Patent Publication Number: US-10767762-B2

Title: Low load dual flap seal assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 14/147,027, filed on Jan. 3, 2014. The entire disclosure of the above application is incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to seals and more particularly to a low load dual flap seal assembly. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     Sealing applications typically require sealing between two members and sometimes require the ability to accommodate significant movement, misalignment or offset between the two members. Static offset sealing applications are used in engine, transmission and industrial applications. Conventional static seals sometimes use trapped rubber beads which produce too much force and are difficult to mold with undercuts and which produce significant radial force for assembly. Accordingly, it is desirable in the art to provide a seal arrangement that has the ability to accommodate perennial offset between two members and which requires a relatively low load for installation on the two members. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     According to one aspect of the present disclosure, a seal is provided for sealing between a first member and a second member and including a first annular insert and a second annular insert axially spaced from the first annular insert. An elastomeric body includes a first portion over-molded on the first annular insert and a second portion over-molded on the second annular insert and an intermediate web extending between the first and second portions. The first and second portions including an annular flap extending from the first and second annular inserts that in an un-installed condition, extend radially relative to the first and second annular inserts and in an installed position are adapted to be compressed between the annular inserts and a surface of the first and second members. 
     According to another aspect of the present disclosure, a helical coil insert includes a first end and a second end and an intermediate portion extending between the first and the second ends. The elastomeric body of the seal includes a first portion overmolded on the first end of the helical spring insert and a second portion overmolded on the second end of the helical spring insert. An intermediate web portion is overmolded on the intermediate portion of the helical spring insert and extends between the first portion and the second portion. The first portion and second portion each include an annular flap extending radially relative to the first and second ends of the helical spring insert and in an installed position is adapted to be compressed between the first end and second end of the helical spring insert and an annular surface of the first and second members. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a cross-sectional view of a low load dual flap seal assembly for sealing between two bores of opposing members according to the principles of the present disclosure; 
         FIG. 2  is a cross-sectional view of the low load dual flap seal assembly of  FIG. 1  shown installed within two bores of opposing members; 
         FIG. 3  is a cross-sectional view of a low load dual flap seal assembly having an alternative flap design for sealing between two bores of opposing members according to the principles of the present disclosure; 
         FIG. 4  is a cross-sectional view of a low load dual flap seal assembly for sealing between a bore and exterior surface of two opposing members according to the principles of the present disclosure; 
         FIG. 5  is a cross-sectional view of a low load dual flap seal assembly having an over-molded helical coil spring for sealing between two bores of opposing members according to the principles of the present disclosure; 
         FIG. 6  is a cross-sectional view of a low load dual flap seal assembly having an over-molded helical coil spring for sealing between two bores of opposing members according to the principles of the present disclosure; 
         FIG. 7  is a cross-sectional view of a low load dual flap seal assembly having an over-molded helical coil spring for sealing between a bore and exterior surface of two opposing members according to the principles of the present disclosure; 
         FIG. 8  is a cross-sectional view of the low load dual flap seal assembly of  FIG. 7  shown installed between a bore and exterior surface of two opposing members; 
         FIG. 9  is a cross-sectional view of a low load dual flap seal assembly having a center flange; and 
         FIG. 10  is a cross-sectional view of the low load dual flap seal assembly having a center flange as shown in  FIG. 9  for sealing between first and second members shown for illustrative purposes; 
         FIG. 11  is a cross-sectional view of a low load dual flap seal assembly having a center flange and alternative and flap design; and 
         FIG. 12  is a cross-sectional view of the low load dual flap seal assembly having a center flange as shown in  FIG. 11  for sealing between first and second members shown for illustrative purposes; 
         FIG. 13  is a cross-sectional view of a low load dual flap seal assembly having a center flange and alternative and flap design; and 
         FIG. 14  is a cross-sectional view of the low load dual flap seal assembly having a center flange as shown in  FIG. 13  for sealing between first and second members shown for illustrative purposes; 
         FIG. 15  is a cross-sectional view of a low load flap seal assembly for sealing between a bore and exterior surface of two opposing members according to the principles of the present disclosure; and 
         FIG. 16  is a cross-sectional view of the low load flap seal assembly of  FIG. 15  shown installed between a bore and exterior surface of two opposing members. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. 
     Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     With reference to  FIGS. 1 and 2 , a low load dual flap seal assembly  10  according to the principles of the present disclosure will now be described. The seal assembly  10  is designed to be inserted in a sealing engagement between a first bore  12  of a first member  14  and a second bore  16  of a second member  18 . By way of non-limiting example, the seal assembly  10  can be utilized for providing a sealed connection between a turbocharger  14  and mixer  16 . However, it should be understood that the seal assembly  10  can be used in other applications for sealing between first and second members  14 ,  16 . 
     As shown in  FIG. 1 , the seal assembly  10  includes a first annular insert  20  and a second annular insert  22 . An elastomeric body  24  is provided with a first portion  26  over-molded on the first annular insert  20  and a second portion  28  over-molded on the second annular insert  22 . An intermediate web portion  30  extends between the first portion  26  and second portion  28 . A first annular flap  32  extends from the first portion  26  and a second annular flap  34  extends from the second portion  28 . The first and second annular flaps can include a generally U-shaped body  36  and a terminal and portion  38  having a wider thickness than the U-shaped body  36 . According to one aspect of the present disclosure, the terminal end portions  38  of the first and second annular flaps  32 ,  34  can include a raised bead region  40  on a radially inner surface of the annular flaps  32 ,  34 . The terminal end portions  38  of the first and second annular flaps can be disposed radially outward of the first and second annular inserts  20 ,  22  due to the U-shaped body portion  36  of each of the annular flaps  32 ,  34 . The first and second annular flaps  32 ,  34  are designed to be received within a respective bore  12 ,  16  in the first and second members  14 ,  18 . First and second members  14 ,  18  can each include a chamfered end surface  42  that engages the outer surface of each of the annular flaps  32 ,  34 . As the annular flaps  32 ,  34  are engaged with the chamfered and services  42  of the first and second members  14 ,  18 , the annular flaps are folded over so that the raised bead portion  40  is compressed against the elastomeric material that is overmolded on the annular inserts  20 ,  22 . The raised bead portions  40  are then compressed and dig into the elastomeric material overmolded on the annular inserts  20 ,  22 . The annular flaps allow for relatively low insertion loads to be inserted into the bores, but provide great resistance against removal of the seal  10  from each of the bores  12 ,  16 . In other words, the wedging effect that occurs upon attempted removal of the seal  10  on the bores  12 ,  16  behaves like a Chinese finger lock to prevent the removal of the seal  10  from the bores  12 ,  16 . 
     As shown in  FIG. 1 , the raised bead portions  40  at the ends of the annular flaps  32 ,  34  are generally triangular shaped. As an alternative, as illustrated in  FIG. 3 , the ends of the annular flaps  32 ′,  34 ′ can be V-shaped or otherwise shaped to provide differing insertion loads and retention loads. The V-shaped ends  44  of the annular flaps  32 ′,  34 ′ are provided with a notched out region  46 . The depth of the notched out region  46  can be selected to increase or decrease the retention forces achieved by the seal  10 ′. Similarly, with respect to the width of the ends of the annular flaps  32 ,  34 , it is noted that the width of the no flaps can be modified to increase or decrease the retention forces as well as the installation forces that are necessary to insert the seal  10  into the bores  12 ,  16 . 
     With reference to  FIG. 4 , an alternative low load dual flap seal assembly  50  is shown. The seal assembly  50  includes a first annular insert  52  and a second annular insert  54 . An elastomeric body  56  is provided with a first portion  58  over-molded on the first annular insert  52  and a second portion  60  over-molded on the second annular insert  54 . An intermediate web portion  62  extends between the first portion  58  and second portion  60 . A first radially outwardly extending annular flap  64  extends from the first portion  58  and a second radially inwardly extending annular flap  66  extends from the second portion  60 . The first and second annular flaps  64 ,  66  can include a generally U-shaped body  68  and an end portion  70  having a wider thickness than the U-shaped body  68 . According to one aspect of the present disclosure, the end portion  70  of the first annular flap  64  can include a raised bead region  72  on a radially inner surface of the first annular flap  64 . The end portion  70  of the second annular flap  66  can include a raised bead region  72  on a radially outer surface of the second annular flap  66 . The end portion  70  of the first annular flap  64  can be disposed radially outward of the first annular insert  52  due to the U-shaped body portion  68  of the first annular flap  64 . The end portion  70  of the second annular flap  66  can be disposed radially outward of the second annular insert  54  due to the U-shaped body portion  68  of the second annular flap  66 . The first annular flap  64  is designed to be received within a bore  12  in a first member  14 . The second annular flap  66  is designed to be received on an exterior annular surface of a shaft or housing of a second member similar to the seal shown in  FIGS. 7 and 8 . The first and second members can each include a chamfered end surface  80  that engages the outer surface of each of the annular flaps  64 ,  66 . As the annular flaps  64 ,  66  are engaged with the chamfered end surfaces  80  of the first and second members, the annular flaps are folded over so that the raised bead portion  72  is compressed against the elastomeric material that is overmolded on the annular inserts  52 ,  54 . The raised bead portions  72  are then compressed and dig into the elastomeric material overmolded on the annular inserts  52 ,  54 . The geometry of the annular flaps  64 ,  66  allow for relatively low installation loads, but provide great resistance against removal of the seal  50  from each of the opposing members. In other words, the wedging effect that occurs upon attempted removal of the seal  50  behaves like a Chinese finger lock to prevent the removal of the seal  50  from the first and second members. 
     The embodiment shown in  FIGS. 1 and 2  illustrate an example of the annular flaps being both on the radially outer side of the seal  10 , while the embodiment of  FIG. 4  shows one annular flap  64  on the radially outer side and one annular flap  66  on the radially inner side of the seal  50 . It is noted that it is also anticipated that the seal could be provided with both annular flaps on the radially inner side of the seal. The annular flaps can have the configuration as illustrated in  FIG. 1  or alternative shapes of the annular flap such as that illustrated in  FIG. 3 . 
     With reference to  FIGS. 5 and 6 , an alternative low load dual flap seal assembly  110  according to the principles of the present disclosure will now be described. The seal assembly  110  is designed to be inserted in a sealing engagement between a first bore  12  of a first member  14  and a second bore  16  of a second member  18 . 
     As shown in  FIG. 5 , the seal assembly  110  includes a helical spring insert  112  having a first end  114  and a second end  116 . An intermediate portion  118  extends between the first end  114  and the second end  116 . The winding of the helical spring insert  112  can be tighter in the first and second ends  114 ,  116 . An elastomeric body  124  is provided with a first portion  126  over-molded on the first end  114  of the helical spring insert  112  and a second portion  128  over-molded on the second end  116  of the helical spring insert  122 . An intermediate web portion  130  extends between the first portion  126  and second portion  128  and is overmolded on the intermediate portion  118  of the helical spring insert  112 . A first annular flap  132  extends from the first end portion  126  and a second annular flap  134  extends from the second end portion  128 . The first and second annular flaps  132 ,  134  function in the same manner as the annular flaps  32 ,  34  as discussed above with reference to  FIGS. 1 and 2 . Therefore, a detailed description of the annular flaps  132 ,  134  has been omitted. 
     As shown in  FIG. 5 , the raised bead portions at the ends of the annular flaps  132 ,  134  are generally triangular shaped. As an alternative, as illustrated in  FIG. 3 , the ends of the annular flaps  32 ′,  34 ′ can be V-shaped or otherwise shaped to provide differing insertion loads and retention loads. 
     The first and second ends  114 ,  116  of the over-molded helical spring insert  112  functions in the same manner as the first and second annular inserts in the embodiment of  FIGS. 1 and 2 . In addition, the intermediate portion  118  of the helical spring insert  112  serve to reinforce the intermediate web portion of the seal  110  in order to prevent buckling therein. 
     With reference to  FIGS. 7 and 8 , an alternative low load dual flap seal assembly  150  is shown including a helical spring insert  112  in the same manner as the embodiment of  FIGS. 5 and 6 , as discussed above. In the embodiment of  FIGS. 7 and 8 , the seal assembly  150  includes one annular flap  152  on the radially outer side and one annular flap  154  on the radially inner side of the seal  50 . Similar to the embodiment of  FIG. 1 , the annular flaps  152 ,  154  can include a raised bead region that, in an assembled condition, is compressed against the elastomeric material that is over-molded on the spring insert  112 . It is noted that it is also anticipated that the seal could be provided with both annular flaps on the radially inner side of the seal. The annular flaps can have the configuration as illustrated in  FIG. 1  or alternative shapes of the annular flap such as that illustrated in  FIG. 3 .  FIG. 8  shows the seal assembly  150  installed between first and second members  156 ,  158  with the annular flap  152  received in a bore  160  in the first member  156  and the annular flap  154  received on an outer surface  162  of the second member  158 . The first and second members  156 ,  158  are shown in a misaligned or offset position with the intermediate web portion  130  of the seal  150  flexing to accommodate for the offset. 
     With reference to  FIGS. 9 and 10 , the low load dual flap seal assembly shown in  FIGS. 5 and 6  has been modified to include a central flange  140  extending radially outward from the intermediate web portion  130 . The central flange  140  can be reinforced with an annular insert  142  that can be generally disc-shaped with a central opening therein. The center flange  140  stabilizes the intermediate web portion at offset in order to keep the intermediate web portion  130  from buckling and also allows the use of through bores by providing a centering feature that prevents the seal assembly  110 ′ from being inserted too far into the bores  12 ,  16  of either of the first or second members  14 ,  18 , thereby keeping the seal assembly  110 ′ properly centered. The center flange  140  also stiffens the intermediate web portion  130  when the seal assembly  110 ′ is pressurized and gives the two end portions  126 ,  128  added support for assembly. Although the center flange  140  is shown with the embedded helical coil spring embodiment of  FIGS. 5 and 6 , it should be understood that the center flange concept can be utilized with each of the alternative embodiments disclosed herein. 
     With reference to  FIGS. 11 and 12 , a further alternative embodiment of the dual flap seal assembly  110 ″ is shown including a center flange  140  extending from the web portion  130  in the same manner as the embodiment of  FIGS. 11 and 12 . In the embodiment of  FIGS. 11 and 12 , the end flaps have been modified to provide a non-overlapping configuration. In particular, each of the angled end flaps  170  extend axially from the end portions  126 ,  128  and are angled radially outwardly to provide an interference with the surface of the bores  12 ,  16  of the first member  14  and second member  18 , respectively. Therefore, upon insertion of the angled end flaps  170  into the bores  12 ,  16 , the angled flaps  170  are deformed radially inward and due to their deformation are self biased into a sealing engagement with the inner surface of the bores  12 ,  16 . Although the angled flaps  170  are shown with the embedded helical spring  112 , the angled flaps  170  could be used with alternative seal assemblies having the inserts  20 ,  22  or with other insert designs or without inserts. The angled flaps  170  can extend outwardly at an angle α of between 15 and 45 degrees and more preferably approximately 30 degrees relative to a direction parallel to a center axis of the seal  110 ″. Like with the prior embodiments, the first and second members  14 ,  18  can be provided with a beveled end surface  42  that are angled such that as they engage the angled flaps  170  the angled flaps are bent inward to an increasing degree until they are fully received within the bores  12 ,  16  past the beveled end surfaces  42 . The beveled end surfaces  42  can be angled between 15 and 45° and more preferably approximately 30° relative to a direction parallel to a center axis of the bores. The use of an oil or other lubricant would help to facilitate the sliding engagement of the angled flaps  170  along the beveled and surfaces  42  during assembly of the seal. 
     With reference to  FIGS. 13 and 14 , a further alternative embodiment of the dual flap seal assembly  110 ″′ is shown including a center flange  140  extending from the web portion  30  in the same manner as the embodiment of  FIGS. 9-12 . In the embodiment of  FIGS. 13 and 14 , the end flaps  180  have been modified to provide an alternative configuration. In particular, each of the end flaps  180  extend at an angle generally radially inwardly from the end portions  26 ,  28  and include an axially extending flap portion  182  with a hinge section  184  so that the flap portion  182  is designed to engage a shoulder  186  within the bores  12 ,  16  of each of the first and second members  14 ,  18 . Upon engagement of the shoulders  186 , the axially extending flap portion  182  is deformed radially inward about the hinge  184 . The axially extending flap portions  182  are then self biased due to their deformation into a sealing engagement with the shoulder portions  186  of the first member  14  and second member  18 , respectively. Therefore, upon insertion of the end flaps  180  into the bores  12 ,  16 , the flaps  182  are deformed radially inward about the hinge section  184  and due to their deformation are self biased into a sealing engagement with the shoulder surface  186  of the bore. The flaps  182  include raised bead portions  185  that can be compressed against the end portions  26 ,  28  to further apply a spring load on the flaps  182 . In the embodiment of  FIGS. 15 and 16 , the first and second inserts  20 ,  22  can be formed cylindrical with an elongated straight cross-section, or can have an L-shaped or other cross-section. An L-shaped cross-section can provide the insert with additional hoop strength to resist against deformation. A raised seal bead  188  can be provided on an exterior surface of the seal radially outward of the inserts  20 ,  22  for engagement on an interior surface of the bores  12 , 16  of the first and second members  14 ,  18  in order to provide additional sealing engagement therewith. 
     With reference to  FIGS. 15 and 16 , an alternative low load flap seal assembly  210  is shown including a first annular insert  220  and a second annular insert  222 . An elastomeric body  224  is provided with a first portion  226  over-molded on the first annular insert  220  and a second portion  228  over-molded on the second annular insert  222 . An intermediate web portion  230  extends between the first portion  226  and second portion  228 . A annular flap  232  extends from the first portion  226 . The annular flap  232  is formed in the same manner as the annular flap  32  as shown in the embodiment of  FIGS. 1 and 2 , or can be formed in the manner as the annular flap  32 ′ as shown in  FIG. 3 . The second portion  228  of the elastomeric body can be provided with a protruding rib portion  234  for engaging a second member. Therefore, in the embodiment of  FIGS. 9 and 10 , the seal assembly  210  is provided with an annular flap  232  only at one end. It should be understood that the annular flap  232  could extend radially outward to overlap annular insert  220  on the outer surface for receipt in a bore as illustrated, or alternatively, the annular flap  232  could extend radially inward to overlap the annular insert on the inner surface for receipt on a shaft or exterior surface of the first member. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.