjacent to one another may be contiguous or adjacent to each other, respectively, at least in one example. As an example, components laying in face-sharing contact with each other may be referred to as in face-sharing contact. As another example, elements positioned apart from each other with only a space there-between and no other components may be referred to as such, in at least one example. As yet another example, elements shown above/below one another, at opposite sides to one another, or to the left/right of one another may be referred to as such, relative to one another. Further, as shown in the figures, a topmost element or point of element may be referred to as a “top” of the component and a bottommost element or point of the element may be referred to as a “bottom” of the component, in at least one example. As used herein, top/bottom, upper/lower, above/below, may be relative to a vertical axis of the figures and used to describe positioning of elements of the figures relative to one another. As such, elements shown above other elements are positioned vertically above the other elements, in one example. As yet another example, shapes of the elements depicted within the figures may be referred to as having those shapes (e.g., such as being circular, straight, planar, curved, rounded, chamfered, angled, or the like). Further, elements shown intersecting one another may be referred to as intersecting elements or intersecting one another, in at least one example. Further still, an element shown within another element or shown outside of another element may be referred as such, in one example.
[0073] It will be appreciated that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not to be considered in a limiting sense, because numerous variations are possible. Moreover, unless explicitly stated to the contrary, the terms “first,” “second,” “third,” and the like are not intended to denote any order, position, quantity, or importance, but rather are used merely as labels to distinguish one element from another. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.
[0074] As used herein, the term “approximately” or “substantially” is construed to mean plus or minus five percent of the range unless otherwise specified.
[0075] The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.
