Sealing systems for cars and commercial vehicles. systems for cars and commercial vehicles. ......

Sealing systems for cars and commercial vehicles.Extremely versatile. Extremely tough.

03

04 ElringKlinger worldwide

06 Sealing systems for cars and commcercial vehicles

08 Types of gaskets

09 Metaloseal®

11 Volumesoftseal™

12 Metal-elastomer sealing systems

13 Elastomer sealing systems

13 Sealing systems made of high-performance plastics

14 Combustion engines and electric applications

16 Transmission applications

20 Exhaust gas system applications

24 Auxiliaries applications

26 Development and production

Metaloflex® cylinder-head gaskets are presented in a separate brochure. In our brochure “Volumesoftseal™ and Metaloseal® - Sealing systems for all sectors of industry” as well as in our company brochure

“The ElringKlinger Group” you will find information about applications outside the automotive industry.

SUPPLEMENTARY MATERIAL S

CONTENTS

Experience mobility – Drive the future.The ElringKlinger Group.

We are dedicated to developing cutting-edge solutions and new

technologies for current and future generations of vehicles. As

an expert development partner and approved OEM supplier, we

take an all-embracing approach and focus on the vehicle system

as a whole. Our particular strength is that we are one of the few

automotive suppliers capable of developing and manufacturing

technologically sophisticated components for all types of drive

system – based on either combustion engines or electric solutions.

Customized components from ElringKlinger for engine, transmis-

sion, exhaust gas system, underbody, chassis, and body are used

by virtually all vehicle and engine manufacturers and countless

automotive suppliers worldwide. Our product range includes gas-

kets, lightweight polymer components, shielding systems, battery

and fuel cell technology, transmission control plates, exhaust gas

purification systems, components made of high-performance

plastics, tooling technology, and development services. Building

on our innovative products, we set industry benchmarks and help

to achieve environmentally compatible mobility. We also supply

an extensive range of spare parts to the aftermarket sector in more

than 140 countries. In addition, ElringKlinger boasts a successful

track record in other branches of industry, e.g., with exhaust gas

purification systems, PTFE products, and fuel cells. These efforts

are supported by a dedicated workforce of more than 9,000 peo-

ple at 49 ElringKlinger Group locations around the globe.

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ElringKlinger worldwide.

Africa FRIK A

´

SOUTH AFRIC A

Johannesburg

North America

C ANADA

Leamington

USA

Plymouth

Southfi eld

Buford

Austin

Fremont

ME XICO

Toluca

South America

BR A ZIL

Piracicaba

Cylinder-head gaskets

Sealingsystems

Lightweight plastic components

Plastic modules

Thermal and acoustic shielding

systems

Exhaust after-treatment systems

Transmission control plates

05

Asia

PR CHINA

Changchun

Suzhou

Qingdao

Chongqing

SOUTH KORE A

Gumi

Seoul

JAPAN

Tokyo

Saitama

Europe

GERMAN Y

Dettingen/Erms

Langenzenn

Runkel

Geretsried-Gelting

Thale

Lenningen

Bissingen/Teck

Bietigheim-Bissingen

Heidenheim

Mönchengladbach

Idstein

Rottenburg am Neckar

Magdeburg

Neubrandenburg

Nürtingen

SPAIN

Reus

ITALY

Settimo Torinese

Milan

HUNGARY

Kecskemét-Kádafalva

ROMANIA

Timisoara

TURKE Y

Bursa

GRE AT BRITAIN

Redcar

Gateshead

FR ANCE

Nantiat

Chamborêt

Poissy

SWIT ZERL AND

Sevelen

Elsau

NE THERL ANDS

Enschede

INDIA

Ranjangaon

INDONESIA

Karawang

THAIL AND

Bangkok

PTFE components

Engine development services

Tooling technology

PEM fuel cell stacks

Development services with hofer

powertrain

Battery technology

Electric Drive Unit

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Sealing systems for cars and commercial vehicles.Built-in top performance.

A lot is expected of modern vehicles: maximum effi ciency and

minimum environmental impact, combined with enhanced

performance, comfort and safety. As partner to the automotive

industry, ElringKlinger makes a valuable contribution in the

form of intelligent, innovative product solutions for all drive

technologies, including both internal combustion engines and

electric vehicles.

Gaskets are used at all locations in motor vehicles where com-

ponents are connected or meet. They reliably seal off the var-

ious media – oil, coolant, fuels and combustion gases – with

respect to both the atmosphere and one another and prevent the

ingress of dirt. Gaskets also act as power transmission elements

between components and can assume various additional func-

tions depending on the usage location.

Attention remains particularly focused on the reduction of emis-

sions and the ever more stringent limit values around the world.

Downsizing makes today's engines more economical than ever

before. With turbocharging it is possible to obtain the same

power from an engine with reduced capacity as from a larger

engine. The turbocharger is exposed to high temperatures and

sealing is a real challenge. Exhaust aftertreatment also makes

extremely exacting demands on the sealing system employed.

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Our sealing systems are just as varied as their possible usage locations. There may be as many

as 50 gaskets from ElringKlinger in a modern car, for example. Because we offer tailor-made,

effi cient sealing systems specifi cally for the wide range of sealing tasks in engines, transmissions,

exhaust systems and auxiliaries (e.g. compressors or pumps), as well as for bodywork and sus-

pension applications. Materials and designs are perfectly matched to the particular requirements

involved. What's more, it is possible to integrate additional functions such as heat shields, fi lters,

sensors and pre-assembly elements. The benefi ts: fewer individual components, less installation

work, reduced weight, lower costs and optimized operation.

Around 140 years of experience in the fi eld of sealing systems form the basis for our comprehensive

development and manufacturing expertise. Sealing systems from ElringKlinger ensure maximum

safety, top performance and excellent cost-effectiveness, even under the toughest usage conditions.

Seals and gaskets from ElringKlinger.Always the right solution.

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This highly effective sealing system from ElringKlinger is based on elastomer-coated and uncoated

metallic carrier materials. One of the greatest advantages is that different metals can be combined

with different types of elastomer and thus precisely adapted to the requirements in each case.

Metaloseal®.

ME TALOSE AL® L : LINE SE AL

With the Metaloseal® “L” (line seal), metal beads or elastomer lips reduce the surface pressure to

a line compression. This makes it possible to achieve higher sealing pressures with the same bolt

forces or the same sealing pressures with lower bolt forces. Thanks to the wide range of elastomer

and metallic carrier material combinations available, and the single or multi-layer structure, this

sealing system is suitable for use at almost all locations.

COATINGMETAL CARRIER

FULL BEAD

COATINGMETAL CARRIER

HALF BEAD

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ME TALOSE AL® M:

ME TAL RING GA SKE TS

In situations involving extreme mechanical and thermal load-

ing in particularly confi ned spaces, our metal ring gaskets

provide a reliable seal. The merits of Metaloseal® M: maximum

reliability even in the high temperature range up to 850 °C,

highly elastic recovery potential, thermal stability and a uniquely

low assembly force.

V profi le, open inside E profi le, open inside

V profi le, open outside C profi le, open outside

Customized Metaloseal® M design solutions

C profi le, open inside

R profi le, with radial effect

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The combination of soft materials (mica, graphite) and selected

steels makes it possible to create reliable sealing solutions that

satisfy the most stringent leakage standards even in highly

demanding applications. Volumesoftseal™ fl at gaskets and

volume sealing rings from ElringKlinger set new standards in

terms of thermal stability, service life and adaptability.

Volumesoftseal™.

VOLUMESOF TSE AL™ F : FL AT GA SKE T

Particularly good media resistance, dimensional stability and

reliability are the outstanding features of Volumesoftseal™ fl at

gaskets. The unique material properties of mica and graphite

in combination with metallic carrier materials make this sealing

system ideal for use in a wide variety of applications.SCR system with mica insulator SCR system with

graphite heat transfer disk

VOLUMESOF TSE AL™ V: SE ALING RING

Our mica and graphite-based volume sealing rings offer excel-

lent performance and thermal stability. Requiring only a low

bolt force, they are a great alternative to the sealing systems

normally used, such as spiral-wound gaskets for example. Vol-

umesoftseal™ V is installed in structures with pressure boundary

fl anged connections or similar. All conceivable types of fl ange

are possible – from a bolted fl anged connection right through to

a compact, easy to fi t, V-band clamp. Volumesoftseal™ solid fl ange design for high pressures and temperatures

Volumesoftseal™ lightweight design

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Metal-elastomer gaskets consists of a metal carrier with integrated elastomer profiles and serve

for sealing highly stressed components, such as transmission components, covers, oil pans and

cooler. The elastomer materials used are developed in-house by ElringKlinger and precisely tai-

lored for specific applications. Thanks to modern injection molding technologies, various materi-

als can be bonded to a carrier in metal or plastic. As a result, it is possible to use a best-in-class

material for every medium to be sealed.

The benefits at a glance: reliable seal even at low sealing pressures, compensation of larger com-

ponent tolerances, three-dimensional shaping, reduced bolt force and number of bolts and acoustic

isolation of components. Metal-elastomer sealing systems can be used in a wide range of sealing

applications, for example in oil pans, cam covers, heat exchangers or timing cases.

BOLT COMPONENTAEM ELASTOMER FOR OIL SEALING

METAL CARRIER

Metal-elastomer sealing systems.

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Elastomer specialty gaskets can be used on nearly all sealing

joints within the engine. A pressure-boundary fl anged connec-

tion has to be created for elastomer sealing systems in the case of

load-carrying joints, e.g. by means of a groove in the component.

Specifi cally matched profi le geometries ensure maximum func-

tionality at very low sealing pressures.

Elastomer sealing systems.

ElringKlinger supplies innovative gaskets and engineered parts

that are made of PTFE, PTFE compounds, PEEK, Moldfl on® and

other high-performance plastics and are precisely adapted to

each particular application. They can effortlessly withstand high

pressures, friction, corrosive media, chemicals and other loads,

whilst at the same time helping to achieve greater effi ciency

and reduce the environmental impact. Our products, such as

rotary shaft seals, spring-energized seals, support rings, piston

rings and guide elements, as well as multi-component injection

molded parts, provide greater design freedom and a more eco-

nomical solution in all sorts of usage locations.

As a leading supplier of technology and system partner to the

automotive sector, ElringKlinger Engineered Plastics develops

tailor-made, innovative engineering solutions employing high-

performance plastics such as PTFE, PTFE compounds and PEEK,

as well as the thermoplastic material Moldfl on® with its new, eco-

nomical working methods.

Further information can be found in the special brochure

“Leading the way. With innovations made of high-performance

plastics.” from our subsidiary ElringKlinger Engineered Plastics.

I profi le, crimped in groove H profi le, crimped in groove

Sealing systems made of high-performance plastics.

ELRINGKLINGER ENGINEERED PL A STIC S

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ME TALOSE AL® L ME TALOSE AL® L

ME TAL-EL A STOMER GA SKE T ME TAL-EL A STOMER GA SKE T

ME TAL-EL A STOMER GA SKE T

For the crankcase; consisting of various metal segments connected via the elastomer sealing lip

For the timing case; for the purpose of sealing oil and coolant; slimline design with a thickness of just 1.0 mm; fast installation

Cam cover gasket with integrated cable routing

Oil pan gasket with optimized bolt force distributionExhaust gas manifold gasket

Combustion engines and electric applications. Extremely reliable.

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EL A STOMER SPECIALT Y GA SKE TS SPRING -ENERGIZED SE AL S

SE ALING RINGS POLYAMIDE INJEC TION-MOLDED PART

ROTARY SHAF T SE AL S

Made from special PTFE compounds to seal fuel at high pressures and temperatures in the cylinder head (fuel injection)

Sealing of a drive belt by means of an injection-molded part made of polyamide; includes integrated PTFE lip, Metaloseal® gasket, and elastomer seals. To improve a vehicle's wading capabilities

Rotary shaft seals with PTFE lips for high circumferential speed require-ments coupled with low friction. Dynamic seals made of high-performance plastics and innovative solutions for electric drive systems demanding high speeds, dry running and minimal leakage rates

For intake manifold and spark plug sealing Special double-spring seal design for the separation of fuel and engine oil in high-pressure gasoline and diesel injection pumps

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Transmission applications.Ready to install, reliable, economical.

The control plates used to seal off the control unit of automatic

and dual-clutch transmissions have to withstand high hydraulic

pressures and often greatly fluctuating thermal loads. Four dif-

ferent systems are available from ElringKlinger to suit different

component properties and operating parameters: Metaloseal®,

Metaloprint®, metal-soft material and plastic transmission con-

trol plates. The outstanding strengths: good sealing action is

achieved at all operating points, permitting even greater effi-

ciency in the transmission system. On top of that, additional filter,

orifice plate and restrictor functions, for example, can be incorpo-

rated into the control plates for better transmission control.

Transmission control plates.

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ME TALOSE AL®-L-

TR ANSMISSION CONTROL PL ATE

ME TAL-SOF T MATERIAL


ME TALOPRINT ®-



IN THERMOPL A STIC PPS

With partial elastomer coating; complete and ready-to-install With integrated solid silicone providing an elastomer sealing function on both sides; this is the centerpiece of a pneumatic transmission control module for heavy-duty commercial vehicles

With 3D stainless steel screen structure; reliable and cost-effi cientReliable under challenging conditions and at maximum operating pressures; with integrated fi lter function

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For many years now, ElringKlinger has been supplying various series-produced composite pistons

for vehicle transmission systems. Our customers can count on innovative design, fi rst-class hys-

teresis properties and outstanding reliability.

Our engineers have steadily evolved their skills in this fi eld over the years, allowing us to manufac-

ture our composite pistons entirely in-house: development of materials, simulation, design, surface

treatment, and rubber injection molding – everything from a single source.

One of the unique features of ElringKlinger composite pistons is their extremely smooth surface.

This ensures effi cient transmission management and high-precision gear shifting – for the ultimate

driving experience.

Pistons for transmission systems.

Illustration of requisite elastic capacity of an R-ring in a slide seal system

20

Exhaust gas system applications. Maximum safety.

R-ring for sealing off exhaust gas manifold sliding seats.

Future-proof sealing systems for exhaust gas applications have

to offer not just good sealing action, but also maximum flex-

ibility to be able to adapt to all thermal and mechanical load

situations. With its comprehensive design and material portfolio,

ElringKlinger can supply the ideal solution for every application.

Modern sliding seat manifolds for example demand radial and

axial adaptation to the relative movements of the components.

This is a particular challenge requiring a combination of two

sealing technologies. Only the use of a soft R-ring (Metaloseal® M)

together with a hard mica sealing element (Volumesoftseal™ V)

can ensure successful sealing over the wide range of load sit-

uations occurring with sliding seats in exhaust gas manifolds.

3D illustration of a slide seal system

3D detailed cutaway view of a slide seal system

21

Metaloseal® L EGR gasket with integrated rescue fi lter.

The sealing systems used for low-pressure exhaust gas recir-

culation in diesel and gasoline engines have to be able to with-

stand high temperatures of more than 800 °C and corrosive

media. The compressor components in the turbocharger also

need a rescue fi lter to protect them against mechanical damage

from solid particles. The metallic volumetric mesh used offers

maximum fi ltration effi ciency with minimum pressure loss.

Special feature: instead of being welded, the rescue fi lter is

mechanically joined to the gasket. The bowl shape additionally

enlarges the fi lter to prevent possible fouling (accumulation of

deposits in the gas fl ow) and to further reduce back pressure.

ElringKlinger specializes in integrating gaskets into complex

EGR systems and in managing the module as a whole.

ME TALOSE AL® L

EGR gasket with integrated rescue fi lter

Separation function of rescue fi lter in low-pressure exhaust gas recirculation system

> 200μm < 200μm

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ME TALOSE AL® L ME TALOSE AL® M

7-layer EGR gasket in a high-temperature alloy Metal ring gaskets for dynamic applications in the high-temperature range

Multi-layered exhaust gas manifold gasket with heat-resistant coating system to reduce abrasive wear

Turbocharger gasket for isolation of components subject to high-frequency load and to reduce wear

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VOLUMESOF TSE AL™ F SPEEDFLON ®ME TALOSE AL® L

P TFE MOLDED HOSES AND C ABLE GUIDES

Thermal insulation of cables plus anti-kink protection, used in lambda sensors for exhaust aftertreatment and engine management

Rotary shaft seal made of PTFE special compound; specially developed (patent pending) for turbochargers and other high-speed engine charging systems (tested up to 150,000 rpm). Uniform radial force over the entire pressure and speed range and thus less friction and wear. Enclosed sealing concept means no leakage on starting/stopping and when stationary

Mica-based turbocharger fl at gasket with fl ameproof metal enclosure

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Auxiliaries applications. Tailor-made solutions.

Valve control plate.

Metallic alloys and elastomer systems, combined with profound

knowledge of these material groups, form the foundations for

the sealing technology of the ElringKlinger Group. They are

also the basis on which new sealing systems are constantly

being developed. These systems assume a whole range of

other functions in addition to simply meeting the challenge

of providing sealing action. Thanks to this expertise, it proved

possible to create a gasket and valve module for an A/C com-

pressor in the course of a development project. Alongside

enhanced functionality, the overall costs of the A/C compressor

were also further reduced.3D sectional drawing of the overall system

3D detailed cutaway view through the ElringKlinger sealing and valve module

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Water pump gasket with foamed coating system for greater adaptation to surface defects (machining steps, porosities, ...)

Water pump gasket with integrated pre-assembly solution on the water pump

Compressor gasket for specifi c sealing of pressure oil and compressed air zones

Battery housing seal with integrated pre-assembly solution as well as specially developed coating system, tailored to IP Code requirements

ME TALOSE AL® L

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Development and production. Innovative system expertise.

Short development cycles, the complex interaction of the indi-

vidual components, and exacting demands in terms of both

cost-effectiveness and sustainability, all make a comprehen-

sive approach essential. That is the particular strength of

ElringKlinger. Our expertise in the fields of sealing systems, mate-

rials, engineering and production sets new standards. In close

cooperation with our customers, we develop high-performance,

economical sealing solutions for all sorts of usage locations.

For all products with elastomer content, ElringKlinger makes

use of rubber blends developed by the company itself, as well

as the latest technology to ensure a reliable process for the appli-

cation of adhesion promoters with corresponding pre-treatment

of the components. The specially developed elastomers (AEM,

ACM, EPDM, FKM, FMVQ, MVQ etc.) can be designed to suit

any requirement. So component developers always have the

ideal material to work with, whatever the application.

As a leading technology supplier, ElringKlinger is not satisfied

with just maintaining existing standards but is always looking

for something even better. For instance, we spent nearly five

years developing a completely new production method for high

temperature-resistant metal ring gaskets: scrap-free rolling and

forming. This involved precisely revising the entire process

from material infeed, cutting to size and forming, right through

to welding. A whole new tooling system was also developed

and established as standard. A further task was to implement

in-process monitoring facilities. These check the component

for dimensional accuracy, weld quality and freedom from leaks

before it leaves the machine. Reject parts can then be separated

out at an early stage to stop them unnecessarily passing through

any further process stages. ElringKlinger has thus succeeded in

developing a new, revolutionary manufacturing process.

At every step along the way – the first formulation idea, mate-

rial testing to determine characteristic properties employing

the latest measurement techniques, the appropriate design, the

establishment of process parameters (for example with the aid

of modern rheovulcameters) and finally large-scale usage –

all the necessary fields of expertise available to ElringKlinger

are perfectly coordinated in their interaction. Global standards

guarantee the identical quality of the manufactured products

everywhere in the world and ensure the reliable life-long seal-

ing of assemblies.

In the area of high-performance plastics, we have installed all

the relevant production processes (machining, blow molding,

injection molding etc.). We are also the only supplier to engage in

the injection molding of PTFE material in the form of Moldflon®.

W W W.ELRINGKLINGER .COM

ElringKlinger AG

Max-Eyth-Straße 2

72581 Dettingen/Erms

Germany

Phone +49 7123 724-0

Fax +49 7123 724-9006

E-mail [email protected]

www.elringklinger.com 08/1

7

The following applies to this brochure: ® = registered trademarks of the ElringKlinger AG in Europe, the United States, and China

The information provided in this brochure is the result of technological analyses and may be subject to changes depending on the design of the system. We reserve the right to make technical changes and

improvements. The information is not binding and does not represent warranted characteristics. We do not recognize any claims for compensation based on this information. We accept no liability for printing errors.

Sealing systems for cars and commercial vehicles. systems for cars and commercial vehicles. ......

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Transcript of Sealing systems for cars and commercial vehicles. systems for cars and commercial vehicles. ......