Segmented Exhaust Manifold Gas Seals

Abstract

System and methods for preventing leakage of exhaust gasses in the segmented manifold of an engine system are disclosed. In an aspect, an assembly includes a first manifold, a flange, and a first carrier and a second carrier having recessed portions configured to accommodate compressions rings to deliver a sealing force.

We claim: 
     
         1 . A composite exhaust manifold assembly comprising:
 a first manifold segment having a first fluid conduit formed therein and having a flange at a first end thereof;   a first carrier disposed adjacent the flange, the first carrier defining at least a portion of a first internal surface,   a first recessed portion disposed adjacent the first carrier;   a second manifold segment having a second fluid conduit formed therein, the second manifold segment disposed adjacent the first internal surface; and   a compression ring disposed adjacent the first recessed portion, the compression ring comprising an outer shell having a mesh core disposed within the shell.   
     
     
         2 . The composite exhaust manifold assembly of  claim 1 , further comprising a second carrier disposed between the first carrier and the first manifold segment, wherein a first end of the first carrier abuts a first end of the second carrier, wherein at least a portion of the first carrier and the second carrier define the first internal surface, and wherein one of the first end of the first carrier and the first end of the second carrier comprises the first recessed portion. 
     
     
         3 . The composite exhaust manifold assembly of  claim 1 , wherein the outer shell comprises a split housing with a first portion coupled to a second portion. 
     
     
         4 . The composite exhaust manifold assembly of  claim 1 , wherein the first carrier is integrated with the flange or coupled thereto. 
     
     
         5 . A composite exhaust manifold assembly comprising:
 a first manifold segment having a first fluid conduit formed therein and having a flange disposed at a first end of the first manifold segment;   a first carrier coupled to the flange, wherein the first carrier defines at least a portion of a first recess and a portion of a second recess;   a first compression ring disposed adjacent the first recess;   a second compression ring disposed adjacent the second recess, wherein the second compression ring has a concave curvature or concave polygonal cross-section, wherein an interior angle is oriented towards the first compression ring; and   a second manifold segment having a second fluid conduit formed therein, the second manifold disposed adjacent an internal surface of the first carrier, wherein the first and second compression rings provide sealing engagement between the second manifold and the first carrier.   
     
     
         6 . The composite exhaust manifold assembly of  claim 5 , further comprising a second carrier disposed between the first carrier and the flange, wherein the second manifold segment is disposed adjacent an internal surface of the second carrier. 
     
     
         7 . The composite exhaust manifold assembly of  claim 6 , wherein the second carrier defines at least a portion of the first recess. 
     
     
         8 . The composite exhaust manifold assembly of  claim 5 , further comprising a retainer disposed adjacent the second recess, wherein the second compression ring is interposed between the retainer and a portion of the first carrier. 
     
     
         9 . The composite exhaust manifold assembly of  claim 8 , wherein the retainer has an annular shape and is configured to circumscribe an outer periphery of the second manifold segment. 
     
     
         10 . The composite exhaust manifold assembly of  claim 5 , wherein the first compression ring comprises an outer shell having a mesh core disposed within the shell. 
     
     
         11 . The composite exhaust manifold assembly of  claim 10 , wherein the outer shell comprises a split housing with a first portion coupled to a second portion. 
     
     
         12 . The composite exhaust manifold assembly of  claim 5 , wherein the first compression ring comprises a woven wire mesh having a high temperature filler. 
     
     
         13 . The composite exhaust manifold assembly of  claim 5 , wherein the first recess has an annular shape and a rectangular cross-section. 
     
     
         14 . A composite exhaust manifold assembly comprising:
 a first manifold segment having a first fluid conduit formed therein and having a flange disposed at a first end of the first manifold segment;   a first carrier coupled to the flange, the first carrier having a first end;   a first recessed portion formed in the first end of the first carrier;   a spring element disposed adjacent the first recessed portion;   a compression ring disposed adjacent the spring element; and   a second manifold segment having a second fluid conduit formed therein, the second manifold segment disposed adjacent an internal surface of the first carrier, wherein the spring biases the compression ring to provide sealing engagement between the second manifold segment and the first carrier.   
     
     
         15 . The composite exhaust manifold assembly of  claim 14 , further comprising a second carrier disposed between the first carrier and the flange, wherein the second manifold segment is disposed adjacent an internal surface of the second carrier. 
     
     
         16 . The composite exhaust manifold assembly of  claim 14 , wherein the compression ring has a polygonal cross-section such as a triangular, trapezoidal, or pentagonal cross-section. 
     
     
         17 . The composite exhaust manifold assembly of  claim 14 , wherein the compression ring comprises a woven wire mesh comprising a high temperature filler. 
     
     
         18 . The composite exhaust manifold assembly of  claim 14 , wherein the spring element comprises a conical spring washer in series. 
     
     
         19 . The composite exhaust manifold assembly of  claim 14 , wherein the second manifold segment further comprises a shoulder spaced from a second end thereof, wherein the shoulder abuts one or more of the spring element and the compression ring. 
     
     
         20 . A composite exhaust manifold assembly comprising:
 a first carrier defining at least a portion of a first internal surface, the first carrier comprising one or more recesses formed in the first internal surface; and   one or more compression rings disposed respectively in the one or more recesses wherein the one or more compressions rings comprises a mesh ring, comprises a concave curvature or concave polygonal cross-section, or comprises a biasing spring element.