SELF-FORMING GASKET ASSEMBLY AND METHODS OF CONSTRUCTION AND ASSEMBLY THEREOF

Abstract

A gasket assembly and methods of construction and assembly thereof are provided. The gasket assembly includes an elastically deformable, resilient carrier layer having an upper surface and a lower surface extending in planar, generally parallel relation with one another between an inner periphery and an outer periphery when in a disassembled state. At least one top layer is fixed to the upper surface proximate at least one of the inner periphery and the outer periphery. At least one bottom layer is fixed to the lower surface in radially spaced relation from the at least one top layer. The upper surface and the lower surface take on a non-planar, spring-biased shape upon compressing the gasket assembly between a pair of surfaces to an assembled state.

Claims

1. A gasket assembly, comprising: an elastically deformable, resilient carrier layer having an upper surface and a lower surface extending in planar, generally parallel relation with one another between an inner periphery and an outer periphery when in a disassembled state; at least one top layer fixed to said upper surface proximate at least one of said inner periphery and said outer periphery; and at least one bottom layer fixed to said lower surface in radially spaced relation from said at least one top layer, wherein said upper surface and said lower surface take on a non-planar, spring-biased shape upon compressing the gasket assembly between a pair of surfaces to an assembled state.

2. The gasket assembly of claim 1, wherein said at least one top layer is a single top layer fixed proximate said inner periphery and said at least one bottom layer is a single bottom layer spaced outwardly from said top layer.

3. The gasket assembly of claim 2, wherein said top layer has a thickness and said bottom layer has a thickness, the thicknesses of said top layer and said bottom layer being the same.

4. The gasket assembly of claim 2, wherein said top layer has a width and said bottom layer has a width, the widths of said top layer and said bottom layer being the same.

5. The gasket assembly of claim 1, wherein said at least one top layer includes a pair of top layers, one of said pair of top layers being fixed proximate said inner periphery and the other of said pair of top layers being fixed proximate said outer periphery, said at least one bottom layer being spaced between said pair of top layers.

6. The gasket assembly of claim 5, wherein each of said pair of top layers has a thickness and said bottom layer has a thickness, the thicknesses of said top layers being the same.

7. The gasket assembly of claim 5, wherein each of said pair of top layers has a width and said bottom layer has a width, the widths of said pair of top layers and said bottom layer being the same.

8. The gasket assembly of claim 5, wherein one of said pair of top layers and said at least one bottom layer are spaced from one another a first distance and the other of said pair of top layers and said at least one bottom layer are spaced from one another a second distance, wherein the first distance and the second distance are the same.

9. The gasket assembly of claim 1, wherein said at least one top layer is peripherally continuous and said at least one bottom layer is peripherally continuous.

10. The gasket assembly of claim 9, wherein said at least one top layer is circular and said at least one bottom layer is circular.

11. A method of constructing a gasket assembly, comprising: providing an elastically deformable, resilient carrier layer having an upper surface and a lower surface extending in planar, generally parallel relation with one another between an inner periphery and an outer periphery when in a disassembled state; fixing at least one top layer to said upper surface proximate at least one of said inner periphery and said outer periphery; and fixing at least one bottom layer to said lower surface in radially spaced relation from said at least one top layer, wherein said upper surface and said lower surface take on a non-planar, spring-biased shape upon compressing the gasket assembly between a pair of surfaces to an assembled state.

12. The method of claim 11, further including fixing the at least one top layer as a single, sole top layer to the upper surface proximate at least one of the inner periphery and the outer periphery.

13. The method of claim 12, further including providing the top layer having a thickness and providing the bottom layer having a thickness, with the thicknesses of the top layer and the bottom layer being the same.

14. The method of claim 12, further including providing the top layer having a width and providing the bottom layer having a width, with the widths of the top layer and the bottom layer being the same.

15. The method of claim 11, further including fixing the at least one top layer including a pair of top layers, and fixing one of the pair of top layers proximate the inner periphery and fixing the other of the pair of top layers proximate the outer periphery, and fixing the at least one bottom layer in radially spaced relation between the pair of top layers.

16. The method of claim 15, further including providing each of the pair of top layers having a thickness and providing the bottom layer having a thickness, the thicknesses of the top layers and the bottom layer being the same.

17. The method of claim 15, further including providing each of the pair of top layers having a width and providing the bottom layer having a width, the widths of the pair of top layers and the bottom layer being the same.

18. The method of claim 15, further including spacing one of the pair of top layers and the at least one bottom layer from one another a first distance and spacing the other of the pair of top layers and the at least one bottom layer from one another a second distance, wherein the first distance and the second distance are the same.

19. A method of assembling a gasket assembly into an internal combustion engine, comprising: providing the gasket assembly including an elastically deformable, resilient carrier layer having an upper surface and a lower surface extending in planar, generally parallel relation with one another between an inner periphery and an outer periphery when in a disassembled state; at least one top layer fixed to said upper surface proximate at least one of said inner periphery and said outer periphery; and at least one bottom layer fixed to said lower surface in spaced relation from said at least one top layer; sandwiching the gasket assembly between opposite surfaces to be fixed together in sealed relation with one another; and fixing the opposite surfaces to one another and compressing the at least one top layer and the at least one bottom layer in opposite axial directions and causing the upper surface and the lower surface of the carrier layer to take on a non-planar, spring-biased shape, thereby causing the at least one top layer to exert a sealing force against one of the opposite surfaces in a first axial direction to form a seal there against and the at least one bottom layer to exert a sealing force against the other of the opposite surfaces in a second axial direction opposite the first axial direction to form a seal there against.

20. The method of claim 19, further including providing the at least one top layer as a single, sole top layer fixed to the upper surface proximate at least one of the inner periphery and the outer periphery.

21. The method of claim 19, further including providing the at least one top layer including a pair of top layers, with one of the pair of top layers being fixed proximate the inner periphery and the other of the pair of top layers being fixed proximate the outer periphery, and providing the at least one bottom layer in spaced relation between the pair of top layers, thereby causing the pair of top layers to each exert a sealing force against one of the opposite surfaces in a first axial direction to form a seal there against and the at least one bottom layer to exert a sealing force against the other of the opposite surfaces in a second axial direction opposite the first axial direction to form a seal there against.

22. The method of claim 21, further including providing the at least one bottom layer as a single, sole bottom layer fixed to the lower surface between the pair of top layers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] These and other aspects, features and advantages of the invention will become more readily appreciated when considered in connection with the following description of the presently preferred embodiments, appended claims and accompanying drawings, in which:

[0034] FIG. 1 is a top plan view of a gasket assembly constructed in accordance with one aspect of the disclosure;

[0035] FIG. 2 is a top perspective view of the gasket assembly of FIG. 1;

[0036] FIG. 3 is a bottom perspective view of the gasket assembly of FIG. 1;

[0037] FIG. 4 is a cross-sectional view of the gasket assembly of FIG. 1 taken generally along the line 4-4;

[0038] FIG. 5 is a cross-sectional view of the gasket assembly of FIG. 1 as installed between two mating flanges of an internal combustion engine;

[0039] FIG. 6 is a top plan view of a gasket assembly constructed in accordance with another aspect of the disclosure;

[0040] FIG. 7 is a top perspective view of the gasket assembly of FIG. 6; and

[0041] FIG. 8 is a bottom perspective view of the gasket assembly of FIG. 6;

[0042] FIG. 9 is a cross-sectional view of the gasket assembly of FIG. 8 taken generally along the line 9-9; and

[0043] FIG. 10 is a cross-sectional view of the gasket assembly of FIG. 6 as installed between two mating flanges of an internal combustion engine.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0044] Referring to the Figures, wherein like numerals indicate corresponding parts throughout the several views, a first exemplary embodiment of self-forming (self-biasing, self-sealing) gasket assembly, referred to hereafter as gasket assembly 20, which is constructed according to one aspect of the present disclosure, is generally shown in FIGS. 1-4. In the first exemplary embodiment, the gasket assembly 20 is an exhaust manifold gasket, by way of example and without limitation, with it to be understood that the teachings herein are applicable to any type of gasket, such as a cylinder head gasket, or any other location requiring sealing between parts to be sealed with one another, which is configured to automatically deform elastically and resiliently to establish a gas tight seal between a pair of surfaces upon clamping the surfaces together, such as an exhaust manifold 22 (FIG. 6) and a cylinder head 24 (FIG. 6) in an internal combustion engine by way of example and without limitation. As discussed in further detail below, although the gasket assembly 20 lacks any preformed, raised seal beads, as are commonly formed via embossing processes and found in MLS-type gaskets, gasket assembly 20 is nonetheless able to elastically flex to resiliently maintain the gas tight seal between the exhaust manifold 22 and the cylinder head 24 as the exhaust manifold 22 lifts at least partially away from the cylinder head 24 during operation of the internal combustion engine. The gasket assembly 20 is also more economical to manufacture as compared to other known gasket assemblies because the equipment and labor required to emboss one or more gasket layers are not required.

[0045] The gasket assembly 20 includes an active layer, also known as a functional carrier layer, referred to hereafter as carrier layer 26, which is made as a monolithic sheet of a resilient, elastically deformable metal, such as steel, spring grade steel (spring steel) or an alloy steel. The carrier layer 26 has at least one inner periphery 28 which surrounds an opening which may correspond to, for example, a cylinder bore, a coolant channel, or an exhaust port, and an outer periphery 29. The carrier layer 26 has a generally uniform, constant first thickness T.sub.1 extending between a top face, also referred to as upper surface 25, and a lower face, also referred to as lower surface 27. Upper surface 25 and lower surface 27 extend in parallel or generally parallel relation with one another, with upper surface 25 and lower surface 27 being planar while in a disassembled state.

[0046] At least one first layer, such as a peripherally continuous layer, which can be circular, square, rectangular, or any geometric shape, also referred to as annular top layer or simply top layer 30, is fixedly attached to top face 25 of the carrier layer 26 proximate at least one of the inner periphery 28 and the outer periphery 29, and at least one second layer, such as a peripherally continuous layer, which can be circular, square, rectangular, or any geometric shape, also referred to as annular bottom layer or simply bottom layer 32, is fixedly attached to the bottom face 27 of the carrier layer 26 in radially spaced relation from the at least one top layer 30. The bottom layer(s) 32 has a generally constant second thickness T.sub.2 extending between opposite faces 31, 33, and the top layer(s) 30 has a generally constant third thickness T.sub.3 extending between opposite faces 35, 37. In the first exemplary embodiment, the second and third thicknesses T.sub.2, T.sub.3 are the same or approximately equal to one another and are the same or similar to the first thickness T.sub.1 of the carrier layer 26, though it is contemplated herein that their thicknesses T.sub.1, T.sub.3 could be different. In the embodiment illustrated in FIGS. 1-5, the at least one annular top layer 30 is a single annular top layer 30 having the lower face 37 fixed proximate the inner periphery 28 and the at least one annular bottom layer 32 is a single annular bottom layer 32 spaced outwardly, such as being spaced radially outwardly from the annular top layer 30 having the upper face 31 fixed proximate the outer periphery 29. The top and bottom layers 30, 32 are preferably made of the same metal as the carrier layer 26 and are preferably fixedly attached with the carrier layer via a weld joint in a welding process and/or via suitable adhesives. Similar to the carrier layer 26, the top and bottom layers 30, 32 are sheet-like, i.e., generally planar along their opposite faces 31, 33, 35, 37, wherein the opposite faces 31, 33, 35, 37 are parallel or generally parallel to one another.

[0047] Each of the top and bottom layers 30, 32 can be annular and toroidal in shape, by way of example and without limitation, with an inner periphery and an outer periphery and has a respective radial width extending between the inner periphery and outer periphery. Specifically, the bottom layer 32 has a first radial width W.sub.1 extending between its inner periphery 34 and outer periphery 36, and the top layer 30 has a second radial width W.sub.2 extending between its inner periphery 38 and outer periphery 40, and the first and second radial widths W.sub.1, W.sub.2 are equal or similar to one another, though it is contemplated herein that their widths W.sub.1, W.sub.2 could be different. As best shown in FIG. 4, the outer periphery 40 of the top layer 30 is spaced radially inwardly of the inner periphery 34 of the bottom layer 32 by a horizontal edge distance X. Thus, the gasket assembly 20 has only the first thickness T.sub.1 of carrier layer 26 in an area of the horizontal edge distance X and radially outwardly from bottom layer 32 and has a greater total thickness (T.sub.1+T.sub.2 or T.sub.1+T.sub.3) in the areas extending along the top and bottom layers 30, 32.

[0048] Referring now to FIG. 4, before the gasket assembly 20 is installed to an assembled state in the internal combustion engine, the carrier layer 26, while in a disassembled state, is planar, with the opposite upper and lower surfaces 25, 27 thereof extending along respective planes P1, P2 in planar, parallel relation with one another, and thus the top layer 30 is disposed in its entirety vertically upwardly above plane P1, while bottom layer 32 is disposed in its entirety vertically downwardly below plane P2. Accordingly, top layer 30 and bottom layer 32 and extend along planes in parallel relation with one another, with the planes along which top layer 30 and bottom layer 32 extend being spaced from one another by at least the thickness T.sub.1 of carrier layer 26. Accordingly, the total combined thickness of gasket assembly 20 while in an un-deformed, relaxed state is T.sub.1+T.sub.2+T.sub.3.

[0049] When the gasket assembly 20 is installed in the internal combustion engine and the exhaust manifold 22 is fixed, such as via being bolted, to the cylinder head 24, opposite forces (identified as F in FIG. 5) are applied to the top and bottom layers 30, 32 and the forces F are imparted into the carrier layer 26. These opposing forces F applied directly to top face 31 of top layer 30 and to bottom face 33 of bottom layer 32 cause the carrier layer 26 to bend and deform elastically and resiliently in the area of the horizontal edge distance X to the shape shown in FIG. 5 to assume an elastically and resiliently deformed assembled state. In the embodiment described and illustrated, the gasket assembly 20, while in its assembled state, is caused to take on a generally S-curved shape extending between the inner and outer periphery 28, 29, as viewed in lateral cross-section (FIG. 5). As such, upon being brought to the assembled state, the top layer 30 and bottom layer 32 are caused to be brought into coplanar relation with one another, at least in part, with a portion of the thickness T2 of bottom layer 32 and a portion of the thickness T3 of top layer 30 being coplanar. Because the deformation is elastic and resilient, the bend in the carrier element 26 serves as an elastic and resilient functional sealing feature which allows the carrier element 26 to flex resiliently in spring-biased fashion with equal and opposite forces F to the opposed forces F maintaining both of the top and bottom layers 30, 32 in sealed engagement with the surfaces clamped toward one another, e.g. exhaust manifold 22 and the cylinder head 24, respectively, even as the exhaust manifold 22 deflects away from the cylinder head 24. Because the elastic, resilient bend is automatically imparted into the carrier layer 26 during installation of the gasket assembly 20 into the engine, no step of embossing or otherwise plastically deforming step of the carrier layer 26 before installing it in the engine is required, and thus, the sealing aspect of gasket assembly 20 is self-forming without the expense of forming processes. Accordingly, prior to assembly, the carrier layer 26 remains un-deformed and planar and without embossed or otherwise plastically deformed features.

[0050] Referring now to FIGS. 7-10, a second exemplary embodiment of a gasket assembly 120 is generally shown, wherein like reference numerals as used above, offset by a factor of 100, are used to identify like features. In contrast to the first exemplary embodiment, the gasket assembly 120 includes a plurality of, shown as a pair of, by way of example and without limitation, first and second top layers 130, 130, such as annularly-shaped, by way of example and without limitation, (specifically, a radially inner top layer 130 and a radially outer top layer 130) in addition to a single annularly-shaped third layer, also referred to as bottom layer 132. The inner top layer 130 has a first width W.sub.1, the bottom layer 132 has a second width W.sub.2, and the outer top layer 130 has a third width W3, wherein the respective first and second W.sub.1, W.sub.2, can be the same, whereas the width W3 can be the same or different from the widths W.sub.1, W.sub.2, as desired for the intended application.

[0051] The inner top layer 130 is spaced in radially staggered relation inwardly from the bottom layer 132 by a first horizontal edge distance X.sub.1, and the bottom layer 132 is spaced in radially stagger relation inwardly from the outer top layer 130 by a second horizontal edge distance X.sub.2, wherein X.sub.1 and X.sub.2 can be provided as desired, including being the same or different. Accordingly, one of the pair of annular top layers 130 is fixed proximate an inner periphery 128 and the other of the pair of annular top layers 130 is fixed proximate an outer periphery 129, with the at least one annular bottom layer 132 being spaced radially between the pair of annular first and second top layers 130, 130. Thus, when the gasket assembly 120 is clamped between two flanges or surfaces, such as exhaust manifold 22 and the cylinder head 24, in an internal combustion engine, as discussed above for gasket 20, the carrier layer 126 will bend and be able to flex resiliently in the areas of both of the first and second horizontal edge distances X.sub.1, X.sub.2. In the embodiment described and illustrated, the carrier layer 126 of the gasket assembly 120 is caused to take on a generally bell-curved shape extending between the inner periphery 128 and outer periphery 129. Accordingly, prior to assembly, the carrier layer 126 remains planar and without embossments.

[0052] In this embodiment, the inner top layer 130 has a second thickness T.sub.2, the bottom layer 132 has a third thickness T.sub.3, and the outer top layer 130 has a fourth thickness T.sub.4. The second, third, and fourth thicknesses T.sub.2, T.sub.3, T.sub.4 are all the same, by way of example and without limitation. Alternately, the second and fourth thicknesses T.sub.2, T.sub.4 of the inner and outer top layers 130, 130 respectively could be the same, and the third thickness T.sub.3 of the bottom layer 132 could be different from T.sub.2, T.sub.4.

[0053] In accordance with another aspect of the disclosure, a method of constructing a gasket assembly 20, 120 is provided. The method includes providing an elastically deformable, resilient functional carrier layer, referred to hereafter as carrier layer 26, 126 having an upper surface 25, 125 and a lower surface 27, 127 extending in planar, generally parallel relation with one another between an inner periphery 28, 128 and an outer periphery 29, 129 when in a disassembled state. Further, fixing at least one top layer 30, 130, such as annular top layers 30, 130, by way of example and without limitation, to the upper surface 25, 125 proximate at least one of the inner periphery 28, 128 and the outer periphery 29, 129. Further, fixing at least one bottom layer 32, 132, such as an annular bottom layer 32, 132, by way of example and without limitation, to the lower surface 27, 127 in radially spaced relation from the at least one annular top layer 30, 130, wherein the upper surface 25, 125 and the lower surface 27, 127 are caused to take on a non-planar, spring-biased shape upon the gasket assembly being compressed between a pair of surfaces 22, 24 to an assembled state.

[0054] In accordance with a further aspect of the disclosure, the method can further include providing the at least one annular top layer as a single, sole top layer 30 fixed to the upper surface 25 proximate at least one of the inner periphery 28 and the outer periphery 29.

[0055] In accordance with a further aspect of the disclosure, the method can further include providing the at least one annular top layer including a pair of annular top layers 130, 130, with one of the pair of annular top layers 130 being fixed proximate the inner periphery 128 and the other of the pair of annular top layers 130 being fixed proximate the outer periphery 129, and providing the at least one annular bottom layer 132 in radially spaced relation between the pair of annular top layers 130, 130, thereby causing the pair of annular top layers 130, 130 to each exert a sealing force against one of the opposite surfaces 22 in a first axial direction to form an annular seal there against and the at least one annular bottom layer 132 to exert a sealing force against the other of the opposite surfaces 24 in a second axial direction opposite the first axial direction to form an annular seal there against.

[0056] In accordance with a further aspect of the disclosure, the method can further include providing the at least one annular bottom layer as a single, sole bottom layer 132 fixed to the lower surface 127 between the pair of annular top layers 130, 130.

[0057] As noted above, it is to be recognized that the top and bottom layers 30, 32, 130, 132 discussed herein can take on any desired peripheral shape, including round, square, rectangular, or otherwise, and further, that the top and bottom layers 30, 32, 130, 132 can be peripherally continuous or discontinuous, as desired.

[0058] Obviously, many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while within the scope of the appended claims. Additionally, it is to be understood that all features of all claims and all embodiments can be combined with each other as long as they do not contradict each other. It should also be appreciated that directional terms, such as top and bottom are in reference to the particular orientations of the features in one or more of the drawings and are not intended to require the gasket assembly to have any particular orientation.