Patent Application
20160053891
The present invention relates to a compressor head. It finds particular application in conjunction with including a gasket and will be described with particular reference thereto. It will be appreciated, however, that the invention is also amenable to other applications.
Heavy vehicles commonly include a compressor for generating compressed air to run system components (e.g., air brakes) on the vehicle. Compressing air in a cylinder head can create a substantial amount of heat, which may be considered excessive if the heat is transmitted to other components (e.g., an air dryer) on the vehicle. For example, it is not uncommon for compressed air to be discharged to an air dryer for conditioning the compressed air before being used in other vehicle systems such as the air brakes. Compressed air discharged from the compressor head may be heated above a desirable temperature for the air dryer. Furthermore, the heat tends to reduce the useful life of the cylinder head and the parts therein. For example, gaskets and seals in the cylinder head tend to degrade more quickly when exposed to heat. Therefore, reducing heat in a cylinder head can extend the life of the cylinder head and other components to which the compressed air is discharged.
Some cylinder head assemblies are made up of two mating halves. One known method for improving heat transfer and lowering discharge air temperatures of such cylinder head assemblies is to use a dividing plate, which extends the full width and length of the cylinder head assembly, as an air baffle to double the discharge air velocity through the head. This design requires the use of two gaskets to allow the sealing of the upper cylinder head half and the lower cylinder head half to the air baffle. Because the air baffle is also a gasket sealing surface, the surface flatness and surface finish of the air baffle is controlled to reduce air and coolant leaks. The controlled flatness and surface finish, along with the size of the dividing baffle plate, contributes to its expense. Also, the use of multiple gaskets tends to cause additional warranty issues through coolant or air leaks since more gaskets offer more opportunities for seal failures.
The present invention provides a new and improved compressor head and gasket and method of manufacturing same.
In one embodiment, a compressor head includes an upper part, a lower part, an air baffle, and a gasket between the upper part and the lower part. The gasket includes an inner perimeter portion between, and substantially delineating, an upper inner mating portion and a lower inner mating portion of the compressor head. The gasket also includes an outer perimeter portion between, and substantially delineating, an upper outer mating portion and a lower outer mating portion of the compressor head. A tab extends toward the first volume in the compressor head from the inner perimeter portion. The tab cooperates with an upper ledge and a lower ledge of the compressor head to reduce vibration of the air baffle between the upper part and the lower part.
In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to exemplify the embodiments of this invention.
With reference to
With reference to
An upper inner mating portion 32 (upper inner shelf) defines parts of the upper portion 22 of the first volume 24 and the upper portion 26 of the second volume 30. An upper outer mating portion 34 (upper outer shelf) also defines parts of the upper portion 22 of the first volume 24 and the upper portion 26 of the second volume 30. The upper outer mating portion 34 is proximate to an upper outer perimeter 36 of the upper portion 12.
At least one upper ledge 40 extends into the upper portion 22 of the first volume 24. In the illustrated embodiment, the at least one upper ledge 40 includes fourteen (14) upper ledges 401, 402, 403, 404, 405, 406, 407, 408, 409, 4010, 4011, 4012, 4013, 4014 (collectively, 40). The upper ledges 401-11 are positioned along the upper inner mating portion 32, and the upper ledges 4012-14 are positioned along the upper outer mating portion 34.
With reference to
A lower inner mating portion 46 (lower inner shelf) defines parts of the lower portion 42 of the first volume 24 and the lower portion 44 of the second volume 30. A lower outer mating portion 50 (lower outer shelf) also defines parts of the lower portion 42 of the first volume 24 and the lower portion 44 of the second volume 30. The lower outer mating portion 50 is proximate to a lower outer perimeter 52 of the lower portion 14.
At least one lower ledge 54 extends into the lower portion 42 of the first volume 24. In the illustrated embodiment, the at least one lower ledge 54 includes fourteen (14) lower ledges 541, 542, 543, 544, 545, 546, 547, 548, 549, 5410, 5411, 5412, 5413, 5414 (collectively, 54). The lower ledges 541-11 are positioned along the lower inner mating portion 46, and the lower ledges 5412-14 are positioned along the lower outer mating portion 50.
In one embodiment, each of the lower ledges 54 is substantially aligned with a respective one of the upper ledges 40. In other words, when the lower portion 14 of the compressor head 10 is substantially aligned with the upper portion 12 of the compressor head 10, respective lower faces 56 of the lower ledges 54 are substantially aligned with respective upper faces 60 of the upper ledges 40. For ease of illustration, only the lower face 561 and upper face 601 are illustrated.
With reference to the embodiment illustrated in
With reference to
The gasket 16 includes an inner perimeter portion 62 and an outer perimeter portion 64. In one embodiment, the gasket 16 is a rubber coated steel material. The rubber coating provides a sealing surface while the steel material provides strength.
With reference to
The outer perimeter portion 64 is between the upper outer mating portion 34 and the lower outer mating portion 50 of the compressor head 10. In addition, the outer perimeter portion 64 substantially delineates the upper outer mating portion 34 and the lower outer mating portion 50 of the compressor head 10. In other words, the outer perimeter portion 64 substantially follows a path defined by both the upper outer mating portion 34 and the lower outer mating portion 50. Since the gasket 16 acts as a sealing device, the outer perimeter portion 64 provides a seal between the upper outer mating portion 34 and the lower outer mating portion 50 of the compressor head 10. Therefore, the outer perimeter portion 64 of the gasket 16 provides a seal between the second volume 30 and atmosphere along the path defined by the upper outer mating portion 34 and the lower outer mating portion 50 of the compressor head 10. The gasket 16 also provides a seal between the upper outer perimeter 36 of the upper portion 12 and the lower outer perimeter 52 of the lower portion 14.
The at least one tab 66 extends toward (e.g., into) the first volume 24 from the inner perimeter portion 62 of the gasket 16. In the illustrated embodiment, the gasket 16 includes fourteen (14) tabs 661, 662, 663, 664, 665, 666, 667, 668, 669, 6610, 6611, 6612, 6613, 6614 (collectively 66). The at least one tab 66 is substantially aligned with both the respective faces 60 of the at least one upper ledge 40 and the respective faces 56 of the at least one lower ledge 54 when the upper portion 12 is aligned with the lower portion 14. For example, the tab 661 is substantially aligned with both the respective face 601 of the at least one upper ledge 401 and the respective face 561 of the at least one lower ledge 541 when the upper portion 12 is aligned with the lower portion 14.
With reference to
A height 791 (e.g., an original height) of the at least one projection 701 along the projection axis 74 is based on a maximum expected force to be exerted on the baffle 20. In one embodiment, the original height 791 along the projection axis 74 is about 1/3 more than a distance 801 between the respective faces 601 of the at least one upper ledge 401 and the respective faces 561 of the at least one lower ledge 541, plus a maximum possible gap 811, and less a thickness 831 of the baffle 20, considering the respective tolerances of the distance 801, the gap 811, and/or the thickness 831 when the upper portion 12 and the lower portion 14 of the compressor head 10 are matingly assembled and secured together.
With reference to
The at least one flattened projection 70 does not extend into the first volume 24. More specifically, the at least one flattened projection 70 does not extend beyond the edges of the respective faces 60 of the at least one upper ledge 40 and the respective faces 56 of the at least one lower ledge 54. In other words, a surface area covered by the at least one partially flattened projection 70 is less than a surface area of the respective faces 60 of the at least one upper ledge 40; and the surface area covered by the at least partially flattened projection 70 is less than a surface area of the respective faces 56 of the at least one lower ledge 54.
The at least one tab 66 cooperates with the faces 56 of the at least one lower ledge 54 and the baffle 20 to reduce vibration of the baffle 20 between the upper portion 12 and the lower portion 14 of the compressor head 10. In one embodiment, the cooperation of the projection 70 of the at least one tab 66 with the at least one lower ledge 54 and the baffle 20 acts to frictionally secure the baffle 20 between the upper portion 12 and the lower portion 14 to reduce vibration as air flows through the first volume 24 of the compressor head 10. In the illustrated embodiment, the at least one projection 70 and the at least one tab 66 of the gasket 16 act as a means to reduce vibration of the baffle 20 between the upper portion 12 and the lower portion 14 of the compressor head 10. In the illustrated embodiment, the means to reduce vibration of the baffle 20 between the upper portion 12 and the lower portion 14 of the compressor head 10 is integrated with the inner perimeter portion 62 of the gasket 16. Also, the at least one projection 70 and the at least one tab 66 of the gasket 16 act as a vibration reduction member of the baffle 20. Other means to reduce vibration of the baffle could be a continuous bead in the gasket, a spring loaded mechanism in addition to the gasket, a projection on the upper head to mate with baffle etc.
With reference to
Because of the cooperation of the webbing portion 82 with the wall 85, fluid (e.g., coolant and/or water) entering the inlet port 84 in the lower portion 14 of the compressor head 10 is initially maintained in the first lower section 44a of the second volume 30 in the lower portion 14 of the compressor head 10. More specifically, the fluid entering the inlet port 84 is directed by at least one of the wall 85 and the webbing portion 82 to flow along a path 88 in the first lower section 44a of the second volume 30. Upon reaching a first opening 90 in the gasket 16 between the inner perimeter portion 62 and the outer perimeter portion 64 of the gasket 16, the fluid passes through the first opening 90 and into the upper portion 26 of the second volume 30. Once in the upper portion 26 of the second volume 30, the fluid travels along a path 92 in the upper portion 26 of the second volume 30 along the webbing portion 82. After the fluid reaches the end of the webbing portion 82 and has passed over the wall 85 in the lower section 44 of the second volume 30, the fluid reaches a second opening 94 in the gasket 16 between the inner perimeter portion 62 and the outer perimeter portion 64 of the gasket 16. Upon reaching the second opening 94 in the gasket 16, the fluid continues to freely flow in the upper portion 26 of the second volume 30 and is also free to flow in the second lower section 44b of the second volume 30. At this point, since the fluid can freely pass (e.g., mix) between the upper portion 26 of the second volume 30 and the second lower section 44b of the second volume 30, the fluid is illustrated as following a path 96 in the upper portion 26 of the second volume 30 and the second lower section 44b of the second volume 30. The fluid flows along the path 96 until reaching a fluid outlet port 97 of the compressor head 10. The fluid may exit the compressor head 10 via the fluid outlet port 97. It is to be understood that gasket support structures 98 between the inner perimeter portion 62 and the outer perimeter portion 64 do not significantly extend into either the upper portion 26 of the second volume 30 or the second lower section 44b of the second volume 30 and, therefore, do not obstruct the fluid flowing along the path 96.
Since the compressor head 10 is typically at elevated temperatures (e.g., >˜300° F.), maintaining the fluid (e.g., coolant and/or water) in the lower portion 14 of the compressor head 10 for at least the length of the webbing portion 82 and then in the upper portion 12 of the compressor head 10 for at least the length of the webbing portion 82 helps prevent the fluid (e.g., coolant and/or water) vaporizing (e.g., burning off). More specifically, if the fluid (e.g., coolant and/or water) enters the compressor head 10 and touches an inside wall of the compressor head 10 that is substantially dry, the fluid (e.g., coolant and/or water) may vaporize. Providing the webbing portion 82 adjacent the inlet port 84 initially restricts (e.g., maintains) the fluid (e.g., coolant and/or water) in a smaller volume (e.g., the first lower section 44a of the second volume 30 as opposed to the entire second volume 30 and then the upper portion 26 of the second volume 30 along the webbing portion 82 as opposed to the entire second volume 30) to help avoid dry areas from forming on the inner wall of the second volume 30 of the compressor head 10 and, furthermore, to help avoid the fluid (e.g., coolant and/or water) from vaporizing when entering the compressor head 10. In addition, the webbing portion 82 acts to increase coolant and/or water velocity, provide more uniform coolant and/or water flow, and reduce low heat transfer area for coolant and/or water flow.
The webbing portion 82 acts as a means for directing the fluid (e.g., coolant and/or water) passing through the second volume 30, increasing coolant and/or water velocity, providing more uniform coolant and/or water flow, and reducing low heat transfer area for coolant and/or water flow. In the illustrated embodiment, the webbing portion 82 extends along only a portion of the second volume 30. However, other embodiments in which the webbing portion 82 extends almost substantially the entire second volume 30 are also contemplated.
As illustrated, the webbing portion 82 is integrated between the inner perimeter portion 62 and the outer perimeter portion 64 of the gasket 16.
With reference to
With reference to
In a step 106, the baffle 20 is placed on the lower ledges 54. In a step 110, the tab(s) 66 extending from the inner perimeter portion 62 of the gasket 16 are placed on top of the baffle 20 and aligned with the lower face 56 of the lower ledge 54. Then, in a step 112, the tab 66 is aligned with the other of the upper face 60 of the upper ledge 40 and the lower face 56 of the lower ledge 54.
Then, in a step 114, the upper portion 12 of the compressor head 10 and the lower portion 14 of the compressor head 10 are urged together. As the upper portion 12 and the lower portion 14 are urged together, the tab 66 frictionally engages the baffle 20 and the at least one upper face 60 of the upper ledge 40, and the projection 70 frictionally engages the at least one upper face 60 of the upper ledge 40 in a step 116. The projection 70 is at least partially flattened between the baffle 20 and the upper face 60 of the upper ledge 40 in a step 120.
With reference to
With reference to
While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
