Abstract:
An engine gasket is provided. The gasket includes a main body having a first sealing surface, a second sealing surface, an inner edge, and an outer edge. The inner edge defines an opening through the main body between the first and second sealing surfaces. A protrusion extends from the main body. The protrusion has a preestablished configuration that is accessible after the first and second sealing surfaces are adapted for sealing therebetween.

Description:
TECHNICAL FIELD  
         [0001]    The present invention is directed to an engine gasket. More particularly, the present invention is directed to an engine manifold sealing gasket.  
         BACKGROUND  
         [0002]    Engines are commonly assembled from a number of separately manufactured parts. For example, an engine typically includes a cylinder head, an intake manifold, and an exhaust manifold, which are normally manufactured as separate components. These components are then assembled with the other necessary parts to produce an engine.  
           [0003]    During operation of the engine, the intake manifold directs an intake air into one or more combustion chambers that are formed within the cylinder head. Fuel, such as diesel, gasoline, or natural gas, is mixed with the intake air. The fuel and air mixture is combusted to drive a piston housed within the combustion chamber. An exhaust gas resulting from the combustion is then forced from the cylinder head into the exhaust manifold. This exhaust gas may be treated to reduce the emissions in the gas, such as by an engine gas recirculation system. In addition, the exhausted gas may be used to drive a turbocharger that pre-charges the intake air.  
           [0004]    Achieving consistent air flow to and from the engine is important for proper operation of the engine. To prevent leaks, sealing devices, such as gaskets, are typically placed between components that are joined together to define a passageway into or out of the engine. For example, gaskets may be placed between the cylinder head and the intake manifold and between the cylinder head and the exhaust manifold to prevent gases from leaking at the joints between the respective parts.  
           [0005]    Gaskets may also be placed between other engine components to prevent gases from leaking from the engine. For example, an engine may be equipped with sensors or probes that monitor the operating conditions of the engine. These sensors and probes may be coupled with a cover plate that is engageable with the engine. A gasket may be disposed between the cover plate and the engine to form a seal and prevent gases from leaking from the engine.  
           [0006]    During assembly, however, it may be difficult to properly position gaskets between the engine components. This difficulty arises, in large part, due to the cumbersome assembly process of two relatively large and/or heavy components. An improperly positioned gasket may interfere with the operation of the engine. If the gasket slips relative to the cylinder head and manifold during assembly, the gasket may result in a position where the gasket blocks the passageway between the components. Any such blockage in the passageway to or from the engine may interfere with the intake or exhaust process of the engine.  
           [0007]    Accordingly, care must be taken during the assembly process to ensure that these gaskets are properly positioned. One approach to ensuring the proper positioning of gaskets is described in U.S. Pat. No. 6,328,313. In this approach, an adhesive is used to prevent the gasket from slipping during assembly. However, this adhesive may form a bond between the gasket and the cylinder head or manifold, thereby complicating the removal and replacement of the gasket during normal servicing. Thus, while the adhesive may simplify the assembly process, it may increase the complexity of the maintenance process.  
           [0008]    The engine gasket of the present invention solves one or more of the problems set forth above.  
         SUMMARY OF THE INVENTION  
         [0009]    One aspect of the present invention is directed to an engine gasket. The gasket includes a main body having a first sealing surface, a second sealing surface, an inner edge, and an outer edge. The inner edge defines an opening through the main body between the first and second sealing surfaces. A protrusion extends from the main body. The protrusion has a preestablished configuration that is accessible after the first and second sealing surfaces are adapted for sealing therebetween.  
           [0010]    In another aspect, the present invention is directed to a method of assembling an engine. A cylinder head having an outer surface, at least one intake passageway, and at least one exhaust passageway is provided. At least one of an intake manifold having a flange and an exhaust manifold having a flange is provided. At least one gasket having a protrusion is disposed between the cylinder head and the flange of the at least one of the intake manifold and the exhaust manifold. The protrusion has a preestablished configuration that is accessible after the at least one gasket is positioned between the cylinder head and the flange of the at least one of the intake manifold and the exhaust manifold. The flange of the at least one of the intake manifold and the exhaust manifold is secured to the cylinder head.  
           [0011]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the invention and together with the description, serve to explain the principles of the invention. In the drawings:  
         [0013]    [0013]FIG. 1 is a pictorial representation of an engine gasket in accordance with an exemplary embodiment of the present invention;  
         [0014]    [0014]FIG. 2 is a diagrammatic and schematic representation of an engine in accordance with an exemplary embodiment of the present invention;  
         [0015]    [0015]FIG. 3 is a sectional view of an engine gasket according to an exemplary embodiment of the present invention disposed between a cylinder head and a manifold flange; and  
         [0016]    [0016]FIG. 4 is a pictorial representation of an engine, illustrating a cylinder head and an exhaust manifold. 
     
    
     DETAILED DESCRIPTION  
       [0017]    Reference will now be made in detail to exemplary embodiments of the invention, which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.  
         [0018]    An exemplary embodiment of an engine gasket  10  is illustrated in FIG. 1. As shown, gasket  10  includes a main body  12 . Main body  12  includes a first sealing surface  22  and a second sealing surface  24 . Main body  12  may be constructed of any material readily apparent to one skilled in the art, such as, for example, a metallic or elastomeric material.  
         [0019]    Main body  12  further includes an inner edge  17  that defines an opening  20 . Opening  20  extends between first sealing surface  22  and second sealing surface  24 . Inner edge  17  may include at least one linear segment  18 . Inner edge  17  may further include a series of four linear segments  18  connected by a series of rounded corners  19 . In this exemplary embodiment, opening  20  has a substantially rectangular shape. It should be understood, however, that inner edge  17  may define an opening  20  of any shape readily apparent to one skilled in the art as suitable for its intended purpose. For example, inner edge  17  may define a circular, semi-circular, or oval opening. In addition, inner edge  17  may include a combination of arcuate and linear sections.  
         [0020]    As also shown in FIG. 1, a protective substance  25  may be disposed on inner edge  17  and along each of first and second sealing surfaces  22  and  24  adjacent inner edge  17 . In certain circumstances, a high temperature fluid may be directed through opening  20  in main body  12 . Protective substance  25  is applied to main body  12  adjacent inner edge  17  to protect main body  12  from damage caused by the high temperature fluid. Protective substance  25  may be a heat-sensitive multi-layer or composite sealing material. Examples of material used for the protective substance  25  include a soft metallic or non-metallic material, such as a mild steel, a nitrile rubber, a heat curable liquid silicone, a fluoroelastomer, a thermoplastic resin having a filler therein, or a graphite facing. In addition, the protective substance may be impregnated with a conventional temperature, oil and water resistant impregnate. Other suitable materials readily apparent to one skilled in the art may be used as the protective substance  25 .  
         [0021]    Main body  12  also includes an outer edge  14 . Outer edge  14  may include at least one linear segment  15  that extends substantially parallel to one of linear segments  18  of inner edge  17 . Outer edge  14  may further include three linear segments  15 , each of which adjoin a rounded corner  16 . Each of the three linear segments  15  extend substantially parallel to one of linear segments  18  of inner edge  17 . In this exemplary embodiment, main body  12  has a substantially rectangular shape. It should be understood, however, that outer edge  14  may have any shape readily apparent to one skilled in the art as suitable for its intended purpose. For example, outer edge  14  may have a circular or oval shape. In addition, outer edge  14  may include a combination of arcuate and linear sections.  
         [0022]    As further shown in FIG. 1, main body  12  may include a series of openings  28 . Each opening  28  may be disposed adjacent a rounded corner  19  of inner edge  17 . One skilled in the art will recognize that openings  28  may be placed in various other locations within main body  12  depending upon the particular application of gasket  10 . In addition, one skilled in the art will recognize that openings  28  may be formed as slits or notches in outer edge  14 .  
         [0023]    As also illustrated in FIG. 1, gasket  10  includes a means for positioning the gasket, which may be a protrusion  26 . Protrusion  26  includes a first surface  46  and a second surface  48 . First surface  46  extends from first sealing surface  22  and second surface  48  extends from second sealing surface  24 .  
         [0024]    In the illustrated exemplary embodiment, protrusion  26  has a generally triangular shape and first and second surfaces  46  and  48  are disposed in substantially the same plane as first and second sealing surfaces  22  and  24 , respectively. It should be understood, however, that protrusion  26  may have a variety of different configurations, such as, for example, rectangular, square, semi-circular, or any other shape readily apparent to one skilled in the art. In addition, first and second surfaces  46  and  48  of protrusion  26  may be disposed outside of the planes defined by first and second sealing surfaces  22  and  24 .  
         [0025]    As illustrated in FIG. 2, gasket  10  is configured to be disposed between components of an engine  42 . As a further alternative, gasket  10  may be used with a compressor. Gasket  10  may be disposed between any engine components where a fluid seal is required. For example, gasket  10  may be disposed between a cylinder head  30  and an intake manifold  44  or between cylinder head  30  and an exhaust manifold  34 . In addition, gasket  10  may be disposed between an engine sensor or probe and the engine.  
         [0026]    In the exemplary embodiment schematically illustrated in FIG. 2, cylinder head  30  of engine  42  includes a series of intake passageways  50 . Each intake passageway  50  provides a passageway through cylinder head  30  to a combustion chamber  54 . Cylinder head  30  further includes a series of exhaust passageways  52 . Exhaust passageways  52  provide a passageway through cylinder head  30  from each combustion chamber  54 .  
         [0027]    As shown in FIG. 3, protrusion  26  of gasket  10  extends past an outer surface  32  of cylinder head  30  and past an outer surface  35  of flange  36 . Gasket  10  is properly positioned when opening  20  in main body  12  is aligned with exhaust passageway  52  and a corresponding passageway  40  in exhaust manifold  34 . The extension of protrusion  26  also provides an obvious visual indication that a gasket is positioned between cylinder head  30  and the respective manifold flange.  
         [0028]    As also shown in FIG. 2, intake manifold  44  and exhaust manifold  34  are engageable with cylinder head  30  of engine  42 . Intake manifold  44  is engaged with cylinder head  30  to allow intake air flowing through intake manifold  44  to flow through intake passageways  50  to combustion chambers  54 . Exhaust manifold  34  is engaged with cylinder head  30  to allow exhaust flowing from combustion chambers  54  through exhaust passageways  52  to enter exhaust manifold  34 . It should be understood that intake manifold  44  and exhaust manifold  44  may have any configuration readily apparent to one skilled in the art.  
         [0029]    A first series of gaskets  10  are disposed between intake manifold  44  and cylinder head  30  and are disposed adjacent each intake passageway  50 . A second series of gaskets  10  are disposed between exhaust manifold  34  and cylinder head  30  and are disposed adjacent each exhaust passageway  52 . Each gasket  10  forms a seal between cylinder head  30  and the respective manifold to prevent gases, such as air or exhaust, from leaking at the joints between cylinder head  30  and intake manifold  44  and from between cylinder head  30  and exhaust manifold  34 .  
         [0030]    As illustrated in FIG. 3, gasket  10  may be disposed between cylinder head  30  and a flange  36  on the respective manifold (illustrated as the exhaust manifold  34 ). First sealing surface  22  of main body  12  of gasket  10  engages flange  36  and second sealing surface  24  of main body  12  of gasket  10  engages cylinder head  30 .  
         [0031]    A series of fasteners (not shown) may be disposed in a pattern around exhaust passageway  52 . The fasteners may be bolts that are engageable with corresponding holes in cylinder head  30 . Openings  28  in main body  12  of gasket  10  are configured to receive the bolts. Similarly, flange  36  may include a series of openings  38  that are configured to receive the bolts. The engagement of the bolts with cylinder head  30  will clamp flange  36  to cylinder head  30 .  
         [0032]    As shown in FIG. 4, a gasket  10  may be disposed between each flange  36  of exhaust manifold  34  and cylinder head  30 . Protrusion  26  of each gasket  10  extends past outer surface  32  of cylinder head  30 . When each flange  36  of exhaust manifold  34  is clamped to cylinder head  30  with the fasteners, each gasket  10  will help ensure that a seal is formed between each flange  36  and cylinder head  30  to prevent gas from escaping from its intended path. While FIG. 4 illustrates an internal combustion engine, it is contemplated that the gasket may be used with other types of engines or devices, such as a gas turbine or a compressor as well.  
         [0033]    Industrial Applicability  
         [0034]    As will be apparent from the foregoing description, the present invention provides a gasket  10  for use with an engine  42 . A series of gaskets  10  according to the present invention may be disposed between the cylinder head  30  and each of the intake manifold  44  and the exhaust manifold  34 . As shown in FIGS. 3 and 4, each gasket  10  includes a protrusion  26  that extends past the outer surface  32  of cylinder head  30  and past outer surface  35  of flange  36 .  
         [0035]    The extension of protrusion  26  past the outer surface of cylinder head  30  and the respective flange facilitates the positioning of gasket  10  during engine assembly. As shown in FIG. 4, engine  42  includes many components that are positioned on or around cylinder head  30 . The close proximity of these components make positioning each gasket  10  relative to cylinder head  30  a difficult task. Protrusion  26 , however, may be easily grasped to position each gasket  10 . Each protrusion  26  may be grasped by a worker during a manual assembly process or by a robotic arm during an automated assembly process. Thus, the present invention simplifies the assembly of the engine  42 .  
         [0036]    In addition, protrusion  26  facilitates removal of the gasket  10  for maintenance purposes. During assembly and operation of engine  42 , gasket  10  may adhere to the surface of cylinder head  30  or to the respective manifold flange. When engine  42  is disassembled for service or repair, the protrusion  26  may be grasped to generate the leverage required to remove the gasket  10  from cylinder head  30  or the respective manifold flange.  
         [0037]    Gasket  10  of the present invention may also include a protective substance  25  that protects main body  12  of the gasket from damage due to exposure to high temperatures. In certain applications, such as when used to form a seal between cylinder head  30  and exhaust manifold  34 , gasket  10  may be exposed to high temperature gas. Protective substance  25  is disposed along inner edge  17  and a portion of first and second sealing surfaces  22  and  24  of main body  12  to protect gasket  10  from being damaged by the high temperature gas flowing through opening  20 . The protective substance  25  will reduce the amount of maintenance required and extend the life of gasket  10 .  
         [0038]    It will be apparent to those skilled in the art that various modifications and variations can be made in the engine gasket of the present invention without departing from the scope or spirit of the invention. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims and their equivalents.