Title of Invention

LASER WELDED MULTI-LAYERED STEEL GASKET ASSEMBLY

Abstract Abstract The subject invention provides a method of manufacturing a multi-layered steel gasket assembly including a plurality of steel gasket layers each having a predetermined electrical resistance and including at least one coating layer of a material having an electrical resistance substantially greater than that of the steel gasket layers. The method includes the steps of: applying the coating layer of the selected material to at least one surface of at least one of the steel gasket layers to provide at least one coated gasket layer; assembling the coated gasket layer with at least one other steel gasket layer such that the coating layer prevents the use of traditional resistance welding in joining the gasket layers; and thereafter welding the assembled gasket layers together by either a JAG or C02 laser to form the multi-layered steel gasket assembly.
Full Text

LASER WELDED MULTI-LAYERED STEEL GASKET ASSEMBLY
FIELD OF THE INVENTION
[0001] The subject invention relates generally to multi-layered steel gaskets
for internal combustion engines, and more specifically to a method of manufacturing such a multi-layered steel gasket assembly.
BACKGROUND OF THE INVENTION
[0002] Multi-layered steel gaskets are traditionally used to form a seal
between two mating components of a mechanical system or device, such as an
internal combustion engine, to prevent leakage of combustion gases, cooling water,
lubricating oil, or the like. Common applications involve placing a multi-layered
steel gasket assembly between the engine block and cylinder head and between the
engine block and exhaust manifold. Cylinder head gaskets typically extend around
the cylinder bores of an engine to seal high-pressure combustion gases within the
cylinder bores as well as seal oil and coolant passages. Exhaust manifold gaskets
typically extend around the exhaust ports of an engine to seal high temperature
exhaust gases flowing into the exhaust system. Once installed, the multi-layered
steel gasket assembly bears the load from a bolted connection of the engine
components and relies upon this load to provide an adequate seal there between.
[0003] Often, in the manufacture of multi-layered steel gaskets, at least one
coating layer is disposed between a plurality of steel gasket layers to form a gasket assembly, such that the sealing ports defined by the gasket assembly axe concentric. The coating layers are substantially coextensive with the plurality of steel gasket layers.

[0004] Often, the material selected for the coating layers has inherent an
electrical insulating properties. Thus, the coating layers may have an electrical resistance substantially greater than that of the steel gasket layers, electrically insulating the plurality of steel gasket layers from each other. As such, the possibility of using resistance welding as the means of joining the plurality of steel gasket layers together is not feasible. In such cases, it is a common to secure the coated gasket layers together by means of rivets or eyelets. While effective, the use of rivets or eyelets add to the cost and complexity of manufacturing gaskets.
BRIEF SUMMARY OF THE INVENTION AND ADVANTAGES
[0005] The subject invention provides a method of manufacturing a multi-
layered steel gasket assembly comprising a plurality of steel gasket layers having a
pre-determined electrical resistance and at least one coating layer having an electrical
resistance substantially greater than that of the steel gasket layers. The coating layer
of the material is applied to at least one surface of at least one of the plurality of steel
gasket layers to provide at least one coated gasket layer. The coated gasket layer and
at least one other steel gasket layer are assembled in a desired configuration.
Thereafter, the coated gasket layer and the other steel gasket layer are welded
together by a laser to form the multi-layered steel gasket assembly.
[0006] Thus, it can be appreciated that the subject invention provides an
improved method of manufacturing a multi-layered steel gasket assembly by welding the coated gasket layer and at least one other steel gasket layer together by a laser. This method eliminates the separate operation of joining the coated gasket layer and the other steel gasket layer by rivets or eyelets, thereby improving the efficiency of the manufacturing process and reducing the cost of the multi-layered steel gasket assembly.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] Advantages of the subject invention will be readily appreciated, as the
same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawing wherein:
Figure 1 is an exploded fragmentary perspective view of a multi-layered steel gasket assembly;
Figure 2 is a fragmentary cross sectional view of a multi-layered steel gasket assembly;
Figure 3 is a fragmentary cross sectional view of another embodiment of the multi-layered steel gasket assembly;
Figure 4 is a fragmentary cross sectional view of another embodiment of the multi-layered steel gasket assembly;
Figure 5 is a fragmentary cross sectional view of another embodiment of the multi-layered steel gasket assembly;
Figure 6 is a fragmentary cross sectional view of another embodiment of the multi-layered steel gasket assembly; and
Figure 7 is a fragmentary top view of the multi-layered steel gasket assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0008] Referring to Figure 1, the subject invention provides a method of
manufacturing a multi-layered steel gasket assembly generally shown at 10 and including a plurality of steel gasket layers 12, 14, each having a predetermined electrical resistance, and including at least one coating layer 16 of a material having an electrical resistance substantially greater than that of the plurality of steel gasket layers 12, 14. The method of manufacturing the multi-layered gasket assembly 10 includes the steps of: applying the at least one coating layer 16 of the material to at least one surface 18 of at least one of the plurality of steel gasket layers 12, 14 to provide at least one coated gasket layer generally indicated at 20; assembling the at

least one coated gasket layer 20 with at least one other steel gasket layer 14; and thereafter welding the assembled gasket layers together by one of a JAG or CO2 laser to form the gasket assembly 10.
[0009] As the material chosen for the at least one coating, layer 16 has a
significantly higher electrical resistance than that of the plurality of steel gasket layers 12, 14, it is not always possible to use traditional resistance welding to weld the assembled gasket layers; for example, when the at least one coating layer 16 is disposed between the plurality of steel gasket layers 12, 14. The subject invention provides for welding the plurality of steel gasket layers 12, 14 together with a laser, wherein a weld 46 extends through the at least one coating layer 16 disposed therebetween. The weld 46 is produced by a laser, and unlike traditional resistance welding, does not require an electrical ground to operate. The laser is therefore able to produce a weld 46 between the plurality of steel gasket layers 12, 14 with the at least one coating layer 16 of significantly higher electrical resistance disposed therebetween preventing an electrical ground between the plurality of steel gasket layers 12,14.
[0010] The method of manufacturing the multi-layered steel gasket assembly
10 may further include a step of positioning the plurality of steel gasket layers 12, 14 and the at least one coating layer 16. The plurality of steel gasket layers 12, 14 and the at least one coating layer 16 are positioned in a desired configuration prior to assembly.
[0011] Referring to Figure 2, one possible configuration of the gasket
assembly 10 includes positioning a first 12 and second 14 steel gasket layer and at
least one coating layer 16 wherein the at least one coating layer 16 is disposed
between a joining surface of the first 12 and second 14 steel gasket layers.
[0012] Referring to Figures 3 and 4, a second possible configuration of the
gasket assembly 10 includes positioning a first 12 and second 14 steel gasket layer and a plurality of coating layers 16 wherein at least one of the plurality of coating layers 16 is disposed between a joining surface of the first 12 and second 14 steel

gasket layers and at least one of the plurality of coating layers 16 covers a non-
joining surface of the first 12 and/or second 14 steel gasket layers.
[0013] Referring to Figures 5 and 6, a third possible configuration of the
gasket assembly 10 includes positioning a first 12 and second 14 steel gasket layer and at least one coating layer 16 wherein a joining surface 36 of the first 12 and second 14 steel gasket layers are in direct contact with one another and the at least one coating layer 16 is in contact with a non-joining surface of the first 12 and/or second 14 steel gasket layers.
[0014] Referring to Figure 1, the method of manufacturing the multi-layered
steel gasket assembly 10 may further include a step of placing the plurality of steel
gasket layers 12,14 and the at least one coating layer 16 in a forming die.
[0015] A shaping step may also be included in the method of manufacturing
the multi-layered steel gasket assembly 10. During the shaping step, the forming die shapes the plurality of steel gasket layers 12, 14 and the at least one coating layer 16. The preferred shape of the plurality of steel gasket layers 12, 14 and the at least one coating layer includes a plurality of aligned apertures 40 formed in the plurality of steel gasket layers 12, 14 and the at least one coating layer 16; and a plurality of resilient sealing beads 42 formed in at least one of the plurality of steel gasket layers 12, 14 and around at least one of the plurality of apertures 40 defined by the plurality of steel gasket layers 12, 14.
[0016] While it is contemplated that the step of welding the assembled gasket
layers together may be performed at any time after assembling the gasket assembly 10, a preferred manufacturing process is to weld the assembled gasket layers together after the step of shaping the gasket assembly 10 and while the assembled gasket layers are in the forming die. It is possible that the step of welding the assembled gasket layers together while the assembled gasket layers are in the forming die may be performed before or after the shaping step.
[0017] A preferred material for the at least one coating layer 16 is
molybdenum, although one skilled in the art will realize that there are several alternative materials that may be utilized for their specific material properties. The

material chosen will be dependent upon the intended purpose of the gasket assembly and the required characteristics of the coating material.
[0018] As such, referring to Figures 2 and 7, a preferred embodiment of the
gasket assembly 10 produced by the method of manufacturing includes the first 12 and second 14 steel gasket layers and the coating layer 16 of molybdenum disposed therebetween. The gasket assembly is joined together by the laser weld 46 connecting the first 12 and second 14 steel gasket layers and extending through the coating layer 16.
[0019] Obviously, many modifications and variations of the present
invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than is specifically described. The invention is defined by the claims.

CLAIMS
What is claimed is:
1. A method of manufacturing a gasket assembly including a plurality of
steel gasket layers each having a predetermined electrical resistance and including at least one coating layer of a material having an electrical resistance substantially greater than that of the steel gasket layers, said method comprising the steps of:
applying the at least one coating layer of the material to at least one surface of at least one of the plurality of gasket layers to provide at least one coated gasket layer;
assembling the at least one coated gasket layer with at least one other gasket layer; and
thereafter welding the assembled gasket layers together to form the gasket assembly.
2. A method as set forth in claim 1 wherein the step of welding the
3. assembled gasket layers together is further defined as welding the assembled gasket
4. layers together by a laser.
5. A method as set forth in claim 2 wherein the step of welding the
6. assembled gasket layers together is performed by one of a JAG or CO2 laser.
7. A method as set forth in claim 1 further including the step of
8. positioning the plurality of gasket layers and the at least one coating layer wherein
9. the plurality of gasket layers and the at least one coating layer are positioned in a
10. desired configuration prior to assembly.
11. A method as set forth in claim 4 wherein the step of positioning the
12. plurality of gasket layers and the at least one coating layer is further defined as
13. positioning a first and second gasket layer and a coating layer wherein the coating
14. layer is disposed between a joining surface of the first and second gasket layers.

15. A method as set forth in claim 4 wherein the step of positioning the
16. plurality of gasket layers and the at least one coating layer is further defined as
17. positioning a first and second gasket layer and a plurality of coating layers wherein
18. at least one of the plurality of coating layers is disposed between a joining surface of
19. the first and second gasket layers and at least one of the plurality of coating layers
20. covers a non-joining surface of the first or second gasket layers.
21. A method as set forth in claim 4 wherein the step of positioning the
22. plurality of gasket layers and the at least one coating layer is further defined as
23. positioning a first and second gasket layer and a plurality of coating layers wherein
24. at least one of the plurality of coating layers is disposed between a joining surface of
25. the first and second gasket layers and at least one of the plurality of coating layers
26. covers a non-joining surface of the first and second gasket layers.
27. A method as set forth in claim 4 wherein the step of positioning the
28. plurality of gasket layers and the at least one coating layer is further defined as
29. positioning a first and second gasket layer and a coating layer wherein a joining
30. surface of the first and second gasket layers are in direct contact with one another
31. and the coating layer is in contact with a non-joining surface of the first or second
32. gasket layers.
33. A method as set forth in claim 4 wherein the step of positioning the
34. plurality of gasket layers and the at least one coating layer is further defined as
35. positioning a first and second gasket layer and a plurality of coating layers wherein a
36. joining surface of the first and second gasket layers are in direct contact with one
37. another and at least one of the plurality of coating layers is in contact with a non-
38. joining surface of the first and second gasket layers.

10. A method as set forth in claim 4 further including the step of placing
the plurality of gasket layers in a forming die prior to welding.
11. A method as set forth in claim 10 further including the step shaping
the gasket layers in the forming die.
12. A method as set forth in claim 11 wherein the step of welding the
gasket layers together is performed in the forming die.
13. A method as set forth in claim 1 wherein the coating layer material is
selected as molybdenum.
14. A gasket assembly comprising:
a first and second steel gasket layer and at least one coating layer applied to a surface of said first or second gasket layers and disposed between said first and second gasket layers;
a plurality of aligned apertures formed in said first and second gasket layers and said coating layers;
a plurality of resilient sealing beads formed in at least one of said first and second gasket layers and around at least one of said plurality of apertures defined by said first or second gasket layer; and
a laser weld directly joining said first and second gasket layers and extending through said at least one coating layer.


Documents:

2969-CHENP-2006 AMENDED CLAIMS 21-03-2012.pdf

2969-CHENP-2006 CORRESPONDENCE OTHERS 14-12-2011.pdf

2969-CHENP-2006 CORRESPONDENCE PO.pdf

2969-CHENP-2006 EXAMINATION REPORT REPLY RECEIVED 21-03-2012.pdf

2969-CHENP-2006 FORM-18.pdf

2969-CHENP-2006 FORM-3 21-03-2012.pdf

2969-CHENP-2006 OTHER PATENT DOCUMENT 21-03-2012.pdf

2969-CHENP-2006 POWER OF ATTORNEY 21-03-2012.pdf

2969-chenp-2006-abstract.pdf

2969-chenp-2006-assignement.pdf

2969-chenp-2006-claims.pdf

2969-chenp-2006-correspondnece-others.pdf

2969-chenp-2006-description(complete).pdf

2969-chenp-2006-drawings.pdf

2969-chenp-2006-form 1.pdf

2969-chenp-2006-form 3.pdf

2969-chenp-2006-form 5.pdf

2969-chenp-2006-pct.pdf


Patent Number 252314
Indian Patent Application Number 2969/CHENP/2006
PG Journal Number 19/2012
Publication Date 11-May-2012
Grant Date 08-May-2012
Date of Filing 11-Aug-2006
Name of Patentee FEDERAL-MOGUL CORPORATION
Applicant Address 26555 Northwestern Highway, Southfield, MI 48034
Inventors:
# Inventor's Name Inventor's Address
1 WADE, Lloyd, Garrold 5005 Hwy 36 East, Somerville, AL 35670
PCT International Classification Number B21D 17/02
PCT International Application Number PCT/US2004/037397
PCT International Filing date 2004-11-10
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 10/756,591 2004-01-13 U.S.A.