Abstract:
An integrated seal assembly includes an aperture defined. A carrier includes a generally planar support portion and a contact zone portion formed integral to the support portion. The contact zone portion extends radially of the support portion and terminates adjacent the aperture. A resilient seal portion is formed integrally on at least the contact zone portion and defines the aperture, the resilient seal portion providing an upper support zone and a lower support zone respectively on opposite sides of the assembly.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates generally to a sealing construction for providing a fluid seal intermediate a pair of opposed, mating parts or structures. 
       BACKGROUND 
       [0002]    As is generally known, an internal combustion engine is a type of engine in which combustion of a fuel with an oxidizer, such as air, occurs in a combustion chamber. The expansion of gases during combustion applies a force on the pistons of the engine, and the chemical energy of the fuel is transformed into mechanical energy. In general, internal combustion engine designs have four circuits of working fluids: (1) combustible air/fuel mixture; (2) exhaust gas; (3) coolant; and (4) motor oil for lubrication. In order to maintain good working order of the engine, it is important that these three working fluids do not intermix and are directed to areas of the engine through various structures in accordance with engineering objectives. It is well known to use seals to properly separate these working fluids. One particularly challenging location to seal is in and around the cylinder head interface with the engine block. A head gasket and/or a seal assembly is disposed between the engine block and the cylinder head and, as such, seals the top of the combustion chamber as well as the fluid passages bored into the cylinder head. In order to address this issue, flexible integrated seals may be attached to the head gasket or seal assembly at the pushrod passageways, for example, to isolate each of the fluid connections between the cylinder block and the cylinder head. 
         [0003]    If the seals do not properly seal the fluid passageways, significant problems may result. For example, coolant can leak into the cylinders, which can cause hydrostatic locking of the cylinders and damage the catalytic converter in the exhaust system. These and other problems may damage the engine. 
         [0004]    In a newly manufactured engine, certain tolerances are specified, such as the fit of the engine cylinder block to the cylinder head and, in one specific example, the gap therebetween. When engines are remanufactured, the tolerances between parts are often different from those of the original engine because remanufacturing can involve the removal of material. In such situations, it becomes necessary to specify different fittings, gaskets and seals and so on to accommodate the different tolerances. 
         [0005]    U.S. Pat. No. 7,401,404 (the &#39;404 patent), entitled “Retainer Gasket Construction,” is directed to an improved fluid-tight sealing gasket. The &#39;404 patent describes a seal with grooves that are coined or stamped into the metal retainer, upon which a flexible seal element is bonded. Each of the seal elements is molded into the corresponding grooves. The design of the &#39;404 patent, however, relies primarily on the chemical bonding of the seal element onto the metal carrier. Inadequate bonding of the seal element may cause the seal element to detach from the metal carrier, which can result in failure of the seal. 
         [0006]    It would be desirable to provide a sealing construction that accommodates different tolerances to reduce the number of parts needed to accomplish the same function in newly constructed and in remanufactured machines alike. Also, it would be desirable to provide a sealing construction that generally accommodates variations in tolerances. Accordingly, there is a need for an improved seal and method for manufacturing such a seal. 
         [0007]    It will be appreciated that this background description has been created to aid the reader, and is not to be taken as an indication that any of the indicated problems were themselves appreciated in the art. While the described principles can, in some respects and aspects, alleviate the problems inherent in other systems, it will be appreciated that the scope of the protected innovation is defined by the attached claims, and not by the ability of any disclosed feature to solve any specific problem noted herein. 
       SUMMARY 
       [0008]    In one aspect, the disclosure describes an integrated seal assembly that includes an aperture. A carrier includes a generally planar support portion and a contact zone portion formed integral to the support portion. The contact zone portion extends radially with respect to the support portion and terminates adjacent the aperture. A resilient seal portion is formed integrally on at least the contact zone portion and defines the aperture, the resilient seal portion providing an upper support zone and a lower support zone respectively on opposite sides of the assembly. 
         [0009]    In another aspect, the disclosure provides an assembly that includes a first member including a first passage formed therein terminating in a first port and a second member including a second passage formed therein terminating in a second port. The first member and the second member are configured to be secured together in mating relationship wherein the first port faces the second port when the first and second members are in the mating relationship. An integrated seal assembly is configured to seal between the first member and the second member, the integrated seal assembly including an aperture. A carrier includes a generally planar support portion and a contact zone portion formed integral to the support portion. The contact zone portion extends radially of the support portion and terminates adjacent the aperture and a resilient seal portion integrally formed on at least the contact zone portion and defining the aperture, the resilient seal portion providing an upper support zone and a lower support zone respectively on opposite sides of the assembly. 
         [0010]    In other aspects, the contact zone may be non-planar. The contact zone portion may have a first section extending from the support portion that is angled relative to the plane of the support portion and a second section extending from the first section that is generally perpendicular to the plane of the support portion. The contact zone may include a flattened hem. The contact zone may have a thickness that is at least twice the thickness of the support portion of the carrier. The contact zone may be deformable. The contact zone may include a hem. The hem may be one of an open hem, a tear-drop hem, and a rope hem. 
         [0011]    In yet another aspect, the disclosure describes a method of manufacturing an integrated seal assembly, including providing a generally planar carrier; forming at least one aperture defined through the generally planar carrier; forming on the carrier a non-planar contact zone adjacent the at least one aperture; and forming a resilient seal portion on the contact zone to define the at least one aperture, wherein the seal portion provides an upper support zone and a lower support zone respectively on opposite sides of the assembly. 
         [0012]    In yet other aspects, the disclosure describes that the contact zone may be formed as one of a flattened hem, an open hem, a tear-drop hem, and a rope hem. The contact zone may include a first section extending from the carrier that is angled relative to the plane of the carrier, and a second section extending from the first section that is generally perpendicular to the plane of the carrier. The contact zone may have a thickness that is at least twice the thickness of the carrier. 
         [0013]    Further and alternative aspects and features of the disclosed principles will be appreciated from the following detailed description and the accompanying drawings. As will be appreciated, the principles related to an integrated seal assembly disclosed herein are capable of being carried out in other and different aspects, and capable of modification in various respects. Accordingly, it is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and do not restrict the scope of the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]      FIG. 1  is a perspective and partially exploded view of components of an internal combustion engine with a seal assembly located between the cylinder block and the cylinder head according to an aspect of the disclosure. 
           [0015]      FIG. 2  is a plan view of the seal assembly of  FIG. 1 . 
           [0016]      FIG. 3  is a perspective view of a seal assembly according to another aspect of the disclosure. 
           [0017]      FIG. 4  is a cross section view of a part of the seal assembly of  FIG. 3  including a carrier support portion and a contact zone. 
           [0018]      FIGS. 5-7  are cross section views of a contact zone including various hems. 
           [0019]      FIGS. 8-10  are cross section views of a contact zone and elastomeric portion including various hems. 
           [0020]      FIG. 11  is a cross section view of a part of the seal assembly of  FIG. 3  including a carrier support portion and the contact zone of  FIG. 7 . 
           [0021]      FIG. 12  is a cross section view of a part of the seal assembly of  FIG. 3  including a carrier support portion and the contact zone of  FIG. 7  with a shortened elastomeric portion. 
       
    
    
     DETAILED DESCRIPTION 
       [0022]    Certain terminology may be employed in the following description for convenience rather than for any limiting purpose. For example, the terms “forward” and “rearward,” “front” and “rear,” “right” and “left,” “upper” and “lower,” “top” and “bottom,” and “right” and “left” designate directions in the drawings to which reference is made, with the terms “inward,” “inner,” “interior,” “inside,” or “inboard” and “outward,” “outer,” “exterior,” “outside,” or “outboard” referring, respectively, to directions toward and away from the center of the referenced element, the terms “radial” or “vertical” and “axial” or “horizontal” referring, respectively, to directions, axes, or planes perpendicular and parallel to the longitudinal central axis of the referenced element. Terminology of similar import other than the words specifically mentioned above likewise is to be considered as being used for purposes of convenience rather than in any limiting sense. 
         [0023]      FIG. 1  shows components of an internal combustion engine  10  in accordance with an aspect of the present disclosure. The components of the internal combustion engine  10  include a first member in the form of a cylinder head  12 , a second member in the form of a cylinder block  14 , and a seal assembly  16 . As is generally understood, the seal assembly  16  is disposed between the cylinder head  12  and the cylinder block  14  to form a seal therebetween. The seal assembly  16  may be configured for use in other applications where a fluid-tight seal is desired. For example, the seal assembly  16  may be useful in a hydraulic valve stack, a transmission, a pump and the like. 
         [0024]    The seal assembly  16  includes a carrier  48  that is generally, but not limited to a planar configuration and may be formed of a suitable material, for example, aluminum, copper, bronze, steel, such as stainless steel, zinc plated steel, anodized steel, carbon steel, or some other metal or other non-metallic material like a polymeric material. The seal assembly  16  includes a carrier  48  that could be made of layers of materials, for example. 
         [0025]    The carrier  48  may include a plurality of bolt passages  18 , a plurality of cylinder ports  20 , one or more drain ports  22 , and a plurality of pushrod ports  24  extending therethrough. Any one or more of these openings formed through the seal assembly  16  may include an associated integrated seal  30  (shown in  FIG. 2 ). For simplifying the disclosure, a particular example will be made in the present figure of one of the openings and the integrated seal  30  associated therewith, but it should be appreciated that other openings may include the integrated seal  30  or a similar structure. 
         [0026]    Of note, aspects of the disclosure are not limited to pushrod ports, head gaskets or seal assemblies but, rather, are suitable for use with any seal, opening or passageway that requires sealing. Moreover, although depicted in use with a V-8 engine, it will be readily recognized that this is exemplary and that the teachings of this disclosure can be applied to any type of engine or assembly where seals are employed and to seals utilized in any application requiring sealing of fluids. Further, openings formed through the seal assembly  16 , for example, passages  18 , ports  20 ,  22  and  24 , may also be generically referred to as apertures or passageways. For the purposes of this disclosure, the terms referring to apertures, passageways and so on can be a hole, slot or passage of any suitable shape and/or size. Examples of suitable shapes include round, oval, rectangular, square, triangular, star shaped, disco-rectangular, and the like. 
         [0027]    The cylinder block  14  includes a plurality of threaded bores  34 , a plurality of cylinder bores  36 , a plurality of drain passages  38 , and a plurality of pushrod passages  40 . Any of the bores  36  and passages  38 ,  40  may be generically referred to as passages or ports. The plurality of threaded bores  34  correspond to the plurality of bolt passages  18 . The plurality of cylinder bores  36  correspond to the plurality of cylinder ports  20 . The plurality of drain passages  38  correspond to the plurality of drain ports  22 . The plurality of pushrod passages  40  correspond to the plurality of pushrod ports  24 . When assembled, bolts (not shown) extending out from the plurality of threaded bores  34  and passing through the plurality of bolt passages  18  are used to secure the cylinder head  12  to the cylinder block  14  with the seal assembly  16  being sandwiched therebetween. It will be understood that the bores  34  and passages  38 ,  40  will have corresponding structures in the cylinder head  12 . 
         [0028]    Turning to  FIG. 2 , the seal assembly  16  includes a carrier  48  that forms the main body of the seal assembly and extends into the area of each integrated seal  30  to provide structure upon which an elastomeric portion  50  of each integrated seal is disposed, as will be explained in detail below. As noted above, each integrated seal  30  may be sealingly disposed with respect to some or all of the bolt passages  18 , cylinder ports  20 , drain ports  22 , and pushrod ports  24  to facilitate the formation seals about these elements. The bolt passages  18 , cylinder ports  20 , drain ports  22 , and pushrod ports  24  are shaped and placed to communicate with the threaded bores  34 , cylinder bores  36 , drain passages  38 , and pushrod passages  40  of the cylinder block  14  shown in  FIG. 1 . 
         [0029]    The elastomeric portion  50  of the integrated seal  30  may include any suitable material. Examples of suitable materials generally include elastomers and/or deformable materials. The term “elastomeric” or “elastomer” may refer to a material that exhibits rubber-like properties of compliancy, resiliency, compression deflection, low compression set, flexibility, and/or an ability to recover after deformation. More particularly, suitable materials include natural rubbers, thermoplastic rubbers, thermosetting rubbers, vulcanizable rubbers, synthetic rubbers, such as fluoropolymers, chlorosulfonate, polybutadiene, buna-N, butyl, neoprene, nitril, polyisoprene, silicone, or copolymer rubbers such as ethylene propylene diene monomer (EPDM) rubber, nitrile butadiene rubber (NBR), and styrene-butadiene rubber (SBR), or a combination thereof. The term “synthetic rubbers” may also encompass other thermoplastic or thermosetting elastomers such as polyurethanes, silicones, and the like, as well as other polymers that exhibit rubber-like properties such as plasticized nylons, polyesters, ethylene vinyl acetates, etc. 
         [0030]      FIG. 3  illustrates another form of a seal assembly  116 . The illustrated seal assembly  116  includes a uniformly distributed pattern of bolt passages  118  about a cylinder port  120 . A plurality of drain ports  122  are arranged on the seal assembly  116  for passage of fluids therethrough. A pushrod port  124  is disposed along one side of the seal assembly  116 . It will be understood that seal assemblies  116  might be provided in a number corresponding to the number of cylinder ports  120  formed in a given engine. In other words, an eight cylinder engine would be provided with eight of the seal assemblies  116  illustrated in  FIG. 3 . Seal assemblies  116  could be designed to reduce the number of individual assemblies required for a given engine by combining two or more such constructions. 
         [0031]    The seal assembly  116  includes a planar carrier  148  that forms the main body of the generally rectangular assembly and connects a plurality of integrated seals  130  that are in turn individually arranged in a sealing position on the carrier with respect to the various passages  118  and ports  120 ,  122 , and  124 . 
         [0032]      FIG. 4  shows a cutaway cross section of a cylinder head  12  and cylinder block  14  with a seal assembly  16  disposed therebetween. An exemplary opening in the form of a pushrod port  24  is shown formed through the seal assembly  16  and is defined by the integrated seal  30 . 
         [0033]    According to  FIG. 4 , the carrier  48  is generally planar. The carrier  48  may be considered to have a support portion  49 , which is generally planar and constitutes the major portion of the carrier in terms of total area, and a contact zone  51  that is non-planar and may also be deformable and provide a structural foundation to the integrated seal  30 . The elastomeric portion  50  of the integrated seal  30  is integrally formed over and about the contact zone  51  of the carrier  48 . The elastomeric portion  50  of the integrated seal  30  may be formed over and about the entire carrier  48 . 
         [0034]    The elastomeric portion  50  of the integrated seal  30  may be formed on the contact zone  51  of the carrier  48  in any suitable fashion. The elastomeric portion  50  of the integrated seal  30  may be formed so as to position the contact zone  51  at any suitable position in the seal. In general, how the elastomeric portion  50  of the integrated seal  30  is formed on the carrier  48  depends on the material used to make the elastomeric portion  50 . For example, rubber or rubber-like materials may be injected or otherwise applied as a viscous liquid and cured via a vulcanizing process. During the vulcanization process of the elastomeric portion  50  of the integrated seal  30 , the integrated seal is heated to temperatures and pressures sufficient to vulcanize the material being cured, which may cause the elastomeric portion  50  of the integrated seal to expand. In another example, a thermoset resin may also be applied as a viscous liquid and subjected to heat and/or pressure. In yet another example, a chemically cured polymer may be cured by mixing a monomer with a catalyst, applying the mixture, and allowing the mixture to cure. In these or other examples, a mold or form may be used to obtain a particular geometry of the elastomeric portion  50  of the integrated seal  30 . The elastomeric portion  50  of the integrated seal  30  may be attached to the carrier  48  by gluing, mechanical attachment or mechanically integrated thereto. 
         [0035]    Internally of the elastomeric portion  50  of the integrated seal  30 , the carrier  48  transitions from the planar support portion  49  to the contact zone portion  51 . The support portion  49  and contact zone portion  51  are formed of the same, one-piece construction, i.e., non-separate pieces. In all aspects, the contact zone portion  51  is non-planar as shown in  FIGS. 4-7 , and in other aspects, the contact zone portion  51  is also deformable as shown in  FIGS. 5-7 . 
         [0036]    The contact zone portion  51  of the integrated seal  30  may have several functions. The contact zone portion  51  of the carrier  48  may provide deformation during assembly of the engine  10  to accommodate to different gaps/tolerances between the block  14  and the cylinder head  12  and provide height compensation as desired and therefore provide an effective seal therebetween. The contact zone portion  51  of the carrier  48  may provide an increased resistance to radial motion of the elastomeric portion  50  of the seal (left/right in  FIG. 4 ) when loaded, which may cause a loss of adherence between the elastomeric portion  50  and the carrier  48  due to shear and other forces, as can sometimes be the case with a flat carrier. The elastomeric portion  50  of the integrated seal  30  may be formed so as to position the contact zone  51  at any suitable position in the seal. 
         [0037]    The integrated seal illustrated in  FIG. 4  is a view through line A of  FIG. 3 , for example, that shows a seal configured to resist lateral motion and shearing of the elastomeric portion  50  due to the morphology of the contact zone portion  51 . In particular, the contact zone  51 , assuming that the orientation of the plane of the support portion  49  is zero degrees, has a first section  52  that extends from the support portion and angles away from the plane of the support portion at about 45 degrees relative to the support portion. In this aspect, the first section  52  angles downwardly and toward the side of the integrated seal  30  adjacent the block  14 . The first section  52  may angle toward the opposite side in another aspect. The exact angle of the first section  52  may be designed to produce a selected deviation from the plane of the support portion  49 . 
         [0038]    The contact zone  51  changes direction from the first section  52  by way of a bent section  54 . The bent section  54  leads to a second section  56  at the terminal end of the contact zone, which has an orientation that is generally perpendicular relative to the plane of the support portion  49  of the carrier  48 . The length of the second section  56  depends on the length of the section and deviation produced by the angle of the first section  52 . 
         [0039]    The elastomeric portion  50  is formed on, and envelops, the contact zone  51  and, optionally, at least an additional area of the support portion  49 . The shape and size of the elastomeric portion  50  can be any suitable composition, shape and size to produce an effective seal between the first and second members  12 ,  14 . 
         [0040]      FIG. 4  illustrates two aspects of the elastomeric portion  50 . In the illustrated examples, the elastomeric portion  50  may have one (not shown), two or three primary beads. As shown on the right side of the figure illustrating two primary beads, the elastomeric portion includes an inner bead  58  proximate the passage  40  and an outer bead  60  positioned distal to the passage. The inner bead  58  may be a wedge or tapered shape in cross section that is widest proximate the passage. The outer bead  60  may be rounded or oval in cross section. The second section  56  may be a vertical terminal extent of the contact zone  51  disposed in a position that is between or intermediate to the inner and outer beads  58 ,  60 . It will be understood that the configuration of beads and overall shape of the elastomeric portion  50  will be consistent about the entire seal  30 . 
         [0041]    The elastomeric portion  50  may have three beads as illustrated on the left side of the figure, including an inner bead  58  proximate the passage  40  and an outermost bead  64  that is positioned distal to the passage. The inner bead  58  may be a wedge or tapered shape in cross section that is widest proximate the passage. The outermost bead  64  may a wedge or tapered shape in cross section that is widest distal the passage in cross section. The elastomeric portion  50  may include an intermediate bead  62  that is between or intermediate to the inner and outermost beads  58 ,  64  that may be rounded or oval in cross section. The second section  56  may be a vertical terminal extent of the contact zone  51  disposed in a position that is between or intermediate to the inner and intermediate beads  58 ,  62 . It will be understood that the configuration of beads and overall shape of the elastomeric portion  50  will be consistent about the entire seal  30 . 
         [0042]    The integrated seal  30 , which includes the contact zone  51  and elastomeric portion  50 , forms an upper support zone  66  on one side of the seal and a lower support zone  68  opposite the upper support zone. The upper support zone  66  and lower support zone  68  may be annular, generally rectangular, ovoid or any suitable shape to cooperatively seal around a perimeter of a passageway. 
         [0043]      FIG. 5  shows another aspect of the support portion  49  and a contact zone  151  of the carrier  48 , with the elastomeric portion removed or not yet formed on the seal, to illustrate the contact zone more clearly. In particular, the illustrated contact zone  151  is formed to provide both non-planar and a deformable structure. The contact zone  151  illustrated herein may be referred to as a “tear-drop hem.” Thus, the contact zone  151  has a first section  152  that is a planar extension of the support portion  49  of the carrier  48  and lies in the plane of the support portion. A first bend  154  describes an arc of more than 180 degrees and a second section  156  forms the terminus of the contact zone  151 . The end  159  of the second section  156  may be brought into contact with the support portion  49  to form an eyelet  157  when viewed in cross section. The eyelet  157  permits the contact zone  151  to deform and provide height compensation as desired between flanking elements. In other words, the eyelet  157  can close to a greater or lesser extent depending on the amount of pressure applied thereto, which itself depends on the tolerance between members respectively positioned on the upper support zone  66  and lower support zone  68  (see  FIG. 4 ). The vertical height (thickness) of the contact zone  151  may be about three times the thickness of the support portion  49  of the carrier  48 . 
         [0044]    The eyelet  157 , in another aspect, may be closed before installation to provide a flattened hem configuration, which would have a vertical height of about two times that of the support portion  49  of the carrier  48 . In the flattened configuration, the contact zone  151  would not deform appreciably but would provide an increased resistance to shear of the elastomeric portion of the seal. 
         [0045]      FIG. 6  shows another aspect of the support portion  49  and a contact zone  251  of the carrier  48 , without an elastomeric portion. In particular, the illustrated contact zone  251  is formed to provide both non-planar and deformable aspects. The contact zone  251  illustrated herein may be referred to as an “open hem” or a “rope hem.” Thus, the contact zone  251  has a first section  252  that is a planar extension of the support portion  49  of the carrier  48  and lies in the plane of the support portion. A first bend  254  extends over an arc of more than 180 degrees, when viewed in cross section, and a second section  256  forms the terminus of the contact zone  251 . The end  259  of the second section  256  may be brought into contact with the support portion  49  to form an eyelet  257  with a closed configuration or left shy of the first section  252  to provide an eyelet with an open configuration. The eyelet  257  permits the contact zone to deform to provide height compensation as desired. In other words, the eyelet  257  can close to greater or lesser extents depending on the amount of pressure applied thereto, which itself depends on the tolerance between members respectively positioned on the upper support zone  66  and lower support zone  68 . The vertical height of the contact zone  251  may be about three times the thickness of the support portion  49  of the carrier  48 . 
         [0046]      FIG. 7  shows yet another aspect of the support portion  49  and a contact zone  351  of the carrier  48 , without an elastomeric portion. In particular, the illustrated contact zone  351  is formed to provide both non-planar and deformable aspects. The contact zone  351  illustrated herein may be referred to as an “open hem.” Thus, the contact zone  351  has a first section  352  that is offset from a planar extension of the support portion  49  of the carrier  48  and may be parallel to the plane of the support portion. A first bend  354  describes an arc of about 180 degrees and a second section  356  forms the terminus of the contact zone  351 . The end  359  of the second section  356  is spaced from the support portion  49  to form an eyelet  357  to provide an open and generally rectangular configuration. The eyelet  357  permits the contact zone to deform to provide height compensation as desired. In other words, the eyelet  357  can close to greater or lesser extents depending on the amount of pressure applied thereto, which itself depends on the tolerance between members respectively positioned on the upper support zone  66  and lower support zone  68 . The vertical height of the contact zone  351  is about three times the thickness of the support portion  49  of the carrier  48 . 
         [0047]      FIG. 8  shows contact zone  51  of  FIG. 4  with an elastomeric portion  150  of integrated seal  30 . Carrier  48  includes support portion  49  and contact zone  51 . The elastomeric portion  150  includes a single inner bead  158  formed on the contact zone  51 , wherein the inner bead defines port  124 , which may be a push rod port  124  as illustrated in  FIG. 3  (see B). Upper support zone  66  is shown at the upper side of seal  30  and lower support zone  68  is shown on the side opposite the upper support zone. 
         [0048]      FIG. 9  shows the contact zone  451  with an elastomeric portion  150  according to  FIG. 8  of integrated seal  30 . The contact zone  451  is in the form of a flattened hem. Carrier  48  includes support portion  49  and contact zone  451 . The elastomeric portion  150  includes a single inner bead  158  formed on the contact zone  451 , wherein the inner bead and elastomeric portion  150  defines port  124 , which may be a push rod port  124  as illustrated in  FIG. 3 . Upper support zone  66  is shown at the upper side of seal  30  and lower support zone  68  is shown on the side opposite the upper support zone. 
         [0049]      FIG. 10  shows a contact zone  351  (see  FIG. 7 ) with the elastomeric portion  150  according to  FIG. 8  of integrated seal  30 . The contact zone  351  is in the form of an open hem. Carrier  48  includes support portion  49  and contact zone  351 . The elastomeric portion  150  includes a single inner bead  158  formed on the contact zone  351 , wherein the inner bead and elastomeric portion  150  defines port  124 , which may be a push rod port as illustrated in FIG.  3 . Upper support zone  66  is shown at the upper side of seal  30  and lower support zone  68  is shown on the side opposite the upper support zone. 
         [0050]    Hem structures are used in joining known metallic structures, for example, two or more panels forming a door. The same metal working techniques can be used to form the contact zone portion  51  of the carrier  48  of the present disclosure. 
         [0051]      FIG. 11  shows a cutaway cross section of a cylinder head  12  and cylinder block  14  with a seal assembly  16  disposed therebetween like that shown in  FIG. 4  with the carrier  48  and contact zone portion  351  configuration shown in  FIG. 7 . An exemplary opening in the form of a pushrod port  24  is shown formed through the seal assembly  16  and is defined by the integrated seal  30 . 
         [0052]    In the illustrated aspect, the carrier  48  is generally planar. The carrier  48  may be considered to have a support portion  49 , which is generally planar and constitutes the major portion of the carrier in terms of total area, and a contact zone portion  351  that is non-planar and may also be deformable and provide a structural foundation to the integrated seal  30 . The elastomeric portion  50  of the integrated seal  30  is integrally formed over and about the contact zone  351  of the carrier  48 . 
         [0053]    The elastomeric portion  50  of the integrated seal  30  may be formed on the contact zone  351  of the carrier  48  in any suitable fashion as described above. 
         [0054]    Internally of the elastomeric portion  50  of the integrated seal  30 , the carrier  48  transitions from the planar support portion  49  to the contact zone portion  351 . The support portion  49  and contact zone portion  351  are formed of the same, one-piece construction, i.e., non-separate pieces. In all aspects, the contact zone portion  351  is non-planar as shown in  FIGS. 4-7 , and in other aspects, the contact zone portion  351  may also be deformable as shown in  FIGS. 5-7 . 
         [0055]    The integrated seal illustrated in  FIG. 4  is a view through line A of  FIG. 3 , for example, that shows a seal configured to resist lateral motion and shearing of the elastomeric portion  50  due to the morphology of the contact zone portion  351 . In particular, the illustrated contact zone  351  is formed to provide both non-planar and deformable aspects. The contact zone  351  illustrated herein may be referred to as an “open hem.” Thus, the contact zone  351  has a first section  352  that is offset from a planar extension of the support portion  49  of the carrier  48  and may be parallel to the plane of the support portion. A first bend  354  describes an arc of about 180 degrees and a second section  356  forms the terminus of the contact zone  351 . The end  359  of the second section  356  is spaced from the support portion  49  to form an eyelet  357  to provide an open and generally rectangular configuration. The eyelet  357  permits the contact zone to deform to provide height compensation as desired. In other words, the eyelet  357  can close to greater or lesser extents depending on the amount of pressure applied thereto, which itself depends on the tolerance between members respectively positioned on the upper support zone  66  and lower support zone  68 . The eyelet  357  may define a void that is not filled with the elastomer or a space that is filled. The vertical height of the contact zone  351  is about three times the thickness of the support portion  49  of the carrier  48 . 
         [0056]    The elastomeric portion  50  is formed on, and envelops, the contact zone  351  and, optionally, at least an additional area of the support portion  49 . The shape and size of the elastomeric portion  50  can be any suitable composition, shape and size to produce an effective seal between the first and second members  12 ,  14 . 
         [0057]      FIG. 11  illustrates two aspects of the elastomeric portion  50 . In the illustrated examples, the elastomeric portion  50  may have one (not shown), two or three primary beads. As shown on the right side of the figure illustrating two primary beads, the elastomeric portion includes an inner bead  58  proximate the passage  40  and an outer bead  60  positioned distal to the passage. The inner bead  58  may be a wedge or tapered shape in cross section that is widest proximate the passage. The outer bead  60  may be rounded or oval in cross section. The second section  56  may be a vertical terminal extent of the contact zone  351  disposed in a position that is between or intermediate to the inner and outer beads  58 ,  60 . It will be understood that the configuration of beads and overall shape of the elastomeric portion  50  will be consistent about the entire seal  30 . 
         [0058]    The elastomeric portion  50  may have three beads as illustrated on the left side of the figure, including an inner bead  58  proximate the passage  40  and an outermost bead  64  that is positioned distal to the passage. The inner bead  58  may be a wedge or tapered shape in cross section that is widest proximate the passage. The outermost bead  64  may a wedge or tapered shape in cross section that is widest distal the passage in cross section. The elastomeric portion  50  may include an intermediate bead  62  that is between or intermediate to the inner and outermost beads  58 ,  64  that may be rounded or oval in cross section. The second section  56  may be a vertical terminal extent of the contact zone  51  disposed in a position that is between or intermediate to the inner and intermediate beads  58 ,  62 . It will be understood that the configuration of beads and overall shape of the elastomeric portion  50  will be consistent about the entire seal  30 . The eyelet  357  may define a void that is not filled with the elastomer (see left side) or a space that is filled (see right side). 
         [0059]    The integrated seal  30 , which includes the contact zone  351  and elastomeric portion  50 , forms an upper support zone  66  on one side of the seal and a lower support zone  68  opposite the upper support zone. The upper support zone  66  and lower support zone  68  may be annular, generally rectangular, ovoid or any suitable shape to cooperatively seal around a perimeter of a passageway. 
         [0060]      FIG. 12  is similar to  FIG. 11 , except the elastomeric portion  50  is truncated. Thus, only one bead  58  is formed on the elastomeric portion  50  and it is possible to prevent elastomer filling the void  357  because the elastomer does not enrobe the entire structure of the contact zone  351  of the carrier portion  48 . The elements shown that have the same reference characters as those shown in  FIG. 11  have the same structure in the present aspect. 
       INDUSTRIAL APPLICABILITY 
       [0061]    The present disclosure is generally applicable to seals used in any device where seals are conventionally utilized. More particularly, the seal assembly  16  disclosed herein may be applicable in sealing fluid ports, chambers, and housings of mechanical systems such as engines, transmissions, pumps, hydraulic systems, and the like. The engines can be used in power generation, hydraulic fracking, or to power other machinery such as vehicles. Although the disclosure has illustrated the seal assembly  16  for use in an engine, the layered carrier seal assembly  16  can also be adapted for use in other applications where a seal is needed between two metal members and/or interfaces, such as in a hydraulic valve stack, a transmission, or a pump. 
         [0062]    Generally, the seal assembly  16  includes an integrated seal  30  formed on a carrier  48  that may be considered to have a support portion  49 , which is generally planar and constitutes the major portion of the carrier in terms of total area, and a contact zone  51  that is non-planar and may also be deformable. An elastomeric portion  50  of the integrated seal  30  is integrally formed over and about the contact zone  51  of the carrier  48 . 
         [0063]    It will be appreciated that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated. 
         [0064]    Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. 
         [0065]    Accordingly, this disclosure includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.