JP2011094759A - Gasket and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a gasket constructed by combining and welding a pair of gasket components 11 and 21 which consist of a plane gasket material covered by a seal material consisting of elastic body on the upper/lower surfaces of metal plates 12 and 22 and are produced by punching the material with a press, wherein it is free from an increase in man-hours with an excellent material yield and an increase in cost, and is stable in quality. <P>SOLUTION: The end surfaces of joint 31 of pierced gasket components 11 and 21 are applied with a rubber cement 16, wherein the application can be made to one or both sides of the end surfaces, and a film thickness of the rubber cement 16 is 5-500 μm or 5-100 μm desirably from viewpoints of sealing performance and welding quality. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a metal gasket in which a sealing material made of an elastic material is applied to both upper and lower surfaces of a metal plate, and is divided into a plurality of gasket components on a plane, and the gasket components are combined. The present invention relates to a split gasket that is welded at a joint. The gasket of the present invention is used, for example, in the field of automobiles or used in other fields.

  Conventionally, flat gaskets used for valve covers, oil pans, etc., as shown in FIG. 10, have sealing materials made of rubber-like elastic bodies on the upper and lower surfaces of a metal plate made of cold-rolled steel, stainless steel or the like. The gasket material a is deposited in layers, and the gasket material a is produced by punching into a product shape b with a press. Therefore, the remaining part c after punching out the gasket is discarded or used to produce a smaller gasket. In this regard, the larger the shape of the product, the larger the area of the remaining portion c to be discarded or reused. Therefore, when considering the target gasket alone, the yield of the material is remarkably poor and the increase in cost is avoided. It is not possible.

  In order to solve such a problem, as shown in FIG. 11, a split gasket having a structure in which a gasket is divided into a plurality of gasket components d on a plane and the gasket components d are combined and welded at a joint e is proposed. For example, in Patent Document 1 below, as shown in FIG. 12, after temporarily assembling a plurality of gasket component parts d, the joint portion e is integrated by welding f or caulking, and the joint portion e is formed on the upper and lower surfaces. A metal gasket characterized by filling and forming a covering material g made of a soft elastic sealing member has been proposed.

  However, in this metal gasket, although the yield of the material is improved, it is necessary to fill and form the coating material g after the joint portion e is integrated, so that the number of man-hours, the stability of the quality, the increase in cost, etc. There seems to be a problem.

JP 2003-336743 A Special table 2003-507660 gazette

  In view of the above points, the present invention has a good gasket material yield and does not need to be filled with a coating material at the joints of gasket components, thus increasing man-hours, improving quality stability, increasing costs, etc. It is an object of the present invention to provide a gasket and a method for manufacturing the same that do not cause a problem in this respect.

  In order to achieve the above object, a gasket according to claim 1 of the present invention is made of a planar gasket material in which a sealing material made of an elastic material is applied to both upper and lower surfaces of a metal plate, and the gasket material is punched out by a press. A gasket formed by combining and joining a set of gasket components produced in the same plane on the same plane, and a filler is applied to the joint end face of the punched gasket constituent parts, and only in the vicinity of both ends of the joint end face Is welded.

  Here, the filler is a substance that can be expected to improve the sealing performance, such as rubber glue or liquid gasket (liquid rubber), and the end face to be applied may be only one end face to be abutted or both. good. Further, since the filler is present at the joint portion of the metal plate of the gasket, the sealing performance and the reliability are greatly improved as compared with the case where the metal contacts the metal. Furthermore, the excess filler is pushed out to the upper and lower surfaces of the gasket when they are brought into contact with each other during welding, which contributes to improving the sealing performance of the rubber layers on the upper and lower surfaces of the gasket. Therefore, it is not necessary to fill and form the covering material at the joint portion of the gasket component.

  The gasket according to claim 2 of the present invention is the gasket according to claim 1 described above, wherein the gasket is provided with a seal bead so as to intersect with a joint portion of the set of gasket components. It is characterized by. The gasket is flat, but if a seal bead is made of a full bead, half bead, trapezoidal bead, etc. and the seal line is made three-dimensional, it becomes possible to locally increase the surface pressure due to the bead reaction force when the gasket is attached. Further, it becomes possible to further improve the sealing performance of the gasket.

  A gasket manufacturing method according to claim 3 of the present invention is a gasket manufacturing method for manufacturing the gasket according to claim 1, wherein the set of gasket components is formed by punching the gasket material with a press. A first step of manufacturing, a second step of applying a filler to the gasket component, and a third step of combining and welding the set of gasket components are sequentially performed. In the first step, The set of gasket components is produced by punching out the gasket material with a press, and in the second step, a filler is applied to the end face of the joint of the gasket component, and in the third step, the set of the set These gasket components are combined together, and only the vicinity of both end portions of the joint end face is welded. According to such a procedure, since a set of gasket components is punched out by pressing, it is possible to ensure ease of pressing.

  According to a fourth aspect of the present invention, there is provided a gasket manufacturing method according to the third aspect of the present invention, wherein the seal bead is formed before the first step.

  Furthermore, the gasket manufacturing method according to claim 5 of the present invention is characterized in that, in the gasket manufacturing method according to claim 3, the seal bead is formed after the third step. There is an advantage that the processing accuracy (processing accuracy with respect to the continuity of the bead) at the portion intersecting with the joint portion is good.

  The present invention has the following effects.

  That is, according to the present invention, as described above, the filler is applied to the joint end face of the punched gasket component, and only the vicinity of both ends of the joint end face is welded. Even if it does not fill and form the covering material separately in the joint portion, the sealability between the metal plates can be ensured. Therefore, as the intended purpose of the present invention, the yield of the gasket material is good, and it is not necessary to fill and form the coating material at the joint portion of the gasket component parts. It is possible to provide a gasket that does not cause any problems.

  In addition, as described above, since a set of gasket components are punched out by pressing as described above, the ease of pressing can be ensured.

  In addition, when a seal bead is provided, the sealing performance can be further enhanced by the bead reaction force, and when the seal bead is formed after the third step, the processing accuracy (the processing accuracy regarding the continuity of the bead). ) Can be secured sufficiently.

FIG. 1A is a plan view of the gasket according to an embodiment of the present invention, FIG. 1B is an enlarged cross-sectional view taken along line AA in FIG. 1A, and FIG. Is an enlarged sectional view taken along line BB in FIG. 2A is an enlarged sectional view taken along line CC in FIG. 1A, and FIG. 2B is an enlarged sectional view taken along line DD in FIG. 1A. Explanatory drawing which shows an example of the press process in the manufacturing process of the gasket Explanatory drawing which shows the other example of the press process in the manufacture process of the gasket Explanatory drawing which shows the process after a press in order of FIG. 5 (A) (B) and (C) (plan view) 6A is an enlarged view of the main part in the process after pressing. FIG. 6B is the perspective view. Explanatory drawing showing locations to be welded 8A and 8B are views showing a gasket according to another embodiment of the present invention, in which FIG. 8A is a plan view of an essential part thereof, FIG. 8B is an enlarged cross-sectional view taken along line EE in FIG. C) is an enlarged sectional view taken along line FF in FIG. The figure which shows the gasket which concerns on the other Example of this invention. Explanatory drawing which shows the press process of the integrated gasket which concerns on a prior art example Explanatory drawing which shows the press process and welding process of the split type gasket which concerns on a prior art example Sectional view of a conventional split gasket

  The present invention includes the following embodiments.

(1) As shown in FIG. 3 or FIG. 4, a gasket (gasket component) is punched out by pressing.
(2) As shown in FIG. 6, a filler, that is, rubber paste (a sealing material covering the upper and lower surfaces of the gasket dissolved in a solvent) or liquid at the center of the joint end face of the punched gasket component Apply a material that can improve sealing performance by filling gaps such as gaskets (liquid rubber).
(3) The filler may be applied to the entire end face of the joint. The end face to be applied may be only one end face to be abutted or both. In addition, when applying the filler, a large number of punched gasket components may be applied in layers, so that the filler can be applied to a number of gasket components in a single application operation. .
(4) In the case of rubber paste, the film thickness of the rubber paste after drying is 5 to 500 μm, desirably 5 to 100 μm, from the viewpoint of sealing properties and weld quality of the butt portion.
(5) The pressed product to which the rubber paste is applied is abutted and only both ends of the joint are welded as shown in FIG. The rubber layer at the welded portion is removed, but the rubber layer at the center of the joint remains without being affected by welding.
(6) In addition, since rubber paste is present at the joint of the metal plate of the gasket, it becomes metal, rubber, and metal contact. Therefore, the sealing performance and reliability are dramatically improved compared to the case of metal and metal contact. To improve. Furthermore, as shown in the figure, excessive rubber paste is pushed out to the upper and lower surfaces of the gasket during welding, contributing to an improvement in the sealing performance of the rubber layers on the upper and lower surfaces of the gasket. Therefore, unlike the invention described in Patent Document 1, it is not necessary to fill and form the covering material.

(7) In addition, it is possible to improve sealing performance by forming a bead after joining.
(8) The joint location is provided near the bolt hole (2 to 10 mm). This is because the surface pressure tends to increase because the vicinity immediately below the bolt is most tightened by the bolt axial force.
(9) The gasket split shape at the time of press working is not particularly limited, but it is desirable to set the joining locations to be 2 locations (minimum number) in consideration of the improvement of the material yield.
(10) Although the rectangular gasket is shown as an example in the following examples, the shape of the gasket is not particularly limited.
(11) After forming the bead, it is possible to change the order of the processes so as to punch out with a press and then weld the joint. It is difficult to ensure the continuity of the beads at the joint from the viewpoint of accuracy, but the cost can be further reduced.
(12) By the above, an improvement in material yield, a reduction in processing cost, and a reduction in the coating material filling process are realized.
(13) In addition, when the dimensional accuracy of a gasket is required etc., you may add suitably the process of performing the press work of a gasket inner and outer periphery, and a bolt hole after welding.

  Next, embodiments of the present invention will be described with reference to the drawings.

First embodiment ...
FIG. 1 shows a gasket according to an embodiment of the present invention. FIG. 1 (A) is a plan view of the gasket, FIG. 1 (B) is an enlarged cross-sectional view along the line AA in FIG. 1 (C) shows an enlarged sectional view taken along line BB in FIG. 1 (A). 2A is an enlarged sectional view taken along line CC in FIG. 1A, and FIG. 2B is an enlarged sectional view taken along line DD in FIG. 1A.

  The gasket according to this embodiment is a planar gasket in which sealing materials 13, 14, 23, and 24 (rubber layers) made of rubber-like elastic bodies are attached in layers on upper and lower surfaces of metal plates 12 and 22 (steel plates), respectively. The gasket 1 is manufactured by combining a set of gasket components 11 and 21 made of the material 1 and stamping the gasket material 1 with a press and welding them on the same plane. . The gasket has a planar rectangular frame shape, and the gasket components 11 and 21 are each punched into a planar L shape, and a pair (two) of them is combined into one gasket. However, in the present invention, the planar shape of the gasket and the planar shape of the gasket component parts 11 and 21 are not limited at all. Moreover, although the planar shape of the gasket component parts 11 and 21 is mutually the same, what is necessary is just to comprise one gasket and combining, and it does not necessarily need to be the same shape. The number of divisions may be three or more (especially even division is preferable), but the smaller number of joints 31 is desirable in terms of sealing performance and process, so that division into two is the best. The figure is divided into two parts, and reference numeral 31 indicates two joint parts (joint parts) between the gasket component parts 11 and 21.

As shown in FIG. 6, a filler, that is, a rubber paste 16 that is a substance that can be expected to improve the sealing performance is applied to the center portion of the end surface of the joint portion 31 of the punched gasket component parts 11 and 21. You may apply the rubber paste 16 to the end surface of the junction part 31 to the whole surface. The end face to be applied may be only one end face to be abutted or both. In the case of rubber paste, the film thickness of the rubber paste 16 after drying is 5 to 500 μm, preferably 5 to 100 μm, from the viewpoint of sealing properties and weld quality of the butt portion. The filler is not limited to rubber paste, but may be any material that can fill a gap such as a liquid gasket (liquid rubber) and can be expected to improve sealing performance.

  Further, as shown in FIGS. 2A and 2B, the pair of gasket components 11 and 21 are welded together. The welding location 32 in each junction part 31 is made into the two places of the width direction both ends in the junction part 31 (refer FIG. 7). In addition, the required number of bolt holes 15 and 25 are provided on the plane of each component part 11 and 21 so that it may penetrate in the thickness direction. The joint portion 31 is provided in the vicinity (2 to 10 mm) of the bolt holes 15 and 25. This is because the surface pressure tends to increase because the vicinity immediately below the bolt is most tightened by the bolt axial force.

  Only the both ends of the joining part 31 are welded as shown in FIG. 7 by abutting the pressed product to which the rubber paste 16 is applied. The sealing materials 13, 14, 23, and 24 (rubber layer) at the weld location 32 are removed, but the sealing materials 13, 14, 23, and 24 (rubber layer) at the center of the joint 31 are affected by welding. It remains without. Further, since the rubber paste 16 exists in the joint portion 31 of the metal plates 12 and 22 of the gasket, the metal-rubber-metal contact is made. Therefore, the sealing performance and reliability are higher than in the case of metal-metal welding. Improve dramatically. Furthermore, as shown in FIG. 6 (A), excess rubber paste 16 is pushed out to the upper and lower surfaces of the gasket during welding, contributing to an improvement in the sealing performance of the rubber layers on the upper and lower surfaces of the gasket.

  Therefore, it is possible to ensure the sealing property between the metal plates 12 and 22 without separately filling and forming the covering material in the joint portion 31 of the gasket component parts 11 and 21 as in the above prior art. ing. Therefore, since it is a split type gasket, the yield of the gasket material 1 is good, and it is not necessary to fill and form the covering material in the joint portion 31 of the gasket component parts 11, 21. It is possible to prevent problems from occurring due to an increase in cost.

  The cross-sectional shape of the joint portion 31 is cut in a direction perpendicular to the plane (vertical direction) in the drawing, but may be cut slightly obliquely.

  Next, a method for manufacturing the gasket will be described.

  3 and 4 show the pressing process. FIGS. 5A, 5B, and 5C show, in this order, the procedure after pressing with a plan view of the gasket.

  When manufacturing the gasket, first, as shown in FIG. 3 or FIG. 4, sealing materials (rubber layers) made of rubber-like elastic bodies were applied in layers on the upper and lower surfaces of the metal plates 12 and 22 (steel plates). A flat gasket material 1 is prepared, and then the gasket material 1 is punched out with a press to perform a first step of producing a plurality of gasket component parts 11 and 21, and then the gasket component parts 11 and 21 are joined. A second step of applying a filler in the vicinity of the center of the end surface of the portion 31 is performed, and then a third step of combining and welding the created gaskets one by one is performed.

  In the first step, a large number of gasket components 11 and 21 are punched out from one (FIG. 3) or two or more (multiple) (FIG. 4) gasket material 1, but all gasket components 11, 21 will be punched out.

  In the second step, as described above, at the joints 31 of the gasket component parts 11 and 21, gaps such as rubber paste 16 (a sealing material covering the upper and lower surfaces of the gasket dissolved in a solvent) or a liquid gasket, etc. Apply a material that can be expected to improve sealing performance. As shown in FIG. 6, as an application method, the rubber paste 16 is filled from the top to the bottom. The end face to be applied may be only one end face to be abutted or both. In the case of the rubber paste 16, the film thickness of the rubber paste 16 after drying is 5 to 500 μm, desirably 5 to 100 μm, from the viewpoint of sealing properties and weld quality of the butt portion.

  In the third step, the pair of gasket components are combined and welded only in the vicinity of both end portions of the joint portion 31. As shown in FIG. 7, the welding locations 32 are two locations at both ends in the width direction of the joint portion 31.

  In addition, when the dimensional accuracy of a gasket is required etc., as a 4th process, you may add suitably the process of carrying out the press work of the inner and outer periphery of a gasket, and a bolt hole after welding.

  According to the above manufacturing method, since a large number of gasket component parts 11 and 21 are punched out by pressing, the ease of pressing can be ensured.

  Although the gasket is manufactured in a flat shape, if a seal bead 33 made of a full bead, a half bead, or a trapezoidal bead is provided to form a three-dimensional seal line, the seal performance of the gasket is further enhanced by the bead reaction force in the gasket mounted state. Can be increased. In another embodiment of FIG. 8, a seal bead 33 made of a full bead is provided over the entire circumference of the gasket, and the seal bead 33 is provided so as to intersect with the joint portions 31 of the plurality of gasket components 11 and 21. Yes. The seal bead 33 is generally formed before the first step (pressing step), but may be performed after the third step (welding step). In the latter case, the seal bead 33 intersects the joint 31. There is an advantage that the processing accuracy at the part (processing accuracy for the continuity of the beads 33) is good.

  Since the crushing amount can be locally increased by providing the beads 33 in this manner, it is more effective in improving the sealing performance.

Second embodiment ...
As shown in FIG. 9, the two joint portions 31 of the two gasket component parts 11 and 21 may not be arranged on the same straight line. Since the joining part 31 does not become a straight line, it becomes difficult to bend at the time of handling.

DESCRIPTION OF SYMBOLS 1 Gasket material 11,21 Gasket component parts 12,22 Metal plate 13,14,23,24 Seal material 15,25 Bolt hole 16 Rubber paste 31 Joint part (joint part)
32 Welded point 33 Seal bead

Claims (5)

  Composed of a flat gasket material with a sealing material made of an elastic material on both the upper and lower surfaces of a metal plate, and a set of gasket components produced by punching the gasket material together on the same plane. A gasket formed by joining, wherein a filler is applied to a joint portion end face of a punched gasket component, and only the vicinity of both end portions of the joint portion end face is welded. The gasket according to claim 1,
The gasket is characterized in that a seal bead is provided so as to intersect a joint portion of the set of gasket components. A gasket manufacturing method for manufacturing the gasket according to claim 1,
A first step of producing the set of gasket components by punching out the gasket material with a press, a second step of applying a filler to the gasket components, and combining the set of gasket components with each other. The third step of welding is performed sequentially,
In the first step, the gasket material is produced by punching the gasket material with a press,
In the second step, a filler is applied to the joint end face of the gasket component,
In the third step, the set of gasket components is combined to weld only the vicinity of both end portions of the joint end face. In the manufacturing method of the gasket of Claim 3,
A method for manufacturing a gasket, comprising: forming a seal bead before the first step. In the manufacturing method of the gasket of Claim 3,
A method for producing a gasket, comprising: forming a seal bead after the third step.

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