Flat Seal Layer Connection via Edge Nesting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for connecting multi-layer flat gaskets, such as welding, riveting, and beading, result in issues like thickening, contamination, and increased costs due to chip formation and the requirement of additional components, which compromise the sealing and handling of gaskets in applications like exhaust systems and hydraulic control plates.
Innovation Solution
A connection method where the free edge of one metallic layer is bent to fit within or overlap the edge of another layer, creating a form-fit connection point without the need for additional components, allowing for secure bonding during transport and assembly without thickening or contamination, and can be applied to both coated and uncoated layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join layers, then bonding strength is improved, but contamination occurs due to weld spatter that can detach and clog through-holes
Solution Approach 1:
The harmful welding process and its byproducts (spatter) are completely removed from the joining method. Instead, a mechanical interlocking system is used where the free edge of one layer is inserted into a recess of another layer, achieving strong bonding without contamination.
Solution Approach 2:
A recess structure acts as an intermediary mechanical feature that enables layer joining without direct welding. The free edge inserts into the recess and is secured by a clamping element, providing bonding strength without the harmful effects of welding spatter.
2Strength
If riveting is used to join layers, then bonding strength is improved, but thickening occurs due to rivet protrusion beyond the sealing layers
Solution Approach 1:
The free edge of one layer is nested within the recess of another layer, creating a compact joint that does not protrude. The clamping element secures the nested structure, providing strong bonding while maintaining the flat profile of the gasket without thickening.
3Strength
If flanging edges is used to join layers, then bonding strength is improved, but device complexity increases due to specific edge design requirements
Solution Approach 1:
The joining system is segmented into distinct functional elements: a recess in one layer, a free edge in another layer, and a clamping element. This segmentation allows each component to be manufactured independently using standard tools, reducing overall complexity while achieving strong bonding.
4Strength
If conventional joining methods are used, then bonding strength is improved, but loss of substance occurs due to chip formation that can be carried into through holes
Solution Approach 1:
Instead of removing material through cutting or drilling (which creates chips), the invention uses a mechanical interlocking approach where material is displaced and deformed plastically. The free edge is bent and clamped into the recess, converting potential chip formation into beneficial plastic deformation that secures the joint without contaminating through-holes.
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
This method ensures a secure, contamination-free connection of gasket layers that avoids thickening, allowing for efficient handling and assembly, and can be implemented using simple tools, reducing costs and improving the reliability of the sealing function.
Implementation Method 1
The free edge (22) of the second layer (2) is bent such that it lies, at least partially, within the thickness of the first layer (1) or on the other side of the first layer (1), facing away from the second layer (2)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a flat seal such as those that are used in motor vehicle construction in particular. Such flat seals can be used for example as seals in the exhaust tract of internal combustion engines, as cylinder head gaskets, or also as hydraulic system control plates. Hydraulic system control plates, such as transmission control plates for example, always have a sealing function in addition to a fluid control function simultaneously.