Expandable gasket, sealed joint and method of forming same

Abstract

An improved expandable gasket, sealed joint and method of forming a sealed joint which includes a gasket having at least 5% by weight unexpanded or unexfoliated graphite. The graphite material is preferably a mixture of expanded and unexpanded graphite compressed in a sheet or other shape affixed to a metal plate. The preferred composition is 5 to 70% by weight of unexpanded graphite and 30 to 95% expanded graphite, wherein the percentage of unexpanded graphite is controlled to provide the desired gasket expansion. A more preferred composition includes at least 10% by weight unexfoliated graphite or more preferably 15 to 50% by weight. The gasket is placed between the surfaces to be sealed and clamped in place. When the joint is heated, the unexpanded graphite exfoliates, causing the gasket to swell or expand, tightly sealing the joint. The expandable gasket of this invention is particularly suitable for automotive application, including head and exhaust gaskets which are subject to temperatures exceeding about 400° C.

I claim: 
     
       1. A heat expandable graphite gasket for sealing a joint subject to fluid pressure and heat, said gasket comprising: a compressed mixture of expanded and unexpanded graphite containing at least 5% by weight unexpanded graphite flakes and said mixture compressed in the form of a gasket and said gasket expandable under pressure when heated to the exfoliation temperature of said unexpanded graphite flakes.   
     
     
       2. The heat expandable graphite gasket defined in claim 1, characterized in that said . .sheet.!. .Iadd.gasket .Iaddend.comprises at least 5 to 70% by weight unexpanded graphite. 
     
     
       3. The heat expandable graphite gasket defined in claim 1, characterized in that said gasket . .sheet.!. consists essentially of 10 to 60% by weight unexpanded graphite and about 40 to 90% by weight expanded graphite. 
     
     
       4. The heat expandable graphite gasket defined in claim 3, characterized in that the concentration of unexpanded graphite in said gasket . .sheet.!. is 15 to 50% by weight. 
     
     
       5. The heat expandable graphite gasket defined in claim 1, characterized in that said graphite . .mixture.!. .Iadd.gasket .Iaddend.is affixed to a metal plate which includes a plurality of integral tangs struck from said metal plate and extending generally transverse to the plane of said plate, said tangs extending into said graphite gasket material affixing said gasket material to said metal plate and providing column support for said gasket. 
     
     
       6. A heat expandable graphite gasket for sealing a joint . .subject to pressure and heat.!., said gasket comprising . .a uniform mixture of.!. expanded and unexpanded graphite containing at least 10% by weight unexpanded graphite flakes and said . .mixture.!. .Iadd.gasket .Iaddend.compressed in a shape configured to be received in a joint and said gasket expandable under pressure when heated to the exfoliation temperature of said unexpanded graphite flakes .Iadd.to seal a joint including said expandable gasket.Iaddend.. 
     
     
       7. The heat expandable graphite gasket defined in claim 6, characterized in that said graphite gasket is affixed to a metal plate. 
     
     
       8. The heat expandable graphite gasket defined in claim 6, wherein said .Iadd.expandable .Iaddend.gasket . .mixture.!. comprises at least 50 to 85% by weight of expanded graphite. 
     
     
       9. The heat expandable graphite gasket defined in claim 8, wherein said . .sheet.!. .Iadd.gasket .Iaddend.consists essentially of 15 to 50% by weight unexpanded graphite and 50 to 85% by weight expanded graphite. 
     
     
       10. The heat expandable graphite gasket defined in claim 8, characterized in that the concentration of unexpanded graphite in said . .sheet.!. .Iadd.gasket .Iaddend.is 20 to 30% by weight. 
     
     
       11. The heat expandable graphite gasket defined in claim 6, wherein said graphite is affixed to a metal plate, said metal plate including a plurality of integral tangs struck from said plate and extending from the plane of said plate, said tangs extending into said graphite gasket, affixing said graphite gasket to said metal plate and providing columnar support for said gasket. 
     
     
       12. A joint subject to fluid pressure and heat, said joint including opposed surfaces to be sealed and a heat expandable graphite gasket located between said surfaces, said gasket comprising a compressed shape of generally fibrous material including at least 10% by weight unexpanded graphite, and said gasket clamped between said opposed surfaces, said unexpanded graphite exfoliating upon heating of said gasket above the exfoliating temperature of said expandable graphite, sealing said joint. 
     
     
       13. The joint defined in claim . .11.!. .Iadd.12.Iaddend., characterized in that said gasket comprises a . .mixture.!. .Iadd.sheet .Iaddend.of expanded and unexpanded graphite comprising 10 to 60% by weight unexpanded graphite and 40 to 90% by weight expanded graphite. 
     
     
       14. The joint defined in claim 12, characterized in that said gasket consists essentially of . .a mixture of.!. 10 to 60% by weight unexpanded graphite and 40 to 90% by weight expanded graphite. 
     
     
       15. The joint defined in claim . .11.!. .Iadd.12.Iaddend., characterized in that said compressed gasket . .sheet.!. is affixed to a metal plate. .Iadd.16. The heat expandable graphite gasket defined in claim 1, wherein said graphite gasket comprises a mixture of expanded and unexpanded graphite flakes uniformly distributed throughout said gasket. .Iaddend..Iadd.17. The joint defined in claim 12, wherein a fluid transmitted through said joint has a temperature greater than the exfoliation temperature of said unexpanded graphite, thereby heating and exfoliating said unexpanded graphite and sealing said joint. .Iaddend..Iadd.18. A heat sealable joint, said joint including opposed surfaces to be sealed and a heat expandable gasket located between said joint surfaces, said gasket comprising exfoliated graphite and at least 5% by weight unexfoliated graphite compressed in a shape generally conforming to said opposed surfaces of said joint, and said unexfoliated graphite in said gasket exfoliating upon heating and said gasket expanding to seal 
     
     
        said opposed surfaces of said joint. .Iaddend..Iadd.19.  The heat sealable joint defined in claim 18, wherein said unexfoliated graphite in said gasket comprises 5 to 70% by weight of said gasket. .Iaddend..Iadd.20. The heat sealable joint defined in claim 18, wherein said unexfoliated graphite in said gasket comprises 15 to 50% by weight of said gasket. .Iaddend..Iadd.21. A heat sealable joint between two tubes aligned to communicate for transmitting fluid, said joint including opposed surfaces for sealing the communication between said tubes, and a heat expandable gasket located between said joint surfaces, said gasket comprising exfoliated graphite and 15 to 50% by weight unexfoliated graphite material compressed and shaped to generally conform to said opposed surfaces of said joint, said unexfoliated graphite in said gasket exfoliating and expanding upon heating of said gasket above the exfoliating temperature of said unexfoliated graphite, causing said gasket to expand and seal said opposed surfaces of said joint and said communication between said tubes. .Iaddend..Iadd.22. A heat expandable graphite gasket for sealing a joint subject to fluid pressure, said gasket comprising: a compressed shape of expanded and unexpanded graphite containing at least 5% by weight unexpanded graphite flakes and said shape compressed in the form of a gasket and said gasket expandable under pressure when heated to the exfoliation temperature of said unexpanded graphite flakes to seal a   
     
     
        joint containing said gasket. .Iaddend..Iadd.23.  A heat sealable joint, said joint including opposed surfaces to be sealed and a heat expandable graphite gasket located between said surfaces, said gasket comprising a compressed shape of generally fibrous material including at least 10% by weight unexpanded graphite, and said gasket clamped between said opposed surfaces, said unexpanded graphite exfoliating upon heating of said gasket above the exfoliation temperature of said exapandable graphite, sealing said joint. .Iaddend.