Abstract:
Unitary radial lip seals are useful to provide permanent lubrication to rotary shaft and bearing assemblies. In addition, these seals also function as excluder seals to keep dirt, chemicals, and other contaminants from contacting the lubricated surfaces. However, previous radial lip seals have a tendency to wear or cut a groove into the associated rotary shaft, as the shaft is rotated during normal operation of the machine. The present disclosure describes a radial lip seal having a sleeve, a seal case, a faceplate and flexible member. This improved seal also has a second sleeve operably positioned between the shaft and the faceplate wiper ring that alleviates the tendency of the wiper ring to cut a groove into the shaft during normal operation of the machine.

Description:
TECHNICAL FIELD 
     Generally, the present disclosure is related to the field of seals for seating rotary shafts. The methods and apparatus are particularly related to the field of unitary combination lip and sleeve seals. More specifically, the present invention relates to an improved seal adapted for use in severe duty applications where oil and grease must be held in contact with rotary shaft and bearing assemblies. The present invention incorporates design features that prevent the seal from wearing or cutting a groove into the associated rotary shaft, which can occur with other seals during normal operation. 
     BACKGROUND 
     The present seal structure yields a very important benefit over prior seal systems, in addition to providing most of the benefits of these seals. Previous seals, an example of which is shown in FIG. 1, have a tendency to cut or wear a circular groove into the associated rotary shaft. Theses grooves are primarily caused by the frictional contact between the faceplate wiper ring  189  and the shaft  121 , as the shaft is rotated during normal operation of the machine. It is undesirable to have the wiper ring cutting a groove into the rotary shaft during operation because these grooves weaken the shaft and can eventually lead to cracking of the spindle. It is equally undesirable to remove the wiper ring from the seal faceplate, because the wiper ring provides an initial barrier against environmental contaminants. Therefore, the present invention alleviates the tendency of the wiper ring to cut or groove the rotary shaft, without compromising the overall seal quality. 
     These and further objects of the apparatus taught in accordance with this specification, the claims, and the appended drawing figures are set forth below. 
     SUMMARY 
     The present disclosure, which incorporates herein by reference in their entirety, U.S. Pat. No. 6,186,507 to Oldenburg and application Ser. No. 09/401,570, filed Sep. 22, 1999, to Oldenburg, shows a retrofittable radial lip seal adapted to fit coaxially around, and reduce wear to, a circular rotatable shaft. In one embodiment, the seal comprises a first sleeve, a cylindrical seal case, a faceplate, a second sleeve and a flexible member. The first sleeve has an inner end that would normally be in contact with the grease, oil, or other fluid to be contained within a housing, an outer end opposite the inner end, a bore that has an elastomeric coating, and a first sleeve flange extending radially outward from the outer end of the first sleeve and generally perpendicular to the first sleeve axis. The first sleeve flange is terminated with an outer edge. 
     A cylindrically hollow seal case adapted for fitting into a bore is disposed coaxially around the first sleeve. The case is formed from a generally cylindrical case body having an outside surface, or outside diameter, that may be disposed in a bore and in contact with the wall of the bore. An elasotmeric coating may be affixed to the outside of the case body. By coating the outside of the metal case body with an elastomeric coating or layer, it is possible for the seal to securely fit a bore that may be worn or slightly damaged through use. 
     A case flange extends radially inwardly from, and generally perpendicular to, the longitudinal axis of the inside of the case. It is believed preferable to draw the case flange from the material of the case body. When formed in that manner, the material of the case body is doubled back on itself to yield two thicknesses of the case material for the distance between the case inner end and the case flange. 
     A generally planar circular faceplate has an inside surface, an outside surface, and a central aperture slightly larger than the outside diameter of the first sleeve. The plane of the inner faceplate surface is disposed generally parallel to the case skirt and the face of the first and second sleeve flanges. An elastomeric faceplate wiper ring, having at least one and preferably two main elastomeric excluding lips, can be attached to the faceplate at the central aperture so that the lips contact the outer surface of the second sleeve. The faceplate wiper ring has the ability to exclude contaminants from the remainder of the seal by contacting the second sleeve. In addition, the second sleeve and second sleeve elastomeric coating prevent the faceplate wiper ring from directly contacting the rotary shaft, and thereby prevent the wiper ring from wearing a groove into the rotary shaft during operation of the machine. 
     A second sleeve is located adjacent to the first sleeve and is adapted to fit coaxially around the shaft. The second sleeve has an outer end that is exposed to ambient conditions, an inner end adjacent to the outer end of the first sleeve, a bore that has an elastomeric coating, and a second sleeve flange that extends radially outward from the inner end of the second sleeve and runs generally perpendicular to the second sleeve axis. A circular elastomeric perimeter lip extends radially outwardly from the inner edge of the second sleeve flange to contact a generally cylindrical hollow seal case. 
     In another embodiment, the first sleeve and the second sleeve are replaced by one continuous sleeve that is adapted to fit coaxially around a shaft. In this embodiment, the seal comprises a continuous sleeve, a cylindrical seal case, a faceplate and a flexible member. The continuous sleeve has an inner end that extends into the sealed region and outer end that contacts the environment excluded by the seal. The continuous sleeve is operably positioned between the faceplate and the rotary shaft, thus preventing the wiper ring excluder lips from contacting the shaft. 
     In one embodiment, the seal is made into a unitary structure by inserting the first sleeve inner end through the case flange so that the first sleeve flange is positioned near the bumper. The second sleeve is then placed inside the seal case so that the perimeter lip of the second sleeve flange contacts the inside surface of the seal case outer end near the case skirt. All of the voids between the case inner flange and the case skirt can be packed with grease before final assembly of the seal. The faceplate is then attached to the case skirt thereby retaining the sleeves within the case portion. It has been found that a high quality water-resistant grease works well. One satisfactory grease is made by Esso Corporation and sold under the trade name “BEACON 325,” although other products may also serve quite satisfactorily. Although it is believed preferable to attach the faceplate to the case by crimping the peripheral edge of the faceplate around the outer edge of the case skirt, the faceplate may also be attached to the skirt by welding, brazing, adhesive bonding, or by any other of the usual means of connecting such items. It is desired that the junction between the case skirt and the faceplate be impervious to external contaminants and internal lubricants at the temperatures, pressures and other conditions in which the seal was operated. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 shows a cross-sectional profile of the structure of an embodiment of a prior art seal, in which the wiper ring directly contacts the rotary shaft. 
     FIG. 2 shows a cross-sectional profile of the structure of an embodiment of the present invention. 
     FIG. 3 shows a cross-sectional profile of the structure of another embodiment of the present invention having a triple lip sealing lip. 
     FIG. 4 shows a cross-sectional profile of the structure of another embodiment of the present invention having one continuous sleeve. 
     FIG. 5 shows a cross-sectional profile of the structure of another embodiment of the present invention having an externally flangeless seal case. 
    
    
     DETAILED DESCRIPTION 
     Referring now to the various figures of the accompanying drawing, FIG. 2 depicts a cross-sectional profile of an embodiment of the seal  120 . A first sleeve, or seal sleeve,  122  is adapted to fit coaxially around a shaft  121 . The first sleeve  122  has an inner end  124  that extends into the sealed region, which normally contains oil or grease, and an outer end  126  opposite. The first sleeve bore  128  may be coated with an elastomeric coating  130  in the region between the first sleeve inner end  124  and the first sleeve outer end  126 . The optional sleeve bore elastomeric coating is desirable because it may prevent leakage from between the seal  120  and the shaft  121  even when the shaft is worn or damaged. The first sleeve flange  132  extends radially outwardly from the first sleeve outer end  126 . The first sleeve flange  132  is adjacent, and runs generally parallel to, the second sleeve flange  205  which is described below. 
     A seal case  150  is disposed coaxially around the outside of the first sleeve  122 . The seal case  150  has a cylindrical case body  152  designed so that the case outside surface  154  can fit into and seal against a bore in a housing or flange through which the shaft  121  to be sealed extends. It is advantageous to coat the case outside surface  154  with an elastomeric coating  156 . The optional elastomeric coating  156  helps prevent the seal  120  from leaking when installed in a damaged bore. The case body  152  has a smoothly finished perimeter lip-contacting case inner surface  158  in the region near the case outer end  160 . The case inner end  162  is axially opposite the case outer end  160  and the case skirt  164  extends radially outwardly from the case outer end  160 . 
     A case flange  166  extends radially inwardly from the case body  152  towards the first sleeve  122 . The case inner flange  166  has a circular central aperture through which the shaft  121  and first sleeve  122  fit. It is preferred to form the case flange  166  from the case body in order to create a case reinforcement  168  with a double layer of material from which the case body  152  is made. 
     The main sealing lip  170  is attached to the case flange  166  and extends both axially and radially inwardly from the case flange  166 . The main sealing lip  170  contacts the first sleeve outer surface  172  to form a primary sealing element by which the contents (generally fluids) of the sealed volume are prevented from transferring to the outside of the assembly. The main sealing lip  170  is optionally biased against the first sleeve outer surface  172  by a garter spring  174 . The first sleeve outer surface  172  may be polished or otherwise finished to reduce wear of the main sealing lip  170 . FIG. 3 shows another embodiment of the present invention where the main sealing lip  170  has been replaced with a triple lip sealing lip  211 . In this alternate embodiment, each lip  212  of the triple lip sealing lip  211  extends axially and radially inward from the case flange  166  to contact the first sleeve outer surface  172 . 
     In one embodiment, a bumper  208  extends coaxially along, and radially inwardly from, the seal case  150  from the case flange  166  to contact the first sleeve flange  132 . The bumper  208  prevents the first sleeve flange  132 , and consequently the first sleeve  122 , from moving out of the desired position. 
     In one embodiment, a dust lip  175  extends axially outward from the main sealing lip and contacts the first sleeve outer surface  172 . Other embodiments of the present invention may contain several dust lips, all contacting either the first sleeve outer surface  172  or the first sleeve flange  132 . The case elasotmeric coating  156 , the main sealing lip  170 , the bumper  208  and the dust lip  175  may be integrally formed and bonded to the case body  152  and case flange  166  in a single injection molding operation. 
     A second sleeve, or face sleeve,  200  is adapted to fit coaxially around the shaft  121  and is adjacent the outer end of the first sleeve  122 . The second sleeve outer end  201  extends out into the environment excluded by the seal. The second sleeve bore  202  may be coated with an elastomeric coating  203  in the region between the second sleeve outer end  201  and the second sleeve inner end  204 . The second sleeve flange  205  extends radially outwardly from the second sleeve inner end  204 , and runs generally parallel to the first sleeve flange  132 . The second sleeve flange  205  has a second sleeve flange inner edge  206  from which a perimeter lip  207  extends radially outwardly towards the seal case outer end  160 . In other embodiments, the perimeter lip  207  may be located on the first sleeve flange outer edge  134 . The perimeter lip  207  contacts the seal case  150  near the seal case outer end  160 . The face sleeve bore elastomeric coating  203  and the perimeter lip  207  may be formed and attached to the second sleeve  200  in a single injection molding operation. 
     On the inner end of the case body  152 , the case elastomeric coating  156  is finished with a case elastomeric coating chamfer  178  to make it easier to install the seal  120  without distortion or damage. A case outside relief channel  179  may be formed in the case elastomeric coating  156  adjacent to the case skirt  164 . The relief channel  179  relieves axial shear stresses from the case elastomeric coating  156  that can result when the seal  120  is installed into a bore. 
     A first sleeve radial channel  190  is preferably formed within the first sleeve bore elastomeric coating  130  to relieve shear as the first sleeve is fitted to a shaft. A second sleeve radial channel  216  is preferably formed within the second sleeve bore elastomeric coating  203  to relieve shear as the second sleeve is fitted to a shaft. The first sleeve  122  is finished with a sleeve outer end chamfer  192  and a sleeve inner end chamfer  194  to reduce the potential for tearing of the sleeve bore elastomeric coating  130  and for distortion of the first sleeve  122  during installation of the seal  120 . Similarly, the second sleeve  200  is finished with a second sleeve outer end chamfer  209  and a second sleeve inner end chamfer  210 . In addition, the seal case  150  may be fitted with a case inner end chamfer  196  to reduce damage to the case elastomeric coating  156  when the case is fitted with elastomeric coating and to prevent case distortion in embodiments without case elastomeric coating  156 . 
     The four main sub assemblies, the first sleeve  122 , the seal case  150 , the second sleeve  200 , and the faceplate  181  are interconnected to form a complete seal  120 . These four subassemblies are generally made of steel or another metal that is shaped, worked, and polished using conventional metalworking techniques and commercially available equipment. Although, any material suitable for fulfilling the functions of the seal may be used. 
     In one embodiment, final assembly of the seal  120  is accomplished by four additional steps. First, the first sleeve  122  is inserted into the seal case  150  so that the first sleeve flange  132  is positioned near the bumper  208 . Second, the second sleeve  200  is inserted into the seal case  150  so that the perimeter lip  207  contacts the seal case outer end  160  in the region near the case skirt  164 . Third, water resistant grease  180  is packed into all of the voids between the case flange  166  and the perimeter lip  207 . Fourth, the faceplate  181  is attached to the case skirt  164  by crimping or other means to complete the seal assembly and unitizing process. 
     After the faceplate  181  is attached to the case skirt  164 , the elastomeric faceplate wiper ring  189  is attached so that the wiper ring excluder lips  208  contact the face sleeve  200 . The face sleeve  200  prevents the wiper ring excluder lips  208  from directly contacting the shaft  121 , which alleviates the tendency of the wiper ring  189  to wear grooves into the shaft  121  during normal operation of the machine. The faceplate includes a central aperture larger than the outside diameter of the first sleeve, with the plane of the faceplate inner side  182  being oriented generally parallel to the case skirt  164  and the second sleeve flange  205 . 
     FIG. 4 shows an alternative embodiment of the seal  120  where the first sleeve  122  and the second sleeve  200  have been replaced by one continuous sleeve  213 . The continuous sleeve  213  has a continuous sleeve flange  214  that extends radially outwardly from, and generally perpendicular to, the continuous sleeve  213 . 
     FIG. 5 shows and alternative embodiment of the seal  120  where the seal case  150  is formed without an external flange. 
     While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the above detailed description, wherein is shown and described only the embodiments of the invention, by way of illustration, of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive. 
     Any references in the above detailed description to front and back, inner and outer, inside and outside, and upper and lower are intended for convenience of description, not to limit the present invention or its components to any one positional or spacial orientation.