Patent Application
20060054401
This invention relates generally to oil control in automotive and similar engines, and more particularly, to a specialized design of plug which will withstand the high pressures in the main oil gallery of such an internal combustion engine.
As is well known, the oil gallery communicates directly with the oil pump and serves as the main source of oil under pressure for lubricating various parts of the engine, including the main bearings, connecting rod bearings, camshaft bearings, etc. For casting reasons, there is an opening into the oil gallery from outside the engine block. Consequently, there must be a plug of some sort to seal this opening. Such a plug must be relatively permanent, be simple and easy to install and must withstand occasional pressures up to as much as 200 psi.
While oil pressure in an engine normally runs about 40 to 80 psi, for example, a much larger pressure surge may be seen in the oil when it is extremely cold, or when the other passages are temporarily blocked, or for some other reason. The oil pressure relief valve does not always function perfectly and, for this reason, and others, the pressure in the oil gallery may approach 200 psi.
Accordingly, it is necessary that the plug for the oil gallery be able to withstand this pressure. When it comes to various designs for this purpose, several designs have been used and/or proposed, but each of them includes a number of disadvantages. Since the desired plug for this purpose is to be used in an automobile, of which literally millions are produced each year, being reliable and capable of easy installation are paramount considerations. Economy is also extremely high on the list of desired features.
Prior attempts in this area have included a thread-in type plug for this part. However, the thread on the plug is usually one made by an automatic screw machine, and hence contains threads which must mate or register with cut threads in the engine block. Consequently, if the engine block is not tapped correctly, or if the threads are discontinuous, or if the threads are cut at an angle, or if there is some other problem, then the threaded plug will not meet the criteria for this application.
Moreover, with a threaded plug, there is always a chance of cross-threading in operation. Cross-threading though not considered likely, is nevertheless a factor to be considered, because these plugs are normally placed in the block by a robotic installer, which may conceivably have an alignment problem. This installation is done with a so-called Avdel plug, which is used in conjunction with an O-ring. The installation of the Avdel type plug and an O-ring also raises the problem of excessive cost. Accordingly, a threaded type plug is not the perfect solution to this type of problem.
Another type of solution which has been proposed for this problem includes merely press fitting a plug in the opening. However, such a press fit normally is not satisfactorily able to be placed in the block in such a way as to be certain to withstand the pressures involved.
Accordingly, it would be advantageous if it were possible to design a plug which could withstand the high pressures involved and which still could be manufactured at low cost.
There is also a need for a low cost plug which could be inserted with little or no labor and which would be a snap-in type installation, thereby insuring that the plug could be reliably installed to the proper depth, and which would not require rotational indexing.
Still further, there is a need for a plug of the type which could be inserted to the correct depth at all times, and which, as a safety factor, would include a flanged retainer such that the plug could not be inserted too far into the opening of the oil gallery.
Accordingly, it is an object of the invention to provide an improved plug for the engine oil gallery of the automotive or like engine.
Another object is to provide a composite plug which would include an elastomeric plug integrated with a steel reinforcing part, and which would be able to withstand the pressures excepted to be seen in the oil gallery.
A still further object is to provide a cup formed of steel or other metal, covered by an elastomeric member having sealing means such as ribs or the like on its exterior surface.
Another object of the invention is to provide a cup-like member which could be used in cooperation with a plastic snap-in fitting that would ensure a reliable installation.
A further object of this invention would be to provide a composite seal having a snap-in plastic component which includes a pair of snap-in flanges having portions adapted to be seated in a groove and which also would have skirt portions terminating in a radial flange to prevent excessive depth of installation, in other words, a plug which inherently has an axial installation gauge.
Another object is to provide an economical plug which would be made entirely of plastic and which could be secured using one or two O-rings in addition to the plastic component.
A still further object of the invention would be to provide a skirted plastic arrangement wherein the skirt would include both a radial flange for establishing the proper depth or “bottoming out” as well as a snap-in fitting for a radial groove into which a portion of the skirt would extend.
Another object of the invention would also be to provide a reliable plug at a low cost.
A still further object is to provide a low cost reliable plug which will withstand the necessary pressures in an oil gallery.
These and other objects of the present invention are achieved in practice by providing a plug having sealing means thereon and which includes, either separately or in a unitary piece, a skirt having both locking tabs, as well as a radial flange to insure proper installation in an engine block, the engine block having been prepared merely by cutting a radial grove therein.
These and other objects and advantages of the invention, and the manner of their attainment will become more clearly apparent when reference is made to the following description of the preferred embodiments of the invention set forth by way of example, and shown in the accompanying drawings, wherein like reference numbers indicate corresponding parts throughout.
While the invention may be practiced in various forms and the preferred embodiments are not to be intended as limiting, a description of such preferred embodiments will now be made.
Referring now to drawings in greater detail.
On the inner surface of the bore 22, spaced just apart from the end face 24, is shallow, preferably rectangular groove generally designated 26. The groove 26 subdivides the gallery 22 into two sections, an axially inner section 28 and an axially outer section 30.
The engine block 20 and the main oil gallery 22 are somewhat schematically represented in this illustration. Located within in the gallery 22, which is cylindrical in form, is a composite plug generally designated 32. The plug 32 comprises two elements, one being a metal cup generally designated 34, having an end face section 36 and a continuous circular skirt portion 38. This cup 34 is overmolded with an elastomeric portion generally designated 40.
This overmolded component includes a radially outer, serrated or ribbed skirt portion 42, a flat crown portion 44 and a radially inner covering 46 for the skirt 38 portion. By “overmolded” is meant using the end face section 36 and the skirt portion 38 as part of the mold when forming the crown 44 and the serrated or ribbed skirt portion generally designated 42. The outer skirt portion may also include, in place of the ribs 42, a plurality of teeth or serrations 47, any of which are intended to make tight sealing contact with the bore 22.
Disposed inside this plug is a fairly tight fitting plastic support unit generally designated 48. The support unit 48 has a closed end face portion 50 as well as a skirt generally designated 52. The skirt 52 is subdivided into three main elements. The elements comprise a lower part 54 which is cylindrical in form and which has a terminal radial flange 56 designed to abut the end face 24 of the block 20 on its inner surface, a transition portion 58 and an upper portion 60 which fits tightly into the metal cup generally designated 34.
The transition portion 58 extends between the lower portion 54 and the upper portion 60 and is of an increasing diameter as it moves downward. The upper part 60 is of a constant diameter and meets and is joined to the uppermost or closed end portion 50 of the support unit 48. In this embodiment there are two separate spring-like elements, generally designated 62 (only one shown in
In use, the oil gallery passage 28 is normally bored to a given diameter and is a precisely formed opening. According to the invention, a groove 26 is cut in the lower end portion 30 of the oil gallery 22. No further preparation is required. When it comes time to insert the composite plug, it is done very simply and in a straightforward manner by first inserting the retainer carrying the metal cup with its ribbed rubber exterior into the opening 22 until the flange 56 bottoms out on the end face 24 on the engine block 20, and releasing the resiliently biased tabs 64, allowing them to engage the groove 26. Nothing else needs to be done to complete the installation.
Referring now to another embodiment, a somewhat similar plug generally designated 132, but differing in several details, is shown in
Referring now to the plug itself, this comprises an upper surface 133 or crown portion, and a downwardly extending body portion 142 having a plurality of grooves 144, 146 therein. A lower portion 154 of the body 142 contains a somewhat flexible, resiliently biased wall portion 160 having a resiliently biased locking tab 164 fitting into the groove 126.
In this embodiment, instead of the ribs 47 on the outside diameter of the plug 32, there are two O-rings 166, 168 disposed in the grooves 144, 146. These rings 166, 168 actually form the seal, with the plug 132 withstanding most of the force developed by the oil under pressure. With this arrangement of the flexible wall portion 160 and the locking tab 164 and the flange 156, the plug 132 is essentially immobile.
To install the plug, the same procedure as in the other embodiment is used. The plug 132 is simply inserted while the tabs 162 are withdrawn until the plug 132 bottoms out on the flange 156. Then the tabs are released from their withdrawn position and allowed to snap into the groove 126.
In a third embodiment (not shown), the plug of the invention could comprise only a single O-ring in a single groove. Likewise, the plug of the invention might have three or more O-rings.
Three embodiments have been shown. In addition, a number of variations are possible. The metal cup of the first embodiment could be made from a tough, hard plastic material. The form of the projections or serrations may be varied considerably. O-rings, one or more, are suggested, but another form of seal member could be substituted—square rings or the like could conceivably be used. A pair of continuous flanges have been suggested, but the flanges themselves could be made discontinuous. Other variations will occur to those skilled in the art.
It will thus be seen that the present invention provides an oil gallery plug having a number of advantages and characteristics, including those pointed out and others which are inherent in the invention. It is anticipated that one skilled in the art may make changes to the form of preferred embodiments shown herein without departing from the spirit of the invention, or the scope of the appended claims.
