Patent Publication Number: US-2012031364-A1

Title: Intake manifold and collar with interlocking molded seals

Description:
FIELD OF THE INVENTION 
     The present invention relates to an engine manifold and a mounting collar for the engine manifold having a resilient sleeve and a resilient annulet 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 toward a manifold assembly for an engine having an engine manifold, a mounting collar, and a resilient annulet. The mounting collar is disposed adjacent an outlet of the engine manifold and the resilient annulet is coupled to the mounting collar. 
     The engine manifold has an inlet, an outlet, a resilient sleeve, and a primary protuberance. The resilient sleeve is coupled to the outer surface of the engine manifold and the primary protuberance is formed adjacent the outlet on the outer surface of the engine manifold. 
     The mounting collar is disposed adjacent the outlet of the engine manifold. The mounting collar has a secondary protuberance and an inner peripheral wall. The inner peripheral wall defines a manifold aperture formed through the mounting collar. 
     The resilient annulet is coupled to the inner peripheral wall. The resilient annulet is sealingly engaged with the resilient sleeve. The primary protuberance abuts the secondary protuberance to prevent 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 fragementary perspective view of the manifold assembly illustrated in  FIG. 1 , a mounting collar of the assembly coupled to a cylinder head; and 
         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 . 
     
    
    
     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 comprises an engine manifold  12 , a mounting collar  14 , and a resilient annulet  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 , a resilient sleeve  22 , and a primary protuberance  24 . 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  18  and outlets  20  may be formed in the engine manifold  12 . 
     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  26 . The stepped portion  26  is formed in an outer surface  28  of the engine manifold  12  adjacent the outlet  20  of the engine manifold  12 . A depth of a stepped wall  30  is substantially equal to a thickness of the resilient sleeve  22 . 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  26  may be formed in the outer surface  28  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  28  adjacent thereto 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 mentioned hereinabove, the stepped portion  26  is formed adjacent the outlet  20  of the engine manifold  12 , onto which the resilient sleeve  16  is disposed. Alternately, the outer surface  26  of the engine manifold  12  adjacent the outlet  20  may be refined for receiving the resilient sleeve  22 . 
     As most clearly illustrated in  FIGS. 1 and 3 , the resilient sleeve  22  is an annulet having a substantially elongate rectangular profile. The substantially elongate rectangular profile of the resilient sleeve  22  substantially corresponds to a shape of the stepped portion  26 . The resilient sleeve  22  is coupled to the stepped portion  26  of the engine manifold  12  adjacent the at least one outlet  20  of the engine manifold  12 . When the resilient sleeve  22  is disposed on the stepped portion  26 , an outer surface of resilient sleeve  22  substantially corresponds to the outer surface  28  of the engine manifold  12 . The resilient sleeve  22  is formed from an elastomeric material, however any other suitable material typically used to form seals or the like may be used. 
     The resilient sleeve  22  is molded to the stepped portion  26 . The engine manifold  12  including the resilient sleeve  22  molded to the stepped portion  26  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 sleeve  22 . A moldable material is injected into the set of molding dies, the moldable material adhering to the stepped portion  26  to form the engine manifold  12  including the resilient sleeve  22  molded to the stepped portion  26 . Alternately, an adhesive disposed between the resilient sleeve  22  and the stepped portion  26  may couple the resilient sleeve  22  thereto. Further, a frictional force between the resilient sleeve  22  and the stepped portion  26  may couple the resilient sleeve  22  thereto. 
     A sealing groove  32  is formed in the resilient sleeve  22 . The sealing groove  32  is a circumferential trough shaped groove formed in the outer surface of the resilient sleeve  22 , but any other shaped groove such as a “V” shaped groove, a rectangular groove, or a semi-circular groove may be used. The sealing groove  32  is formed intermediately between a first distal end and a second distal end of the resilient sleeve  22 . However, the sealing groove  32  may be formed adjacent the first distal end or the second distal end of the resilient sleeve  22 . Further, the sealing groove  32  may be a stepped portion of the resilient sleeve  22 . At least a portion of the resilient annulet  16  is shaped to correspond to the sealing groove  32 . Alternately, the resilient sleeve  22  may include a ridge formed therewith. 
     The primary protuberance  24  is a body extending from the outer surface  28  of the engine manifold  12 . As shown, the primary protuberance  24  is a rectangular prism having a plurality of rounded edges and a rounded transitionary surface formed between the primary protuberance  24  and the outer surface  28  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  24  is formed adjacent the outlet  20  on an outer surface  28  of the engine manifold  12 . As most clearly shown in  FIG. 3 , the stepped wall  30  forms a portion of the primary protuberance  24 . Alternately, the primary protuberance  24  may be formed elsewhere on the outer surface  28  adjacent the outlet  20 . 
     The primary protuberance  24  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 in  FIG. 1 , the engine manifold  12  includes two primary protuberances  24  formed therewith, each of the primary protuberances  24  formed adjacent the outlets  20  of the engine manifold  12 . 
     The mounting collar  14  is a unitary body having a first inner surface  34 , a second outer surface  36 , a secondary protuberance  38 , a manifold aperture  40  formed therethrough, and a fastening point  42  formed therein. The mounting collar  14  is typically formed by casting a metal such as a steel, but other processes such as stamping, machining, or forging 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  38  and two fastening points  42  formed therein. However, the mounting collar  14  may include any number of secondary protuberances  38  and any number of fastening points  42  formed therein. As shown in  FIGS. 2 and 3 , the mounting collar  14  is disposed on the engine manifold  12 , the resilient annulet  16  and resilient sleeve  22  disposed therebetween. The mounting collar  14  is coupled to a cylinder head  44 , the second outer surface  36  disposed adjacent the cylinder head  44 . The collar  14  may also be coupled to a cylinder block. 
     The secondary protuberance  38  is a body extending from the first inner surface  34  of the mounting collar  14 . As shown, the secondary protuberance  38  is a rectangular prism having a plurality of rounded edges and a rounded transitionary surface formed between the secondary protuberance  38  and the first inner surface  34  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  38  is formed adjacent the manifold aperture  40  on the first inner surface  34  of the mounting collar  14 , a portion of the secondary protuberance  38  formed by an inner peripheral wall  46  defining the manifold aperture  40 . Alternately, the secondary protuberance  38  may be formed elsewhere on the first inner surface  34 . The secondary protuberance  38  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  40  is formed through the first inner surface  34  and the second outer surface  36 . The first inner surface  34  is substantially parallel to the second outer surface  36 . The inner peripheral wall  46  defines the manifold aperture  40 , the inner peripheral wall  46  being a stepped wall, as shown in  FIG. 3 . A first peripheral edge  48  located between the inner peripheral wall  46  and the first inner surface  34  has a substantially circular shape and a second peripheral edge  50  located between the inner peripheral wall  46  and the second outer surface  36  has a substantially circular shape. A diameter of the second peripheral edge  50  is greater than a diameter of the first peripheral edge  48 . 
     As illustrated, the second peripheral edge  50  may include a chamfer formed therewith and an interior peripheral edge  52  formed by the stepped wall may include a fillet formed therewith. Any other combination of chamfers and fillets may be formed with the first peripheral edge  48 , the second peripheral edge  50 , and the interior peripheral edge  52  formed by the inner peripheral wall  46 . 
     The fastening point  42  is a perforation formed through the mounting collar  14 . The fastening point  42  is a circular aperture formed outboard from the inner peripheral wall  46  in each of the diametrically opposed rounded tabs. Alternately, the fastening point  42  may be a notch formed in a peripheral edge 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 . As shown in  FIG. 2 , a threaded fastener is disposed through the fastening point  42  and into a threaded aperture (not shown) formed in the cylinder head  44 , the threaded fastener coupling the mounting collar  14  to the cylinder head  44 . 
     The resilient annulet  16  is disposed between the engine manifold  12  and the mounting collar  14 . As most clearly illustrated in  FIG. 3 , the resilient annulet  16  is an annulet having a stepped profile. The resilient annulet  16  is sealingly engaged with the resilient sleeve  22  and includes a first flange portion  54 , a second flange portion  56 , and a sealing ridge  58 . The resilient annulet  16  is formed from an elastomeric material, however any other suitable material typically used to form seals or the like may be used. 
     The resilient annulet  16  is molded to the inner peripheral wall  46 . The mounting collar  14  including the resilient annulet  16  molded to the inner peripheral wall  46  is formed by placing the mounting collar  14  within a set of molding dies (not shown) corresponding to a shape of the mounting collar  14  including the resilient annulet  16 . A moldable material is injected into the set of molding dies, the moldable material adhering to the inner peripheral wall  46  to form the mounting collar  14  including the resilient annulet  16 . Alternately, an adhesive disposed between the resilient annulet  16  and the inner peripheral wall  46  may couple the resilient annulet  16  thereto. Further, a frictional force between the resilient annulet  16  and the inner peripheral wall  46  may couple the resilient annulet  16  thereto. 
     The first flange portion  54  is a portion of the resilient annulet  16  abuttingly disposed on at least a portion of the inner peripheral wall  46  of the mounting collar  14 . A cross-sectional shape of the first flange portion  54  is substantially rectangular. A first distal end of the first flange portion  54  extends to the first peripheral edge  48 . A second distal end of the first flange portion  54  is formed with the sealing ridge  58  and a central rectangular portion  60  of the resilient annulet  16 . 
     The second flange portion  56  is a portion of the resilient annulet  16  abuttingly disposed on at least a portion of the inner peripheral wall  46  of the mounting collar  14  and extending from the central rectangular portion  60  beyond the second outer surface  36 . A cross-sectional shape of the second flange portion  56  is substantially rectangular and is substantially parallel to the first flange portion  54 . A portion of the second flange portion  56  extending beyond the second outer surface  36  forms an interfacial seal between the mounting collar  14  and the cylinder head  44 . 
     The sealing ridge  58  is a portion of the resilient annulet  16  having a substantially triangular cross-section. The sealing ridge  58  is formed between the first flange portion  54  and the second flange portion  56  and extends inboard from the central rectangular portion  60  and the first flange portion  54  of the resilient annulet  16 . A shape of the sealing ridge  58  substantially corresponds to the sealing groove  32 , forming a seal between the resilient sleeve  22  and the resilient annulet  16  when the engine manifold  12  is disposed in the mounting collar  14 . Alternately, the resilient annulet  16  may include a groove formed therewith for receiving a portion of the resilient sleeve  22 . 
     In use, the manifold assembly  10  for the engine minimizes a number of components of the manifold assembly  10  and minimizes a time of assembly of the manifold assembly  10 . The resilient annulet  16  disposed between the mounting collar  14  and the engine manifold  12  simplifies a proper alignment of the mounting collar  14  and the engine manifold  12  when coupling the manifold assembly  10  to the cylinder head  44 . Further, the manifold assembly  10  militates against a rotation of the engine manifold  12 . As shown in  FIGS. 2-3 , the primary protuberance  24  abuts the secondary protuberance  38 . When the engine manifold  12  or any attachment thereto is subjected to a force that would result in the rotation of the engine manifold  12  with respect to the mounting collar  14 , abutment of the primary protuberance  24  and the secondary protuberance  38  militates against a rotation of the engine manifold  12 . Accordingly, damage to the resilient sleeve  22  and the resilient annulet  16  that may result due to movement between the engine manifold  12  and the mounting collar  14  is also 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.