Patent Application
20130277965
The present invention relates to a cylindrical gasket which is suitably used for an insertion-type exhaust pipe joint used in a motor vehicle such as an ATV (All Terrain Vehicle: a four-wheeled buggy), a snowmobile, and a two-wheeled vehicle, a method of manufacturing the same, and an insertion-type exhaust pipe joint using the cylindrical gasket.
An insertion-type exhaust pipe joint includes an inner pipe and an outer pipe having an inside diameter substantially identical to the outside diameter of this inner pipe, wherein the outer pipe has an enlarged-diameter end portion at its pipe end portion, and the inner pipe has a pipe end portion which is passed through the enlarged-diameter portion of the outer pipe and is fitted at its one end portion to the pipe end portion of the outer pipe, and wherein a gasket is fitted in an annular gap between the pipe end portion of the inner pipe and the enlarged-diameter portion of the outer pipe so as to seal the gap between the inner and outer pipes by a tightening band which is disposed on the outer peripheral surface of the outer pipe (refer to Patent Document 1, Patent Document 2, and Patent Document 3).
Further, as a gasket which is used for the above-described exhaust pipe joint, a gasket has been proposed wherein a strip is formed by cutting an expanded graphite sheet into a fixed width and length, a metal wire net cut to a length substantially identical to the length of the expanded graphite sheet is superposed on this strip, this superposed assembly is convoluted around a cylindrical core with the metal wire net placed on the inner side to fabricate a hollow cylindrical member, and this hollow cylindrical member is inserted in a die and is subjected to compression forming in its axial direction, whereby the metal wire net or the expanded graphite is exposed on its inner peripheral surface, and its opposite end faces and its outer peripheral surface are covered by the expanded graphite (refer to Patent Document 1 and Patent Document 3).
In addition, there has also been proposed an annular gasket wherein a gasket main body is provided by enclosing overall surfaces of an expanded graphite sheet by a metallic net, and the gasket main body is curved into a an annular shape and is compressed by a press machine such that the expanded graphite and the net are integrally secured to each other (refer to Patent Document 4).
In the expanded graphite which is used in the gasket proposed in the above-described Patent Documents 1 to 3, its characteristics such as heat resistance, chemical resistance, and low-friction property are substantially equivalent to those of normal graphite; however, such expanded graphite can be easily formed into a thin sheet or a block by being subjected to pressurization without using a binder, and an object thus obtained has a characteristic of being pliable and flexible unlike the aforementioned graphite.
Accordingly, the gasket, which is formed of expanded graphite and a metal wire net and is disposed between the inner pipe and an enlarged-diameter portion of the outer pipe of the exhaust pipe joint, undergoes expansion in volume due to the heat of exhaust gases flowing through the inner pipe and has pliability and flexibility, so that the gasket is capable of adapting itself well and fits to the gap between the inner pipe and the outer pipe, thereby making it possible to improve the sealability between the inner pipe and the outer pipe (refer to Patent Document 1).
In recent years, however, the exhaust pipe had become large in size as a countermeasure for noise, and a catalytic converter has come to be mounted on the exhaust pipe as an emission control measure, so that an excessively large load has come to be applied to the insertion-type exhaust pipe joint. Due to traveling on a rough road, in particular, the joint is repeatedly subjected to vibrational load and bending torque, and prying repeatedly occurs between the inner and outer pipes.
With respect to the vibrational load, bending torque, and prying which repeatedly occur, the gasket is required to have pliability needed to exhibit sealability as well as rigidity for receiving a tightening force without the occurrence of a permanent set at the time of tightening with a tightening band. With respect to these two conflicting performances, the above-described conventional gaskets are respectively specialized in either one of the performances of pliability and rigidity, and it is difficult to render both performances compatible. As a result, in the case of a gasket which is specialized in rigidity, a problem occurs in sealability, while, in the case of a gasket which is specialized in pliability, a problem can possibly occur in that sealability of the gap between the inner and outer pipes is caused to decline due to such as the loosening of the tightening band etc. caused by such as the permanent set of the gasket etc.
The present invention has been devised in view of the above-described aspects, and its object is to provide a cylindrical gasket which is suitably used for an insertion-type exhaust pipe joint and which has both pliability contributing to sealability and rigidity for receiving the tightening force exerted by the tightening band, as well as a method of manufacturing the same, and an insertion-type exhaust pipe joint using the cylindrical gasket.
A cylindrical gasket for use in an insertion-type exhaust pipe joint in accordance with the present invention comprises: a reinforcing member made from a metal wire net and compressed and a heat-resistant material made from expanded graphite compressed and filling meshes of the metal wire net of the reinforcing member, wherein the reinforcing member and the heat-resistant material are intertwined with each other so as to be provided with structural integrity, the density of the heat-resistant material is in a range of 1.21 to 1.58 Mg/m3, and the mass of the reinforcing member occupies 50 to 80% of a total mass.
According to the present invention, since the reinforcing member made from the metal wire net and compressed occupies 50 to 80% of the total mass, the tightening force exerted by the tightening band and the load applied by vibrations can be received mainly by the reinforcing member made of the metal wire net, with the result that a permanent set is unlikely to occur. In addition, since the density of the heat-resistant material is in the range of 1.21 to 1.58 Mg/m3, it is possible to sufficiently obtain the pliability required for sealability. Therefore, it is possible to provide a cylindrical gasket which is suitably used for an insertion-type exhaust pipe joint and which has the two conflicting performances of pliability and rigidity.
A first method of manufacturing a cylindrical gasket in accordance with the present invention, which is suitably used for an insertion-type exhaust pipe joint and includes the reinforcing member made from the metal wire net and compressed and the heat-resistant material made from the expanded graphite compressed and filling meshes of the metal wire net of the reinforcing member, the reinforcing member and the heat-resistant material being intertwined with each other so as to be provided with structural integrity, an inner peripheral surface, an outer peripheral surface, and both end faces being each formed by a surface constituted of the heat-resistant material, the density of the heat-resistant material being in a range of 1.21 to 1.58 Mg/m3, and the mass of the reinforcing member occupying 50 to 80% of a total mass, comprises the steps of: (1) preparing a heat-resistant material constituted by an expanded graphite sheet having a density of 1.0 to 1.15 Mg/m3 and a thickness of 0.3 to 0.6 mm; (2) preparing a reinforcing member made from a metal wire net which is obtained by weaving or knitting a fine metal wire, and fabricating a superposed assembly in which the heat-resistant material and the reinforcing member are superposed on each other such that one lengthwise end of the reinforcing member and a lengthwise end of the heat-resistant material corresponding to that one end are aligned; (3) convoluting the superposed assembly around an outer peripheral surface of a cylindrical core with the heat-resistant material placed on an inner side such that the heat-resistant material is convoluted with one more turn, to thereby form a tubular base member in which the heat-resistant material is exposed on both an inner peripheral side and an outer peripheral side; and (4) inserting the tubular base member into a cylindrical hollow portion of a die, and subjecting the tubular base member to compression forming in the die in an axial direction thereof.
A second method of manufacturing a cylindrical gasket in accordance with the present invention, which is suitably used for an insertion-type exhaust pipe joint and includes the reinforcing member made from the metal wire net and compressed and the heat-resistant material made from the expanded graphite compressed and filling meshes of the metal wire net of the reinforcing member, the reinforcing member and the heat-resistant material being intertwined with each other so as to be provided with structural integrity, an inner peripheral surface, an outer peripheral surface, and both end faces being each formed by a surface where a surface constituted of the heat-resistant material and a surface constituted of the reinforcing member are present in mixed form, the density of the heat-resistant material being in a range of 1.21 to 1.58 Mg/m3, and the mass of the reinforcing member occupying 50 to 80% of a total mass, comprises the steps of: (1) preparing a heat-resistant material constituted by an expanded graphite sheet having a density of 1.0 to 1.15 Mg/m3 and a thickness of 0.3 to 0.6 mm; (2) inserting the heat-resistant material between two layers of a reinforcing member made from a metal wire net which is obtained by weaving or knitting a fine metal wire, and feeding the reinforcing member having the inserted heat-resistant material between the two layers into a nip between a pair of rollers so as to be pressurized and to fill the heat-resistant material in meshes of the metal wire net of the reinforcing member, to thereby form a flattened composite sheet which has both surfaces where a surface constituted of the reinforcing member and a surface constituted of the heat-resistant material are exposed in mixed form and portions where the heat-resistant material is not filled on both widthwise sides of the reinforcing member; (3) convoluting the flattened composite sheet around a core with at least three turns to thereby form a tubular base member; and (4) inserting the tubular base member into a cylindrical hollow portion of a die, and subjecting the tubular base member to compression forming in the die in an axial direction thereof.
According to the first and second methods of manufacturing a cylindrical gasket in accordance with the present invention, since the cylindrical gasket is manufactured such that, in the relation between the density of the heat-resistant material made from the expanded graphite and the mass of the reinforcing member made from the metal wire net, the density of the heat-resistant material is in the range of 1.21 to 1.58 Mg/m3, and the mass of the reinforcing member occupies 50 to 80% of the total mass, it is possible to obtain a cylindrical gasket which has both pliability contributing to sealability and rigidity for receiving the tightening force exerted by the tightening band.
An insertion-type exhaust pipe joint in accordance with the present invention comprises: an outer pipe having a pipe end portion, an enlarged-diameter cylindrical portion having an enlarged diameter and provided to the pipe end portion via an annular shoulder portion, an open end portion provided at one axial end portion of the enlarged-diameter cylindrical portion, a flange portion provided on an outer peripheral surface of the open end portion in such a manner as to extend radially outwardly, and a plurality of slits provided in the enlarged-diameter cylindrical portion and in the flange portion in such a manner as to extend axially from an annular end face of the open end portion and to be arranged equidistantly in a circumferential direction; an inner pipe having a pipe end portion which is passed through an interior of the enlarged-diameter cylindrical portion of the outer pipe and is fitted at its one end portion to the pipe end portion of the outer pipe, and a flange which is provided uprightly on an cylindrical outer surface of another end portion of the pipe end portion; the above cylindrical gasket which is fitted in an annular gap between a cylindrical outer surface of the pipe end portion of the inner pipe and a cylindrical inner surface of the pipe end portion of the outer pipe; and a tightening band which is disposed on a cylindrical outer surface of the enlarged-diameter cylindrical portion of the outer pipe so as to press the cylindrical inner surface of the pipe end portion of the outer pipe against the cylindrical outer peripheral surface of the cylindrical gasket by being tightened, through which pressing the tightening band presses the cylindrical inner peripheral surface of the cylindrical gasket against the cylindrical outer surface of the pipe end portion of the inner pipe, the cylindrical gasket in the annular gap being disposed with an annular end face of its one axial end portion abutting against the flange of the inner pipe.
According to the insertion-type exhaust pipe joint in accordance with the present invention, since the density of the heat-resistant material is in the range of 1.21 to 1.58 Mg/m3 and the mass of the reinforcing member occupies 50 to 80% of the total mass, the cylindrical gasket, which is fitted in the annular gap between the outer peripheral surface of the pipe end portion of the inner pipe and the cylindrical inner surface of the enlarged-diameter cylindrical portion of the outer pipe, has both pliability contributing to sealability and rigidity for receiving the tightening force exerted by the tightening band. As a result, sealability of the gap between the inner pipe and the outer pipe is improved, thereby preventing leakage of exhaust gases from the gap as practically as possible.
According to the present invention, since the density of the heat-resistant material made from expanded graphite is in the range of 1.21 to 1.58 Mg/m3 and the mass of the reinforcing member made from a metal wire net occupies 50 to 80% of the total mass, it is possible to provide a cylindrical gasket which has both pliability contributing to sealability and rigidity for receiving the tightening force exerted by the tightening band and a method of manufacturing the same, as well as an insertion-type exhaust pipe joint which, by incorporating the cylindrical gasket, is capable of improving sealability of the gap between the inner pipe and the outer pipe and of preventing leakage of exhaust gases from the gap as practically as possible.
Next, a more description will be given of the present invention and a mode for carrying it out on the basis of the preferred embodiments illustrated in the drawings. It should be noted that the present invention is not limited to these embodiments.
A description will be given of constituent materials of a cylindrical gasket and a method of manufacturing the cylindrical gasket in accordance with the invention.
While concentrated sulfuric acid of a 98% concentration is being agitated, a 60% aqueous solution of hydrogen peroxide is added to it as an oxidizing agent, and this solution is used as a reaction solution. This reaction solution is cooled and kept at a temperature of 10° C., natural flake graphite powder having a particle size of 30 to 80 meshes is added to the reaction solution, and reaction is allowed to take place for 30 minutes. After the reaction, acid-treated graphite powder is separated by suction filtration, and a cleaning operation is repeated twice in which the acid-treated graphite powder is agitated in water for 10 minutes and is then subjected to suction filtration, thereby sufficiently removing the sulfuric acid content from the acid-treated graphite powder. Then, the acid-treated graphite powder with the sulfuric acid content sufficiently removed is dried for 3 hours in a drying furnace held at a temperature of 110° C., and this is used as an acid-treated graphite powder.
The above-described acid-treated graphite powder is subjected to heating (expansion) treatment for 1 to 10 seconds at temperatures of 950 to 1200° C. to produce cracked gas. The gaps between graphite layers are expanded by its gas pressure to form expanded graphite particles (expansion rate: 240 to 300 times). These expanded graphite particles are fed to a twin roller apparatus adjusted to a desired roll nip and is subjected to roll forming, thereby fabricating an expanded graphite sheet having a desired thickness. This expanded graphite sheet is used as a heat-resistant material.
As the heat-resistant material, a sheet material having a density of 1.0 to 1.15 Mg/m3 or thereabouts and a thickness of 0.3 to 0.6 mm or thereabouts is preferably used.
As a reinforcing member, a woven or knitted metal wire net is used which is formed by weaving or knitting one or more fine metal wires including, as an iron-based wire, a stainless steel wire made of such as austenitic stainless steels SUS 304, SUS 310S, and SUS 316, a ferritic stainless steel SUS 430, or an iron wire (JISG3532) or a galvanized steel wire (JISG3547), or, as a copper wire, a wire member made of a copper-nickel alloy (cupro-nickel) wire, a copper-nickel-zinc alloy (nickel silver) wire, a brass wire, or a beryllium copper wire.
As the fine metal wire for forming the metal wire net, a fine metal wire whose diameter is 0.20 to 0.32 mm or thereabouts is used. In terms of the mesh size of the metal wire net (see
Next, referring to the drawings, a description will be given of a method of manufacturing a cylindrical gasket which is constituted of the above-described constituent materials.
A heat-resistant material 1 is prepared which is constituted by an expanded graphite sheet having a density of 1.0 to 1.15 Mg/m3, a thickness of 0.3 to 0.6 mm, a width of d, and a length of 1 (see
As shown in
As shown in
As shown in
A die 16 such as the one shown in
The tubular base member 11 disposed in the hollow cylindrical portion 15 of the die 16 is subjected to compression forming by a punch 17 under a pressure of 98 to 294 N/mm2 (1 to 3 tons/cm2) in the direction of the core axis. Thus, the cylindrical gasket 23 is fabricated which includes the cylindrical inner peripheral surface 19 defining a through hole 18, the cylindrical outer peripheral surface 20, and the annular end faces 21 and 22, as shown in
In the cylindrical gasket 23 fabricated by the compression forming of the tubular base member 11, the heat-resistant material 1 made from the expanded graphite and the reinforcing member 2 made from the metal wire net are provided with structural integrity by being compressed and intertwined with each other. The inner peripheral surface 19, the outer peripheral surface 20, and the end faces 21 and 22 of the cylindrical gasket 23 are each formed by a surface constituted of the heat-resistant material 1, and in the cylindrical gasket 23, the density of the heat-resistant material 1 is in the range of 1.21 to 1.58 Mg/m3, and the mass of the reinforcing member 2 occupies 50 to 80% of the total mass of the cylindrical gasket 23.
In the same way as the above-described first manufacturing method, a heat-resistant material 1 is prepared which is constituted by an expanded graphite sheet having a density of 1.0 to 1.15 Mg/m3 and a thickness of 0.3 to 0.6 mm (see
In the same way as the above-described heat-resistant material 1, a heat-resistant material 1 having a width d smaller than the diameter of the reinforcing member 2 is continuously inserted (see
As shown in
As shown in
In the above-described first and second fabricating methods, the nip Δ1 between the pair of cylindrical rollers 24 and 25 and the pair of rollers 31 and 32 is appropriately 0.4 to 0.6 mm or thereabouts.
The reinforcing member 2 which is made from the metal wire net in this composite sheet 30 provides the amount of the reinforcing member 2 occupied in the final cylindrical gasket, and is adjusted by the mesh size of the metal wire net of the reinforcing member 2, the diameter of the fine metal wire forming the metal wire net, and the metal wire net which is formed by one-wire knitting or two-wire knitting of the fine metal wire.
A tubular base member 33 is fabricated by convoluting the flattened composite sheet 30 around a cylindrical core by a three-circumference portion (see
A die 16 similar to that of the above-described first method is prepared, and the tubular base member 33 is fitted over the stepped core 14 of the die 16.
The tubular base member 33 disposed in the hollow cylindrical portion 15 of the die 16 is subjected to compression forming by the punch 17 under a pressure of 98 to 294 N/mm2 (1 to 3 tons/cm2) in the direction of the core axis. Thus, the cylindrical gasket 23 is fabricated which includes the cylindrical inner peripheral surface 19 defining the through hole 18, the cylindrical outer peripheral surface 20, and the annular end faces 21 and 22, as shown in
In the cylindrical gasket 23 fabricated by the compression forming of the tubular base member 33, the heat-resistant material 1 made from the expanded graphite and the reinforcing member 2 made from the metal wire net are provided with structural integrity by being compressed and intertwined with each other. The cylindrical inner peripheral surface 19, the cylindrical outer peripheral surface 20, and the axial annular end faces 21 and 22 which are exposed on the cylindrical gasket 23 are each formed by a surface where a surface constituted of the heat-resistant material 1 and a surface constituted of the reinforcing member 2 are present in mixed form, and in the cylindrical gasket 23, the density of the heat-resistant material 1 is in the range of 1.21 to 1.58 Mg/m3, and the mass of the reinforcing member 2 occupies 50 to 80% of the total mass of the cylindrical gasket 23.
The cylindrical gasket 23 which exhibits the above-described properties is used by being incorporated in an insertion-type exhaust pipe joint shown in
In the above-described insertion-type exhaust pipe joint, a hook portion 56 projecting radially inwardly is provided at one end portion 54 of the axial end portions 54 and 55 of the tightening band 49. The hook portion 56 has a cross section similar to that of a notched portion 57 formed in the flange portion 38 of the enlarged-diameter cylindrical portion 36 of the outer pipe 40, and when the tightening band 49 is fitted on the outer peripheral surface 48 of the enlarged-diameter cylindrical portion 36 of the outer pipe 40, the hook portion 56 freely passes through the notched portion 57 formed in the flange portion 38, and is brought into contact at its inner surface with an axial side surface of the flange 43 of the inner pipe 44 and engages the flange 43 of the inner pipe 44, so that the outer pipe 40 at its flange portion 38 axially engages the tightening band 49. As a result, even if a force which tends to separate the inner pipe 44 and the outer pipe 40 in the axial direction, the inner pipe 44 and the outer pipe 40 are prevented from becoming disengaged from each other in the axial direction.
It should be noted that, in the present invention, with the cylindrical gasket 23 whose rigidity has been enhanced, since such defects as the permanent set are not produced even by a large tightening force exerted by the tightening band 49, the hook portion 56 formed on the tightening band 49 and the notched portion 57 formed in the flange portion 38 of the outer pipe 40 may not necessarily be provided.
Next, the present invention will be described in detail in accordance with examples. It should be noted that the present invention is not limited to these examples.
A heat-resistant material constituted by an expanded graphite sheet having a density of 1.0 Mg/m3 and a thickness of 0.4 mm was prepared.
By using one austenitic stainless steel wire (SUS 304) having a wire diameter of 0.28 mm as a fine metal wire, a cylindrical knitted metal wire net whose mesh size was 2 mm long and 2.5 mm wide or thereabouts was fabricated and was passed between a pair of rollers to form a belt-shaped metal wire net, and this metal wire net was used as the reinforcing member.
A superposed assembly was fabricated in which the heat-resistant material and the reinforcing member were superposed on each other such that the heat-resistant material projected in the widthwise direction from both widthwise ends of the reinforcing member, which serve as annular end faces of the cylindrical gasket, and such that one lengthwise end of the reinforcing member and a lengthwise end of the heat-resistant material corresponding to that one end were aligned.
The superposed assembly was convoluted around the outer peripheral surface of a cylindrical core with the heat-resistant material placed on the inner side such that the heat-resistant material was convoluted with one more turn, thereby fabricating tubular base member in which the heat-resistant material was exposed on both the inner peripheral side and the outer peripheral side. In this tubular base member, both axial end portions of the heat-resistant material respectively projected from the reinforcing member in the axial direction thereof.
The die shown in
The tubular base member disposed in the hollow cylindrical portion of the die was subjected to compression forming under a pressure of 196 N/mm2 (2 tons/cm2) in the direction of the core axis. Thus, a cylindrical gasket was fabricated which included the cylindrical inner peripheral surface defining the through hole, the cylindrical outer peripheral surface, and the annular end faces. In this cylindrical gasket, the density of the heat-resistant material was 1.21 Mg/m3, and the mass of the reinforcing member occupied 60% of the mass of the cylindrical gasket.
A heat-resistant material constituted by an expanded graphite sheet having a density of 1.0 Mg/m3 and a thickness of 0.4 mm was prepared.
By using one austenitic stainless steel wire having a wire diameter of 0.28 mm as a fine metal wire, a cylindrical knitted metal wire net whose mesh size was 4 mm long and 5 mm wide was fabricated and was passed between a pair of rollers to form a belt-shaped metal wire net, and this metal wire net was used as the reinforcing member.
In a method similar to that of Example 1, a cylindrical gasket was fabricated which included the cylindrical inner peripheral surface defining the through hole, the cylindrical outer peripheral surface, and the annular end faces. In this cylindrical gasket, the density of the heat-resistant material was 1.23 Mg/m3, and the mass of the reinforcing member occupied 58% of the mass of the cylindrical gasket.
A heat-resistant material constituted by an expanded graphite sheet having a density of 1.15 Mg/m3 and a thickness of 0.4 mm was prepared.
A reinforcing member similar to that of Example 1 was used as the reinforcing member.
Thereafter, a cylindrical gasket was fabricated in a method similar to that of Example 1. In this cylindrical gasket, the density of the heat-resistant material was 1.30 Mg/m3, and the mass of the reinforcing member occupied 63% of the mass of the cylindrical gasket.
As the heat-resistant material, a heat-resistant material similar to that of Example 3 and constituted by an expanded graphite sheet having the density of 1.15 Mg/m3 and the thickness of 0.4 mm was prepared.
The heat-resistant material was continuously inserted into the interior of the reinforcing member made from a hollow cylindrical knitted metal wire net which was obtained by using one austenitic stainless steel wire having a wire diameter of 0.28 mm as a fine metal wire and whose mesh size was 4 mm long and 5 mm wide. The reinforcing member having the heat-resistant material inserted therein was fed, starting with its insertion start end side, into a nip (0.5 mm) between a pair of cylindrical rollers each having a smooth cylindrical outer peripheral surface, so as to be pressurized in the thicknesswise direction of the heat-resistant material and integrate the heat-resistant material made from the expanded graphite sheet and the reinforcing member made from the hollow cylindrical knitted metal wire net, such that the heat-resistant material was filled in the meshes of the metal wire net of the reinforcing member. Thus, a flattened composite sheet was fabricated which had both surfaces where a surface constituted of the reinforcing member and a surface constituted of the heat-resistant material were exposed in mixed form, as well as portions where the heat-resistant material was not filled on both widthwise sides of the reinforcing member.
Thereafter, a cylindrical gasket was fabricated in a method similar to that of Example 1 described above. In this cylindrical gasket, the density of the heat-resistant material was 1.42 Mg/m3, and the mass of the reinforcing member occupied 75% of the mass of the cylindrical gasket.
A heat-resistant material constituted by an expanded graphite sheet having a density of 1.15 Mg/m3 and a thickness of 0.4 mm was prepared.
The heat-resistant material was continuously inserted into the interior of the reinforcing member made from a hollow cylindrical knitted metal wire net obtained by using two austenitic stainless steel wires (SUS 304) having a wire diameter of 0.28 mm as a fine metal wire. The reinforcing member having the heat-resistant material inserted therein was fed, starting with its insertion start end side, into a nip (0.45 mm) between a pair of cylindrical rollers each having a smooth cylindrical outer peripheral surface, so as to be pressurized in the thicknesswise direction of the heat-resistant material and integrate the reinforcing member and the heat-resistant material, such that the heat-resistant material was filled in the meshes of the metal wire net of the reinforcing member. Thus, a flattened composite sheet was fabricated which had both surfaces where a surface constituted of the reinforcing member and a surface constituted of the heat-resistant material were exposed in mixed form, as well as portions where the heat-resistant material was not filled on both widthwise sides of the reinforcing member.
Thereafter, a cylindrical gasket was fabricated in a method similar to that of Example 1 described above. In this cylindrical gasket, the density of the heat-resistant material was 1.52 Mg/m3, and the mass of the reinforcing member occupied 80% of the mass of the cylindrical gasket.
A heat-resistant material constituted by an expanded graphite sheet having a density of 1.0 Mg/m3 and a thickness of 0.4 mm was prepared.
A hollow cylindrical knitted metal wire net, which was obtained by continuously knitting by a knitting machine (not shown) by using one austenitic stainless steel wire having a wire diameter of 0.15 mm as a fine metal wire and whose mesh size was 4 mm long and 3 mm wide or thereabouts, was passed between a pair of rollers, to thereby fabricate a belt-shaped metal wire net having a predetermined width. This belt-shaped metal wire net was cut into a predetermined length, thereby preparing the reinforcing member.
A superposed assembly was fabricated in which the heat-resistant material and the reinforcing member were superposed on each other such that the heat-resistant material projected in the widthwise direction from both widthwise ends of the reinforcing member, which serve as annular end faces of the cylindrical gasket, and such that one lengthwise end of the reinforcing member and a lengthwise end of the heat-resistant material corresponding to that one end were aligned.
The superposed assembly was convoluted around the outer peripheral surface of a cylindrical core with the heat-resistant material placed on the inner side such that the heat-resistant material was convoluted with one more turn, thereby fabricating a tubular base member in which the heat-resistant material was exposed on both the inner peripheral side and the outer peripheral side. In this tubular base member, both axial end portions of the heat-resistant material respectively projected from the reinforcing member in the axial direction thereof.
The die shown in
The tubular base member disposed in the hollow cylindrical portion of the die was subjected to compression forming under a pressure of 196 N/mm2 (2 tons/cm2) in the direction of the core axis. Thus, a cylindrical gasket was fabricated which included the cylindrical inner peripheral surface defining the through hole, the cylindrical outer peripheral surface, and the annular axial end faces. In this cylindrical gasket, the density of the heat-resistant material was 1.21 Mg/m3, and the mass of the reinforcing member occupied 41% (heat-resistant material: 59%) of the mass of the cylindrical gasket.
A heat-resistant material constituted by an expanded graphite sheet having a density of 1.15 Mg/m3 and a thickness of 0.4 mm was prepared.
A hollow cylindrical knitted metal wire net, which was obtained by continuously knitting by a knitting machine (not shown) by using one austenitic stainless steel wire having a wire diameter of 0.20 mm as a fine metal wire and whose mesh size was 4 mm long and 3 mm wide or thereabouts, was passed between a pair of rollers, to thereby fabricate a belt-shaped metal wire net having a predetermined width. This belt-shaped metal wire net was cut into a predetermined length, thereby preparing the reinforcing member.
Thereafter, a cylindrical gasket was fabricated by a method similar to that of Comparative Example 1. In this cylindrical gasket, the density of the heat-resistant material was 1.30 Mg/m3, and the mass of the reinforcing member occupied 42% of the mass of the cylindrical gasket.
Next, a description will be given of the results of a test conducted on the amount of gas leakage (1/min) and a rate of decline (%) of the tightening torque by the tightening band by incorporating each of the cylindrical gaskets obtained in Examples 1 to 5 and Comparative Examples 1 and 2 described above into the exhaust pipe spherical joint shown in
The temperature was raised up to 500° C. in 1 hour while continuing the oscillating motion at ±0.5° at an excitation frequency of 50 Hz at room temperature (25° C.). The oscillating motion was continued at that temperature held for 22 hours, and after the lapse of 22 hours the temperature was lowered to room temperature in 1 hour. Measurement was made of the amount of gas leakage at room temperature (before the test start) and the amount of gas leakage after the lapse of the test time of 24 hours.
An opening portion of the outer pipe 40 of the insertion-type exhaust pipe joint shown in
Tables 1 and 2 show the results of the above-described test.
From the test results shown in Tables 1 and 2, it can be appreciated that the cylindrical gaskets in accordance with Examples 1 to 5 are superior to the cylindrical gaskets in accordance with Comparative Examples 1 and 2 in terms of the amount of gas leakage and the rate of decline of the tightening torque. It was confirmed that an increase in the amount of gas leakage of the cylindrical gaskets in accordance with Comparative Examples was ascribable to a substantial decline in the tightening force of the tightening band due to such as the permanent set and stress relaxation of the cylindrical gaskets.
As described above, since the density of the heat-resistant material constituted by expanded graphite is in the range of 1.21 to 1.58 Mg/m3 and the mass of the reinforcing member made from the metal wire net occupies 50 to 80% of the mass of the cylindrical gasket, the cylindrical gasket in accordance with the present invention has both pliability contributing to sealability and rigidity for receiving the tightening force exerted by the tightening band. Thus, this cylindrical gasket, when incorporated in the insertion-type exhaust pipe joint and tightened firmly by the tightening band, does not produce such defects as the permanent set, and even when, due to traveling on a rough road, the joint portion is repeatedly subjected to vibrational load and bending torque, and prying repeatedly occurs between the inner and outer pipes, the cylindrical gasket is able to prevent gas leakage from the joint portion of the exhaust pipe as practically as possible.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2010-285199 | Dec 2010 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2011/006596 | 11/28/2011 | WO | 00 | 6/14/2013 |
