Patent Publication Number: US-2012031365-A1

Title: Intake manifold and seal

Description:
FIELD OF THE INVENTION 
     The present invention relates to an engine manifold and a mounting collar for the engine manifold having a resilient seal disposed between the mounting collar and the engine manifold. 
     BACKGROUND OF THE INVENTION 
     Manifold assemblies typically include at least one seal to militate against an escape of intake gases and exhaust gases. An engine manifold typically compresses a seal disposed between the engine manifold and a cylinder head. The engine manifold is urged towards the cylinder head by a mounting collar disposed on the engine manifold. An adjustable fastener coupling the mounting collar to the cylinder head permits an urging force to be varied. Upon compression of the seal, the engine manifold is rigidly coupled to the cylinder head, and little relative movement between the engine manifold and the cylinder head is afforded. Such manifold assemblies require a plurality of components, undesirably increasing the complexity of the manifold assembly. 
     Coupling the manifold assembly including the plurality of components may become an arduous or a time consuming task. A positioning of the seal with respect to the cylinder head and the engine manifold, an alignment of the adjustable fasteners and the mounting collar, application of nuts, washers, and thread locking fluid, and the urging force of each fastener must be given particular attention during assembly to ensure proper sealing between the cylinder head and the engine manifold. The engine manifold having a plurality of manifold inlets or a plurality of manifold outlets further complicates coupling the engine manifold to the cylinder head, as simultaneous attention must be given to each of the manifold inlets or each of the manifold outlets. The plurality of components of the manifold assembly undesirably increases an assembly time and an amount of required component manipulation during assembly of the manifold assembly. 
     It is common for portions of an engine assembling process to occur in a plurality of locations. Partially assembled engines and non-operational assembled engines may be transported within a facility or to another facility for further assembly or installation. During transportation of the partially assembled engines and non-operational assembled engines, engine components may move in an undesirable manner. Particularly, the engine manifold may rotate with respect to the cylinder head during transportation of the partially assembled engines and non-operational assembled engines. A rotation of the engine manifold during transportation may result in damage to the seal disposed between the cylinder head and the engine manifold. Further, correction of a positioning of the engine manifold may result in an undesirable increase in a duration of the engine assembling process. 
     It would be advantageous to utilize a manifold assembly for an engine that minimizes a required number of components, minimizes a time of assembly of the manifold assembly, and militates against a rotation of an engine manifold. 
     SUMMARY OF THE INVENTION 
     Presently provided by the invention, a manifold assembly for an engine that minimizes a required number of components, minimizes a time of assembly of the manifold assembly, and militates against a rotation of an engine manifold, has surprisingly been discovered. 
     In one embodiment, the present invention is directed towards a manifold assembly for an engine having an engine manifold, a mounting collar, and a resilient seal. The mounting collar is disposed on the engine manifold and the resilient seal is disposed between the engine manifold and the mounting collar. 
     The engine manifold has an inlet, an outlet, and a primary protuberance formed on an outer surface of the engine manifold. The primary protuberance is formed adjacent the outlet of the engine manifold. 
     The mounting collar has a secondary protuberance. The mounting collar is disposed on the engine manifold adjacent the outlet of the engine manifold. 
     The resilient seal is disposed between the engine manifold and the mounting collar. The primary protuberance abuts the secondary protuberance to militate against a rotation of the engine manifold with respect to the mounting collar. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description when considered in the light of the accompanying drawings in which: 
         FIG. 1  is an exploded perspective view of a manifold assembly for an engine according to an embodiment of the present invention; 
         FIG. 2  is a fragmentary perspective view of the manifold assembly illustrated in  FIG. 1 , a mounting collar of the assembly coupled to a cylinder head; 
         FIG. 3  is a cross-sectional, top elevational view of the manifold assembly shown in  FIG. 1 , taken along section line  3 - 3  in  FIG. 2 ; and 
         FIG. 4  is a cross-sectional, top elevational view of a manifold assembly according to another embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     It is to be understood that the invention may assume various alternative orientations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions, directions or other physical characteristics relating to the embodiments disclosed are not to be considered as limiting, unless the claims expressly state otherwise. 
       FIGS. 1-3  illustrate a manifold assembly  10  for an engine according to an embodiment of the present invention. The manifold assembly  10  includes an engine manifold  12 , a mounting collar  14 , and a resilient seal  16 . As shown, the manifold assembly  10  is an intake manifold assembly, but the manifold assembly  10  may be an exhaust manifold assembly. 
     The engine manifold  12  has an inlet  18 , at least one outlet  20 , and a primary protuberance  22 . The engine manifold  12  is typically formed by casting a metal such as aluminum, but other processes such as machining or forging may be used to form the engine manifold  12 . As illustrated, the engine manifold  12  is a hollow body having one inlet  18  and two outlets  20 . However, any number of inlets and outlets may be formed in the engine manifold. A cross-sectional shape of the engine manifold  12  adjacent the inlet  18  and the outlets  20  is substantially ring shaped. Alternately, other cross-sectional shapes such as rectangles, ellipses, or other closed shapes may be used. 
     A portion of the engine manifold  12  adjacent the at least one outlet  20  has a diameter less than a remaining portion of the engine manifold  12 , forming a stepped portion  24 . The stepped portion  24  is formed in an outer surface  26  of the engine manifold  12  adjacent the at least one outlet  20  of the engine manifold  12 . Alternately, the engine manifold  12  may be tapered to form the portion of the engine manifold  12  having a diameter less than a remaining portion of the engine manifold  12  and a stepped portion  24  may be formed in the outer surface  26  adjacent the inlet  18  of the engine manifold  12 . The engine manifold  12  may include an aperture (not shown) formed therein for coupling a sensor or other device thereto. Further, the engine manifold  12  may include a bracket (not shown) formed therewith for coupling a device or a support member thereto. 
     The inlet  18  is a finish of the engine manifold  12  having a substantially circular peripheral edge. A portion of the engine manifold  12  adjacent the inlet  18  may be adapted for receiving a resilient coupler (not shown) by having a stepped portion formed therein or having the outer surface  26  refined for receiving the resilient coupler. The resilient coupler may couple a fuel mixing device, an intake conduit, or an exhaust conduit to the inlet  18 . Alternately, the inlet  18  may include a mounting flange (not shown) formed therewith. 
     The outlet  20  is a finish of the engine manifold  12  having a substantially circular peripheral edge. As shown, the resilient seal  16  is disposed on the stepped portion  24 . A depth of a stepped wall  28  is substantially equal to a thickness of the resilient seal  16 , affording the resilient seal  16  to sit “flush” with the outer surface  26  of the engine manifold  12 . 
     The primary protuberance  22  is a body extending from the outer surface  26  of the engine manifold  12 . As shown, the primary protuberance  22  has a substantially rectangular prism shape, the substantially rectangular prism shape having a plurality of rounded edges and a rounded transitionary surface formed between the primary protuberance  22  and the outer surface  26  of the engine manifold  12 . However, other shapes such as a cylindrical prism, a bulbous protuberance, or any other shape may be used. 
     The primary protuberance  22  is formed adjacent the outlet  20  on an outer surface  26  of the engine manifold  12 . As most clearly shown in  FIG. 3 , the stepped wall  28  forms a portion of the primary protuberance  22 . Alternately, the primary protuberance  22  may be formed elsewhere on the outer surface  26  adjacent the outlet  20 . The primary protuberance  22  is unitarily formed with the engine manifold  12 , but may be formed separate the engine manifold  12  and coupled thereto using a fastener, a weld, or the like. As illustrated, the engine manifold  12  includes two primary protuberances  22  formed therewith, each of the protuberances  22  formed adjacent the outlets  20  of the engine manifold  12 . The protuberances  22  are aligned with one another, the protuberances  22  similarly positioned on the engine manifold  12  with respect to the inlet  18 . 
     The mounting collar  14  is a unitary body having a first inner surface  30 , a second outer surface  32 , a secondary protuberance  34 , a manifold aperture  36  formed therethrough, and a fastening point  38  and a sealing groove  40  formed therein. The mounting collar  14  is typically formed by casting a metal such as a steel, but other processes such as stamping or machining may be used to form the mounting collar  14 . A shape of a central portion of the mounting collar  14  is substantially circular, the central portion having two diametrically opposed rounded tabs extending therefrom, each of the rounded tabs meeting the central portion tangentially. Alternately, the mounting collar  14  may be any other shape and may have any number of tabs extending therefrom. As illustrated in  FIG. 1 , the manifold assembly  10  includes two mounting collars  14 , each of the mounting collars  14  including one secondary protuberance  34  and two fastening points  38  formed therein. However, the mounting collar  14  may include any number of secondary protuberances  34  and any number of fastening points  38  formed therein. As shown in  FIGS. 2 and 3 , the mounting collar  14  is disposed on the engine manifold  12 , the resilient seal  16  disposed therebetween. The mounting collar  14  is coupled to an engine block or cylinder head  42 , the second outer surface  32  disposed adjacent the engine block or cylinder head  42 . While the collar  14  may be mounted to either the engine block or the cylinder head, the following will utilize cylinder head  42 . 
     The secondary protuberance  34  is a body extending from the first inner surface  30  of the mounting collar  14 . As shown, the secondary protuberance  34  has a substantially rectangular prism shape, the substantially rectangular prism shape having a plurality of rounded edges and a rounded transitionary surface formed between the secondary protuberance  34  and the first inner surface  30  of the mounting collar  14 . However, other shapes such as a cylindrical prism, a bulbous protuberance, or any other shape may be used. The secondary protuberance  34  is formed adjacent the manifold aperture  36  on the first inner surface  30  of the mounting collar  14 . Alternately, the secondary protuberance  34  may be formed elsewhere on the first inner surface  30  adjacent the manifold aperture  36 . The secondary protuberance  34  is unitarily formed with the mounting collar  14 , but may be formed separate the mounting collar  14  and coupled thereto using a fastener, a weld, or the like. 
     The manifold aperture  36  is formed through the first inner surface  30  and the second outer surface  32 . The first inner surface  30  is substantially parallel to the second outer surface  32 . An aperture wall  44  defines the manifold aperture  36 , the aperture wall  44  being substantially perpendicular to the first inner surface  30  and the second outer surface  32 . An intersection of the aperture wall  44  and the first inner surface  30  forms a first peripheral edge  46  having a substantially circular shape. An intersection of the aperture wall  44  and the second outer surface  32  forms a second peripheral edge  48  having a substantially circular shape. A diameter of the second peripheral edge  48  is substantially equal to a diameter of the first peripheral edge  46 . 
     The fastening point  38  is a perforation formed through the mounting collar  14 . The fastening point  38  is a circular aperture formed outboard from the aperture wall  44  in each of the diametrically opposed rounded tabs. Alternately, the fastening point  38  may be a notch formed in a peripheral edge  50  of the mounting collar  14 , a slot formed through the mounting collar  14 , each of the tabs extending from the mounting collar  14 , or any other portion of the mounting collar  14 . The mounting collar  14  includes two fastening points  38  formed therethrough. As shown in  FIG. 2 , a threaded fastener is disposed through the fastening point  38  and into a threaded aperture (not shown) formed in the cylinder head  42 , the threaded fastener coupling the mounting collar  14  to the cylinder head  42 . 
     The sealing groove  40  is a substantially circular groove formed in the second outer surface  32  of the mounting collar  14 . The sealing groove  40  is substantially concentric and formed outboard from the aperture wall  44  in the second outer surface  32 . As shown in  FIG. 3 , when the mounting collar  14  is coupled to the cylinder head  42 , an O-ring  52  is disposed between the mounting collar  14  and the cylinder head  42 , in the sealing groove  40 . The O-ring  52  is formed from an elastomeric material, however any other suitable material typically used to form seals may be used. A profile of the sealing groove  40  is substantially rectangular, however any other profile shape such as a semicircle may be used. 
     Alternately, the mounting collar  14  may include a sealing element molded to the sealing groove  40 . The mounting collar  14  including the sealing element molded to the sealing groove  40  is formed by placing the mounting collar  14  within a set of molding dies corresponding to a shape of the mounting collar  14  including the sealing element. A moldable material is injected into the set of molding dies, the moldable material adhering to an exposed portion of the mounting collar  14  to form the mounting collar  14  including the sealing element molded to the sealing groove  40 . 
     The resilient seal  16  is disposed between the engine manifold  12  and the mounting collar  14 . As most clearly illustrated in  FIGS. 1 and 3 , the resilient seal  16  is an annulet having a substantially rectangular profile. The resilient seal  16  is formed from an elastomeric material, however any other suitable material typically used to form seals may be used. The resilient seal  16  is disposed on the stepped portion  24  of the engine manifold  12 . A frictional force between the resilient seal  16  and the stepped portion  24  couples the resilient seal  16  thereto. The engine manifold  12  including the resilient seal  16  disposed thereon is disposed in the manifold aperture  36  of the mounting collar  14 . A frictional force between the resilient seal  16  and the aperture wall  44  couples the resilient seal  16  to the mounting collar  14 . Alternately, an adhesive disposed between the resilient seal  16  and the stepped portion  24  couples the resilient seal  16  thereto. Further, the resilient seal  16  may be a resilient seal molded to the stepped portion  24 . The engine manifold  12  including the resilient seal  16  molded to the stepped portion  24  is formed by placing the engine manifold  12  within a set of molding dies (not shown) corresponding to a shape of the engine manifold  12  including the resilient seal  16 . A moldable material is injected into the set of molding dies, the moldable material adhering to the stepped portion  24  to form the engine manifold  12  including the resilient seal  16  molded to the stepped portion  24 . 
     Still further, the resilient seal  16  may be a resilient seal molded to the stepped portion  24  and to the mounting collar  14 , coupling the mounting collar  14  to the engine manifold  12 . The resilient seal  16  molded to the stepped portion  24  and to the mounting collar  14  is formed by placing the mounting collar  14  and the engine manifold  12  within a set of molding dies (not shown) corresponding to a shape of the mounting collar  14  and the engine manifold  12  including the resilient seal  16  molded to the stepped portion  24  and to the mounting collar  14 . A moldable material is injected into the set of molding dies, the moldable material adhering to the stepped portion  24  and to the aperture wall  44  to form the manifold assembly  10  including the resilient seal  16  molded to the stepped portion  24  and to the mounting collar  14 . 
       FIG. 4  shows an alternative embodiment of the manifold assembly for an engine. Similar structural features of the manifold assembly include the same reference numeral and a prime (′) symbol. 
     The mounting collar  14 ′ is a unitary body having a first inner surface  30 ′, a second outer surface  32 ′, a secondary protuberance  34 ′, a manifold aperture  36 ′ formed therethrough, and a fastening point (not shown) formed therein. The mounting collar  14 ′ is typically formed by stamping a metal such as a steel, but other processes such as machining may be used to form the mounting collar. As illustrated, the engine manifold  12 ′ includes one secondary protuberance  34 ′ disposed thereon. However, the mounting collar  14 ′ may include any number of secondary protuberances  34 ′. As shown in  FIG. 4 , the mounting collar  14 ′ is disposed on the engine manifold  12 ′, a resilient seal  60  including a unitarily formed interfacial seal  62  disposed between the mounting collar  14 ′ and the engine manifold  12 ′. The mounting collar  14 ′ is coupled to a cylinder head  42 ′, the second outer surface  32 ′ disposed adjacent the cylinder head  42 ′. 
     The manifold aperture  36 ′ is formed through the first inner surface  30 ′ and the second outer surface  32 ′. The first inner surface  30 ′ is substantially parallel to the second outer surface  32 ′. An aperture wall  44 ′ defines the manifold aperture  36 ′, the aperture wall  44 ′ being oblique to the first inner surface  30 ′ and the second outer surface  32 ′. An intersection of the aperture wall  44 ′ and the first inner surface  30 ′ forms a first peripheral edge  46 ′ having a substantially circular shape. An intersection of the aperture wall  44 ′ and the second outer surface  32 ′ forms a second peripheral edge  48 ′ having a substantially circular shape. A diameter of the second peripheral edge  48 ′ is greater than a diameter of the first peripheral edge  46 ′. 
     The resilient seal  60  including the unitarily formed interfacial seal  62  is disposed between the engine manifold  12 ′ and the mounting collar  14 ′. The resilient seal  60  is a tapered annulet having a thickness substantially corresponding a thickness of the mounting collar  14 ′. The unitarily formed interfacial seal  62  is a portion of the resilient seal  60  extending therefrom adjacent the second outer surface  32 ′. The unitarily formed interfacial seal  62  has an inner diameter greater than the stepped portion  24 ′ and an outer diameter greater than the diameter of the second peripheral edge  48 ′. As shown in  FIG. 4 , a portion of the unitarily formed interfacial seal  62  extends in a parallel manner from an outer wall  64  of the resilient seal  60 . The outer wall  64  is oblique to the first inner surface  30 ′ and the second outer surface  32 ′ and substantially corresponds to a shape of the aperture wall  44 ′. The unitarily formed interfacial seal  62  of the resilient seal  60  is disposed between the mounting collar  14 ′ and the cylinder head  42 ′ the mounting collar  14 ′ is coupled to. The unitarily formed interfacial seal  62  of the resilient seal  60  protrudes beyond the second peripheral edge  48 ′. The resilient seal  16 ′ including the unitarily formed interfacial seal  62  is formed from an elastomeric material, however any other suitable material typically used to form seals may be used. The resilient seal  60  including the unitarily formed interfacial seal  62  is molded to the stepped portion  24 ′ and to the mounting collar  14 ′, coupling the mounting collar  14  to the engine manifold  12 ′. The resilient seal  60  including the unitarily formed interfacial seal  62  molded to the stepped portion  24 ′ and to the mounting collar  14 ′ is formed by placing the mounting collar  14 ′ and the engine manifold  12 ′ within a set of molding dies (not shown). The set of molding dies correspond to a shape of the mounting collar  14 ′ and the engine manifold  12 ′ including the resilient seal  60  including the unitarily formed interfacial seal  62  molded to the stepped portion  24 ′ and to the mounting collar  14 ′. A moldable material is injected into the set of molding dies, the moldable material adhering to the stepped portion  24 ′ and to the aperture wall  44 ′ to form the manifold assembly  10 ′ including the resilient seal  60  including the unitarily formed interfacial seal  62  molded to the stepped portion  24 ′ and to the mounting collar  14 ′. 
     In use, the manifold assembly  10 ,  10 ′ for the engine minimizes a number of components of the manifold assembly  10 ,  10 ′ and minimizes a time of assembly of the manifold assembly  10 ,  10 ′. The resilient seal  16 ,  60  disposed between the mounting collar  14 ,  14 ′ and the engine manifold  12 ,  12 ′ simplifies a proper alignment of the mounting collar  14 ,  14 ′ and the engine manifold  12 ,  12 ′ when coupling the manifold assembly  10 ,  10 ′ to the cylinder head  42 ,  42 ′. Further, the manifold assembly  10 ,  10 ′ militates against a rotation of the engine manifold  12 ,  12 ′. As shown in  FIGS. 2-4 , the primary protuberance  22 ,  22 ′ abuts the secondary protuberance  34 ,  34 ′. When the engine manifold  12 ,  12 ′ or any attachment thereto is subjected to a force that would result in the rotation of the engine manifold  12 ,  12 ′ with respect to the mounting collar  14 ,  14 ′, abutment of the primary protuberance  22 ,  22 ′ and the secondary protuberance  34 ,  34 ′ militates against a rotation of the engine manifold  12 ,  12 ′. Accordingly, damage to the resilient seal  16 ,  60  that may result due to movement between the engine manifold  12 ,  12 ′ and the mounting collar  14 ,  14 ′ is minimized. 
     In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiments. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.