Flat Gasket and Process for Its Production

The invention relates to a flat gasket, e.g. a cylinder head gasket for an internal combustion engine, as well as to a process for its production, with at least one through opening provided with a metallic border resting on the opening edge and having a U-shaped cross-section and treated with an impregnating agent solution.

Such gaskets are frequently produced from a soft material on a sheet metal carrier. The gasket material must deform to such an extent under the sealing pressure that on fitting, the adaptation to the sealing faces necessary for sealing is obtained. When used as a cylinder head gasket, the metal border has the function of shielding the soft material against the very hot combustion gases. It must also provide a seal against the gases which are under a high pressure. The cross-sectionally U-shaped borders bent over the opening edge or rim serve to produce a locally increased surface compression for sealing against the high combustion chamber pressures. As is known, in the combustion chamber area much higher pressures are required than in the case of sealing oil and coolants.

In order to ensure an adequate microsealing and macrosealing during the first starting revolutions of a new internal combustion engine the surfaces of the border facing the engine block and cylinder head are covered with elastomeric coatings, which have to be applied in complicated, separate operations. Their basic composition often comprises a silicone-based elastomer, which crosslinks under heat action. The impregnating agents used for treating the flat gasket after stamping and bordering have a similar composition and serve as binders.

A simultaneous coating of the border and impregnation of the soft material has hitherto failed in that during the dripping process following impregnation, uncontrolled residual drip formation and accumulations on the smooth metal surface of the border are unavoidable. Therefore separate cleaning operations for the border are required, in order to obtain a clean surface as a base for a uniform coating thickness of the following elastomer coating. As the cleaning process requires both the dissolving of the accumulations in a solvent and a reliable wiping off, this operation involves relatively high costs.

The problem of the invention is to provide a flat gasket of the aforementioned type, whose manufacture is much less cost intensive, whilst giving equally good sealing characteristics.

This problem is solved in that at least one of the U-legs of the border is at least zonally provided on its outer surface with a structure, whose shape and level difference are dimensioned in such a way that the impregnating agent solution in the unstressed state is held in the structure as a result of its surface tension with an outwardly curved meniscus.

Thus, it is a basic idea of the invention that the effective surface of the border is structured in such a way that a residual quantity of the impregnating agent remains in finely divided and uniformly adhering form, so that following crosslinking an adequate microsealing and macrosealing is ensured, whilst preventing an uncontrolled accumulation of residual quantities. As the surface tension of the impregnating agent solution is known or can be readily determined, the size of the recesses can be chosen in planned manner with respect to the agent used.

The invention has the advantage that there is no need for the hitherto required intermediate stage of cleaning the border faces, whilst obviating the hitherto required subsequent coating process and at the same time the depressions can be produced in a relatively simple manner. The further advantages obtained that the inventive flat gasket can be used with a very good sealing action in the case of internal combustion engines, in which the facing surfaces to be sealed are not made from different metals and are e.g. in the form of a grey cast iron construction. The surface contour of the border in conjunction with the finely divided impregnating agent outward curvatures, as a result of the increased friction, together with the not additionally coated residual surface of the gasket, prevents a transverse movement of the engaging surfaces, but still ensures the necessary fine sealing action. This result is not only achieved after a given running-in time of the particular engine, but also immediately following installation, which can be proved by a high pressure action with a test gas. The prevention of a transverse movement is particularly significant with special engine constructions, e.g. a V-engine with a mounted V-shaped distributor, because transverse forces can occur during assembly.

Although the advantages of the invention are particularly marked in the case of flat gaskets with a soft sealing material, it is also fundamentally suitable for metal-based flat gaskets, which can be made from different sheet steel layers and a bordering of the passages.

In connection with the production process, in which a bent sheet metal strip is shaped by means of a pressing tool to a flange serving as a border, the problem is solved in that the structure is produced by a corresponding shaping out of the pressing tool, at the same time as forming the flange.

This procedure has the advantage that during the production of the structure, no additional working step is required. The tool serves both as a press die and also a pressing tool.

To reduce the pressing pr punching forces it is advantageous for the border to be formed from a steel sheet coated with a soft metal. In particularly preferred manner the coating is of aluminium.

A particularly uniform distribution of the adhering droplets is achieved through the structure comprising offset, juxtaposed crater-like depressions and elevations. Alternatively a good sealing action can also be obtained in that the structure comprises at least one preferably wedge-shaped or U-shaped groove running parallel to the opening rim.

For example, in the case of electroerosive working of the tool irregular, juxtaposed elevations and depressions are formed similar to a sandpaper surface, so that the elastomeric sealing layer is formed from a plurality of outwardly curved points or spots, which are anchored in the structure.

The production of a sealing film is further aided in that the structure comprises juxtaposed elevations and depressions. In this way a type of mountain range is formed, in which the anchoring of the sealant is particularly well ensured.

It is not necessary for the entire surface of the border to be provided with a structure. It can also be advantageous for reducing the sliding characteristics for the structure to have at least one strip of predetermined width on the particular surface of one or both U-legs. It is advantageous for producing several successively arranged sealing zones, to juxtapose several such strips in spaced manner.

Additionally or alternatively it can also be adequate for the structure to be present at predetermined points along the opening rim. This measure makes it possible to take account of particularly critical sealing points in an individual manner.

The invention is described in greater detail hereinafter relative to non-limitative embodiments and the attached drawings, wherein show:

FIG. 1 diagrammatically a plan view of a flat gasket.

FIG. 2 diagrammatically a cross-section through a border of a through opening of the flat gasket according to FIG. 1.

FIGS. 3 and 4 in each case diagrammatically a surface cross-section of the border according to FIG. 2.

FIGS. 5 and 6 in each case diagrammatically a plan view of the border according to FIG. 2.

FIG. 1 shows a cylinder head gasket with four through openings 1 as an example for a flat gasket, given the overall reference numeral 2. The flat gasket comprises a conventional union of a soft material 3 on an inner sheet steel carrier. The soft material 3 is provided in known manner with an impregnating solution of a silicone-based elastomer crosslinking under heat action.

For sealing the combustion chamber passages, the circular through openings 1 are provided with metal borders 4, which are engaged on the opening rims. The borders 4 have a U-shaped cross-section with two legs 5, between which the soft material 3 is pressed along the through opening 1. In FIG. 1 it is possible to see one of the legs 5 running horizontally in the drawing plane, whereas the other leg is concealed.

FIG. 2 illustrates a partial cross-section along section line II--II through the flat gasket 2. The cylinder head or engine block-side leg 5 and 6 are structured on their outer surface, as will be explained in greater detail hereinafter relative to FIGS. 1 to 6. A sheet metal carrier for the soft material 3 is designated 23.

The structure can comprise wedge-shaped depressions 10 and elevations 11, as shown in FIG. 3 for a single example. The depression 10 and elevation 11 can be given a crater shape with a roughly circular rim or in elongated trench-like manner. It is important for a predetermined area to be covered on the surface of the particular U-leg 5,6 at right angles to the edge of the through opening 1, either through displaced crater-like depressions 10 and/or elevations 11, or by trench-like depressions 10 and/or web-like elevations 11. The elevations 11 can be formed by piling up the material of border 4 at the edges.

The construction of depression 10 and elevation 11 is assisted by the border 4 comprising a steel sheet 12 with an aluminium coating 13.

The aforementioned impregnation of the soft material 3 takes place after the punching of the structure in the outer surfaces of legs 5,6, the punching process taking place in one operation with the pressing in of the border 4, which can also be called a flange, in the flat gasket 2. As a result of the structure, a residual quantity of the impregnating agent solution 14 adheres to the U-legs 5,6 and, after crosslinking, forms a sealing layer. The diameter and level differences of the structure 9 are such that in the unstressed state and as a result of its surface tension, the impregnating agent solution is kept in uniformly distributed manner and a meniscus 15 is formed, which is outwardly curved over the edge 16 of depression 10 or elevation 11. Thus, the capillarity of the impregnating agent solution 14 is utilized.

FIG. 4 illustrates the formation of a plateau-like elevation 17 for structuring the outer surfaces of legs 5,6. Within the plateau 17 are provided several juxtaposed rows of depressions 10' with a U-shaped cross-section. The spacing between the depressions 10' is such that the impregnating agent solution 14 of adjacent depressions 10' is linked to form a closed sealing film, as soon as the associated meniscus 15 is flattened by pressure action along the broken line 19. During the fitting of the flat gasket, a corresponding pressure is produced at its intended point when the flat gasket has been inserted between the surfaces to be sealed. A closed, all-round bead is formed by levelling following the complete polymerization of the impregnating agent solution.

By means of a sector-like cutout of leg 5 in FIG. 5, a structure pattern is reproduced, which comprises two spaced, concentric circular rings 20 with in each case a plurality of crater-like, reciprocally displaced depressions and elevations, which are in each case represented as a dot. As a result of this distribution in patterned and unpatterned areas, on the one hand the necessary minimum roughness for preventing transverse movements at the sealing point and on the other hand the desired microsealing and macrosealing are obtained.

In a further patterning example, FIG. 6 shows ring portion-like areas 21 on leg 5 with concentric, segmental trenchs and webs 22.