Flat Metallic Seal With Folded Support Layers
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Solution Overview
Problem
Flat gaskets in high-temperature exhaust gas areas of internal combustion engines face challenges due to uneven compression forces and thermal expansions, leading to leakage issues, as classic spring steel gaskets lose spring-elastic properties at elevated temperatures and cannot adapt to changing sealing gap topography.
Innovation Solution
A flat gasket design featuring gasket layers of different thicknesses with folded sections forming support devices that provide varying effective heights, stabilizing the sealing gap topography and preventing excessive deformation of sealing beads, achieved through the use of gasket layers of different thicknesses or coatings, and embossing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If classic spring steel gaskets are used in high-temperature exhaust gas areas, then the gasket provides initial sealing capability, but the spring-elastic properties are lost at elevated temperatures (approx. 400°C) and the gasket cannot adapt to changing sealing gap topography
Solution Approach 1:
The gasket is divided into multiple functional layers: a first gasket layer with sealing beads for sealing, and a second gasket layer with support devices for structural support. This segmentation allows each layer to perform its specialized function independently - the sealing layer maintains elasticity for adaptation while the support layer provides thermal stability
Solution Approach 2:
The gasket uses a composite structure combining different material properties in each layer. The first layer uses spring steel for elastic sealing, while the second layer uses a thicker, more thermally stable material for support. This composite approach allows the gasket to maintain both adaptability and stability at high temperatures
2Strength
If assembly screws are used to clamp the gasket between flanges, then the flange connection is secured, but compression forces are applied selectively and unevenly, creating local fluctuations in compressive forces that cause sealing gaps to vary in width
Solution Approach 1:
The support devices are strategically positioned at specific locations between assembly screws where compression forces are weakest. These localized support structures provide additional stiffness precisely where needed, compensating for the uneven force distribution without requiring changes to the overall fastening system
Solution Approach 2:
The support devices extend in the thickness direction (z-dimension) of the gasket, creating a three-dimensional structure that bridges the gap between flanges. This vertical extension allows the support devices to span across sealing gaps and provide structural reinforcement that counteracts uneven compression from the screws
3Stability of the object's composition
If the gasket plate material thickness is increased to provide better support and stabilize sealing gap topography, then the structural support and sealing stability are improved, but the gasket loses its ability to adapt to topography changes and the compression forces increase
Solution Approach 1:
The gasket thickness is segmented into two distinct layers with different thicknesses. The first layer remains relatively thin to maintain adaptability and reduce compression forces, while the second layer is thicker to provide the necessary structural support and stabilize the sealing gap topography. This segmentation allows the gasket to achieve both stability and adaptability simultaneously
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design ensures a stable sealing performance across varying temperatures and operational conditions by maintaining effective sealing even under high compressive forces and thermal fluctuations, preventing leakage and maintaining the spring-elastic properties of the gasket layers.
Implementation Method 1
the support device is formed by several folded gasket layer sections and increases the total material thickness of the gasket plate in some areas
Data Source
Figure 1
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AI summary
The invention relates to a flat seal having a sealing plate (10), which has at least two sealing layers (16, 18) arranged one on top of the other and in which at least one passage opening (12) to be sealed is formed. The sealing plate has at least one supporting device (20, 22) that increases the total material thickness of the sealing plate in some areas and that is formed by several folded-over sealing layer sections(161, 181). According to the invention, in order to be able to simply and economically create a supporting device having locally different effective heights, such a flat seal is designed in such a way that the sealing plate (10) has at least one first sealing layer (16) having at least one first layer area in which the first sealing layer (16) has a first layer thickness and in which at least one first folded-over sealing layer section (161) of a supporting device is formed, and the sealing plate has at least one second sealing layer (18) having at least one second layer area in which the second sealing layer has a second layer thickness and in which at least one second folded-over sealing layer section (181) of said supporting device is formed, wherein the first and the second layer thickness are different from each other, such that said supporting device (20, 22) has different total material thicknesses in some areas.