Abstract:
A metal gasket includes first and second metal plates laminated together to form the metal gasket, and having holes to be sealed. At least one of the first and second metal plates has a half bead surrounding the hole. A surface pressure assistance plate is located at least adjacent to the half bead between the first and second metal plates. The assistance plate has depressions and projections with respect to a thickness direction thereof in at least a peripheral part thereof.

Description:
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT 
     The present invention relates to a metal gasket such as a gasket for an exhaust manifold for an engine, or a cylinder head gasket. 
     When a joint surface between an exhaust manifold and an exhaust pipe for an automobile engine, or a joint surface between a cylinder head and a cylinder block (cylinder body) is sealed, a metal gasket is clamped between these members to seal combustion gas, coolant water, and lubrication oil. 
     Such a metal gasket is made by a design method, in which, mainly as sealing means, a full bead with a projected cross-section and a half bead with a step-like (crank-like) cross-section are arranged near the perimeter of a seal target hole. Among them, the half bead can be produced at a low cost, and easily sealed by a small fastening force, so that it is widely used for gasoline engines with a small fastening force compared to diesel engines. 
     With respect to the metal gasket with this half bead, there is a case in which a straight line portion is created in the gasket for the exhaust manifold when the gasket is seen in plan depending on the shape of an attached member. This straight line portion has proven to cause a problem such as water leakage or oil leakage during engine operation as compared to a curved line portion. It is commonly believed that the reason the straight line portion easily creates the above-mentioned problem is that a creep relaxation in the straight line portion of the half bead increases during the operation of an engine wherein the gasket is equipped, so that the seal surface pressure partially decreases. 
     Therefore, when the half bead forms a straight line in a plan view, if the straight line part extends, the half bead has less resistance to a compressive force compared to the full bead. Accordingly, the creep relaxation is generated in this half bead, so that the seal quality cannot be fully exerted. 
     For one solution for the above-mentioned problem, metal gaskets, such as those shown in Japanese Patent Publication No. 2004-92475, are formed by arranging a pair of half beads symmetrically in a thickness direction around a liquid hole which is formed substantially in a square or a rectangular shape. Also, outlines of corner parts of the half beads are formed in a shape with a radius which is larger than that of a corner part of the liquid hole. As a whole, the metal gaskets have a shape extending in a smooth circular shape. However, in order to form this kind of half beads, a space is required around the liquid hole (seal target hole), so that they are not practical. 
     On the other hand, even in the cylinder head gasket, as the weight and size of an engine have been reduced, an engine member tends to have a lower rigidity, and the deformation volume of the cylinder head which repeatedly occurs by engine operation has increased. Accordingly, a force compressing the half bead also increases, so that the serious problem is a creep relaxation of the half bead. 
     In addition, in the metal gaskets, the tightening pressure differs depending on the distance from the tightening bolt bore, so that the seal surface pressure generated in the half beads is also uneven. As a result, the creep relaxation occurs sporadically. 
     In view of the problems described above, the present invention has been made such that the metal gasket prevents the creep relaxation in the half bead formed around the seal target bore of the metal gasket. Also, the metal gasket widens the distribution of the surface pressure generated in the half bead and prevents a scratch in the member clamping the metal gasket, hereby securing an excellent seal quality. 
     Further objects and advantages of the invention will be apparent from the following description of the invention. 
     SUMMARY OF THE INVENTION 
     In order to achieve the objects described above, according to the present invention, a metal gasket includes a seal target bore and a half bead surrounding the seal target bore. The metal gasket is provided with a surface pressure assistance plate forming depressions and projections with respect to a thickness direction inside the half bead, all around the half bead or in a part of the perimeter of the half bead. The depressions and the projections are only required relative to at least one side of the standard line of a plate of the surface pressure assistance plate, and are not necessarily required relative to both sides. 
     According to the structure, the surface pressure assistance plate forming the depressions and the projections is arranged with respect to the thickness direction, so that compressibility of the half bead can be enhanced due to an elastic effect by the depressions and the projections of the surface pressure assistance plate, and creep relaxation of the half bead can be prevented. 
     Also, members disposed on both sides of the metal gasket and abutting against the half bead hit a corner part of the half bead from an area close to a narrow line to an area of a wide surface. In addition, the maximum value of the surface pressure can be decreased and the surface pressure can be reduced, and the surface pressure generated on the half bead, especially, the surface pressure generated at the corner part of the half bead can be reduced. Accordingly, a scratch in a member clamping the metal gasket can be prevented and an excellent seal quality can be secured. 
     Also, in the metal gasket, the direction of top parts of the depressions and the projections of the surface pressure assistance plate is a direction intersecting with the half bead all around the half bead or a part of the perimeter of the half bead. With such a structure, the elastic effect due to the depressions and the projections of the surface pressure assistance plate can be used more efficiently than the structure in which the direction of the top parts of the depressions and the projections is arranged parallel to the half bead. 
     The depressions and the projections of the surface pressure assistance plate may be formed as a straight line such as a trapezoid, or formed as a curved line such as a circular shape or a sine shape. Also, the depressions and the projections may be formed as one step or multiple steps, and may or may not be line-symmetric with respect to the thickness direction. In addition, with respect to the perimeter direction of the seal target bore, the depressions and the projections may be formed in a continuous wave pattern and provided all around the seal target bore, or may be formed only in a part wherein a surface pressure adjustment is required. Also, shapes and sizes of the depressions and the projections may also be changed in the perimeter direction of the seal target bore according to the degree of the surface pressure adjustment. Moreover, the surface pressure adjustment plate itself may be disposed all around the seal target bore, or may be disposed only in a part wherein the surface pressure adjustment is required. 
     Detailed structures of the half bead part of the metal gasket are as follows. In the first structure, a first metal plate and a second metal plate which respectively form the half beads surrounding the seal target bore and expanding outside in a direction away from the seal target bore, are symmetrically disposed, and clamp a middle plate inside flat parts on the inner perimeter side (seal target bore side of half beads). Also, a surface pressure assistance plate, forming the depressions and the projections with respect to the thickness direction, is disposed on the outer perimeter side of the middle plate and inside the half beads between sloping parts of the half beads and flat parts on the outer perimeter side of the sloping parts. In the second structure, the middle plate and the surface pressure assistance plate are formed by the same plate of the first structure. In the third structure, the middle plate is eliminated, and the flat parts on the inner perimeter sides of the half beads of the first metal plate and the second metal plate are abutted against each other in the first structure. 
     In the fourth structure, the first metal plate forming the half bead surrounding the seal target bore and expanding outside in the direction away from the seal target bore; the middle plate disposed inside the flat part on the inner perimeter side of the half bead; the surface pressure assistance plate forming the depressions and the projections which are disposed on the outer perimeter side and inside the half bead between the sloping part of the half bead and the flat part on the outer perimeter side of the sloping part; and the flat second metal plate, are laminated. In the fifth structure, the middle plate and the surface pressure assistance plate are formed by the same plate in the fourth structure. 
     Moreover, instead of disposing the surface pressure assistance plate between the sloping part and the flat part of the half bead, the surface pressure assistance plate may be disposed on the outer perimeter side of the sloping part and inside the flat part on the outer perimeter side of the half bead. In this case, the surface pressure moderation effect on the corner part of the half bead is somewhat little. However, the elasticity of the half bead can be increased by the elasticity of the surface pressure assistance plate, so that it is expected that the creep relaxation be prevented. 
     Also, a metal gasket in which the present invention can be applied includes a metal gasket such as a gasket for an exhaust manifold for an engine, or a cylinder head gasket. These metal gaskets can have the above-mentioned large effect. However, the metal gasket is not limited to the above-mentioned gaskets, and may only be a metal gasket sealing the seal target bore. 
     According to the metal gasket of the present invention, the creep relaxation in the half bead around the seal target bore of the metal gasket can be prevented, and a scratch of a member clamping the metal gasket can be prevented by widening the distribution of the surface pressure generated in the half bead, so that an excellent seal quality can be secured. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic plan view of a metal gasket according to an embodiment of the present invention; 
         FIG. 2  is a schematic plan view showing a state without a first metal plate in  FIG. 1  of the metal gasket according to the first embodiment; 
         FIG. 3  is a schematic sectional view taken along line  3 - 3  in  FIG. 1  of the metal gasket according to the first embodiment; 
         FIG. 4  is a schematic sectional view taken along line  4 - 4  in  FIG. 1  of the metal gasket according to the first embodiment; 
         FIG. 5  is a schematic sectional view similar to  FIG. 4  when the metal gasket is compressed; 
         FIG. 6  is a schematic plan view showing an example of a direction of top parts of depressions and projections of a surface pressure assistance plate; 
         FIG. 7  is a schematic plan view of another example of a direction of the top parts of the depressions and the projections of the surface pressure assistance plate; 
         FIG. 8  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the second embodiment; 
         FIG. 9  is a schematic fragmentary perspective view of the metal gasket according to the second embodiment; 
         FIG. 10  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the third embodiment; 
         FIG. 11  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the fourth embodiment; 
         FIG. 12  is a schematic fragmentary perspective view of the metal gasket according to the fourth embodiment; 
         FIG. 13  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the fifth embodiment; 
         FIG. 14  is a schematic fragmentary perspective view of the metal gasket according to the fifth embodiment; 
         FIG. 15  is a schematic view of a first example of depressions and projections of a surface pressure adjustment plate; 
         FIG. 16  is a schematic view of a second example of the depressions and the projections of the surface pressure adjustment plate; 
         FIG. 17  is a schematic view of a third example of the depressions and the projections of the surface pressure adjustment plate; 
         FIG. 18  is a schematic view of a fourth example of the depressions and the projections of the surface pressure adjustment plate; 
         FIG. 19  is a schematic view of a fifth example of the depressions and the projections of the surface pressure adjustment plate; 
         FIG. 20  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the first embodiment with a different position of the surface pressure adjustment plate; 
         FIG. 21  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the second embodiment with the different position of the surface pressure adjustment plate; 
         FIG. 22  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the third embodiment with the different position of the surface pressure adjustment plate; 
         FIG. 23  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the fourth embodiment with the different position of the surface pressure adjustment plate; and 
         FIG. 24  is a schematic sectional view, similar to  FIG. 3 , of the metal gasket according to the fifth embodiment with the different position of the surface pressure adjustment plate. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Hereunder, a metal gasket according to embodiments of the present invention will be explained with reference to the attached drawings. 
     Incidentally,  FIGS. 1-24  are schematic explanatory views in which sizes of a seal target bore, bolt holes and half beads; widths of a middle plate and a surface pressure assistance plate; and thicknesses of a metal plate, middle plate and the surface pressure assistance plate; and sizes of depressions and projections are different from actual ones and enlarged for the sake of explanation. Also, for the sake of simplicity, hereunder, the seal target bore will be explained as one seal target bore. However, the present invention can be applied even when multiple kinds of seal target bores such as gas circulation holes, combustion chamber holes (bore holes), water holes, or oil holes, are respectively provided with multiple numbers, such as a gasket for an exhaust manifold for a multiple cylinder engine or a cylinder head gasket. Incidentally, the following “outside” and “inside” are terms with respect to a thickness direction of the gasket, and the horizontal direction of the gasket is described as an “outer perimeter side” and an “inner perimeter side”. 
     As shown in  FIG. 1 , the metal gasket  1  of the embodiments of the present invention is formed of multiple metal plates (metal composition plates) made of soft steel, annealed stainless (annealed material), or stainless material (spring steel). Also, the metal gasket  1  is produced in a shape corresponding to the shape of a member clamping the metal gasket  1 , and is provided with a seal target bore  2  and bolt holes  3  for inserting tightening bolts. 
     In the first embodiment shown in  FIGS. 1-5 , this metal gasket  1  has a first metal plate  10  and a second metal plate  20  arranged symmetrically, which clamp a middle plate  40 . Also, a surface pressure assistance plate  30  forming depressions and projections with respect to a thickness direction of the metal gasket  1 , is disposed on the outer perimeter side of the middle plate  40 , and inside between sloping parts  11   b ,  21   b  of half beads  11 ,  21  and flat parts  11   c ,  21   c  on the outer perimeter side. More specifically, an inner perimeter side end of the surface pressure assistance plate  30  is disposed inside the sloping parts  11   b ,  21   b.    
     For example, the first metal plate  10  and the second metal plate  20  are made of soft steel or annealed stainless (annealed material), and provided with the seal target bore  2  and the bolt holes  3  surrounding the seal target bore  2 . Also, the first metal plate  10  and the second metal plate  20  respectively provide the half beads  11 ,  21  surrounding the seal target bore  2  and extending outside with respect to the thickness direction of the gasket in a direction away from the seal target bore  2 . Also, the first metal plate  10  and the second metal plate  20  are symmetrically disposed clamping the middle plate  40 . 
     The middle plate  40  is made of soft steel, annealed stainless (annealed material), or stainless material (spring steel), and as shown in  FIG. 2 , disposed in a ring shape (circularity) around the seal target bore  2 . As shown in  FIG. 3 , an inner perimeter side end  40   a  facing the seal target bore  2  is arranged inside flat parts  11   a ,  21   a  on the inner perimeter side (seal target bore  2  side) of the half beads  11 ,  21 . The middle plate  40  prevents liquid from entering between the half beads  11 ,  21  and adjusts a thickness. Therefore, the middle plate  40  is formed in a sheet of ring-shaped continuous plate in a circumferential direction. 
     As shown in  FIG. 2 , the surface pressure assistance plate  30  is disposed in a ring shape, and as shown in  FIGS. 4 ,  5 , forms the depressions and the projections with respect to the thickness direction. The surface pressure assistance plate  30  has elasticity relative to a compressive direction of the half beads  11 ,  21  of the metal gasket  1 . When the half beads  11 ,  21  are compressed, as shown in  FIG. 5 , the surface pressure assistance plate  30  abuts against the sloping parts  11   b ,  21   b  of the half beads  11 ,  21 , and provides a cushion effect, thereby adjusting the surface pressure of the half beads  11 ,  21 . 
     The surface pressure assistance plate  30  is made of stainless material (spring steel) and the like, and as shown in  FIGS. 4 ,  12 ,  15 ,  16 , the depressions and the projections may be formed with straight lines such as a trapezoid. However, as shown in  FIGS. 9 ,  14 ,  17 ,  18 ,  19 , the depressions and the projections may be formed with curved lines such as a circular shape or a sine shape. In addition, as shown in  FIGS. 4 ,  5 ,  9 ,  12 ,  14 ,  15 ,  17 ,  18 , the depressions and the projections may be formed by a single step, or as shown in  FIGS. 16 ,  19 , formed by multiple steps. Moreover, the depressions and the projections may or may not be axisymmetric with respect to the thickness direction. 
     Also, with respect to the perimeter direction of the seal target bore  2 , the depressions and the projections may be formed in a continuous wave pattern and provided all around the seal target bore  2 , or may be formed in a continuous wave pattern; a single projection; or a single depression, and the depressions and the projections may be formed in only a part wherein a surface pressure adjustment is required. Also, shapes and sizes of the depressions and the projections may also be changed according to the degree of the surface pressure adjustment. Moreover, the surface pressure assistance plate  30  itself may be disposed all around the seal target bore  2 , or may be disposed only in the part wherein the surface pressure adjustment is required. Basically, the depressions and the projections need only to have appropriate elasticity relative to the compressive direction of the metal gasket not to cause creep relaxation. The depressions and the projections can be easily formed by a pressing process and the like. 
     Also, as shown in  FIG. 6 , the direction of top parts  30   a  of the depressions and the projections of the surface pressure assistance plate  30  is a direction intersecting with the half beads  11 ,  21 , preferably, 80-100°, more preferably, 90° (perpendicular), so that an elastic effect by the depressions and the projections of the surface pressure assistance plate  30  can be used more efficiently compared to the case of arranging the top parts of the depressions and the projections parallel to the half beads  11 ,  21 . Also, when the top parts of the depressions and the projections are arranged in the intersecting direction, very narrow (linear) hit of corner parts of the half beads  11 ,  21  can be made wide (planar) hit by abutting the depressions and the projections of the surface pressure assistance plate  30  against the slop parts  11   b ,  21   b  of the half beads  11 ,  21 , so that the local surface pressure can be decreased. As a result, an abutting part in a member in which the half beads  11 ,  21  abut, can be prevented from being scratched. 
     Incidentally, as shown in  FIG. 7 , in the surface pressure assistance plate  30 , when the direction of the top parts  30   a  of the depressions and the projections is made in one direction, an evenly spread surface pressure cannot be achieved as compared to the case wherein the top parts  30   a  of the depressions and the projections are arranged in the direction intersecting with the half beads  11 ,  21 . However, in this case, since the depressions and the projections are simplified, they can be produced more easily. 
     With respect to the arrangement of the intersecting direction, the surface pressure adjustment changes even by an intersecting angle, so that if the intersecting angle is changed by a required compressive elasticity (spring force), a precise surface pressure adjustment can be achieved. More specifically, in a part of perimeters of the half beads  11 ,  21 , or all around the half beads  11 ,  21 , the direction of the top parts of the depressions and the projections of the surface pressure assistance plate  30  is the direction intersecting with the half beads  11 ,  21 . When the direction of the top parts of the depressions and the projections of the surface pressure assistance plate  30  is the direction intersecting with the half beads  11 ,  21  all around the half beads  11 ,  21 , for example, when the seal target bore  2  is a circle, the top parts (valleys and mountains) of the depressions and the projections are arranged radially. 
     Also, the surface pressure assistance plate  30  may be formed as a continuous ring in a perimeter direction of the seal target bore  2 . However, since the function is to adjust the surface pressure, the surface pressure assistance plate  30  does not necessarily need to be provided in a continuous integral part all around the perimeter direction, and divided multiple layers of surface pressure assistance plates  30  may be arranged to contact each other, or may be disposed separately only in parts wherein the surface pressure adjustment is required. More specifically, in the part of the perimeter of the half beads  11 ,  21  or all around the half beads  11 ,  21 , the surface pressure assistance plates  30  forming the depressions and the projections with respect to the thickness direction are disposed inside the half beads  11 ,  21 . 
     According to the structure, the degree of the surface pressure adjustment can be changed with or without the surface pressure assistance plate  30 , by changes of shape and size (height, width and so on) of the depressions and the projections, a length of the top parts of the depressions and the projections (width of the surface pressure assistance plate  30 ), or an intersecting angle between the direction of the top parts of the depressions and the projections and the half beads  11 ,  21 . Accordingly, the surface pressure can be easily adjusted very precisely. 
     As shown in  FIGS. 8 ,  9 , the metal gasket according to the second embodiment of the invention differs from the metal gasket according to the first embodiment, because the middle plate  40  and the surface pressure assistance plate  30  are formed in one sheet of surface pressure assistance plate  30 . The other structure of the metal gasket of the second embodiment is the same as that of the metal gasket of the first embodiment. Incidentally, as shown in  FIG. 9 , the surface pressure assistance plate  30  is made to be flat on the inner perimeter side, and forms curved depressions and projections on the outer perimeter side. 
     In the second embodiment, the same plate has both functions of the middle plate  40  which is required for a sealing effect and the surface pressure assistance plate  30  which is required for an elastic effect. Accordingly, a material cannot be used separately. However, the second embodiment can be produced more easily compared to the first embodiment because the middle plate  40  is eliminated and a width of the surface pressure assistance plate  30  increases. 
     As shown in  FIG. 10 , the metal gasket according to the third embodiment of the invention differs from the metal gasket according to the first embodiment because the middle plate  40  is eliminated. The other structure of the third embodiment is the same as that of the metal gasket of the first embodiment. Due to such a structure, the seal quality cannot be improved by the middle plate  40 . However, the metal gasket of the third embodiment can reduce the weight and size, and be produced more easily than the metal gasket of the first embodiment. 
     As shown in  FIGS. 11 ,  12 , the metal gasket according to the fourth embodiment of the invention laminates the first metal plate  10 , forming the half bead  11  surrounding the seal target bore  2  and expanding outside in the direction away from the seal target bore  2 ; the middle plate  40  disposed on the inner perimeter side of the half bead  11 , i.e., inside the flat part  11   a  on the seal target bore  2  side; the surface pressure assistance plate  30  forming the depressions and the projections and disposed on the outer perimeter side and inside the half bead  11  between the sloping part  11   b  of the half bead  11  and the flat part  11   c  on the outer perimeter side; and the flat second metal plate  20 . The metal gasket of the fourth embodiment differs from the metal gasket of the first embodiment, because the half bead  21  is not formed on the second metal plate  20 . 
     The metal gasket of the fourth embodiment is suitable for the case in which a compressive transformation quantity due to the bead is small as compared to the metal gasket of the first embodiment, thereby saving materials and reducing the weight and size. Also, the thickness of the gasket can be reduced. 
     As shown in  FIGS. 13 ,  14 , the metal gasket according to the fifth embodiment differs from the metal gasket according to the fourth embodiment, because the middle plate  40  and the surface pressure assistance plate  30  are formed by one sheet of surface pressure assistance plate  30 . The other structure of the metal gasket of the fifth embodiment is the same as that of the metal gasket of the fourth embodiment. Incidentally, in  FIG. 14 , the depressions and the projections of the surface pressure assistance plate  30  are made to be flat on the inner perimeter side, and have curved projections only on one side of the half bead  11  side on the outer perimeter side. 
     Also, in  FIGS. 20-24 , in the metal gasket according to the first-fifth embodiments, instead of disposing the surface pressure assistance plate  30  inside between the sloping part  11   b  ( 21   b ) of the half bead  11  ( 21 ) and the flat part  11   c  ( 21   c ) on the outer perimeter side, the surface pressure assistance plate  30  is disposed inside the flat part  11   c  ( 21   c ) on the outer perimeter side of the half bead  11  ( 21 ). In this case, the surface pressure moderation effect on the corner part of the half bead  11  ( 21 ) is a little. However, the elasticity of the half bead  11  ( 21 ) can be enhanced by the elasticity of the surface pressure assistance plate  30 , so that a creep relaxation of the half bead  11  ( 21 ) can be prevented. 
     According to the metal gasket  1  with the above-mentioned structure, the surface pressure assistance plate  30  forming the depressions and the projections is disposed with respect to the thickness direction, so that a creep relaxation of the half bead can be prevented by using the elastic effect due to the depressions and the projections of the surface pressure assistance plate  30 . Also, the surface pressure generated in the half bead  11  ( 21 ), especially, a force generated in the corner part of the half bead  11  ( 21 ) can be eased, so that the member clamping the metal gasket  1  can be prevented from being scratched, thereby securing an excellent seal quality. 
     The disclosure of Japanese Patent Application No. 2006-136113, filed on May 16, 2006, is incorporated in the application. 
     While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative and the invention is limited only by the appended claims.