Multi-layer gasket assembly

1. A gasket assembly, comprising:

a core layer;

a first facing layer disposed on one side of said core layer, and a second facing layer disposed on an opposite side of said core layer; and

a first outer layer of metal disposed on an outer facing surface of said first facing layer facing away from said core layer, and a second outer layer of metal disposed on an outer facing surface of said second facing layer facing away from said core layer;

said core layer, said facing layers, and said first and second outer layers presenting a set of axially aligned openings aligned about a central axis extending in an axial direction;

said first outer layer comprising a substantially flat portion substantially parallel to said outer facing surface of said first facing layer transitioning directly to a completely curved portion being curved into said set of axially aligned openings in a convex manner when viewed form said central axis, being curved towards said second outer layer, and being curved by no greater than ninety degrees, said completely curved portion of said first outer layer completely defining a first outer layer flange, said first outer layer flange extending axially along said set of axially aligned openings from said substantially flat portion of said first outer lam to a distal end of said first outer layer which is located inside of said set of axially aligned openings and approximately at a middle of an overall axial thickness of said gasket near said core layer, and

said second outer layer comprising a substantially flat portion substantially parallel to said outer facing surface of said second facing layer transitioning directly to a completely curved portion being curved into said set of axially aligned openings in a convex manner when viewed form said central axis, being curved towards said first outer layer, and being curved by no greater than ninety degrees, said completely curved portion of said second outer layer completely defining a second outer layer flange, said second outer layer flange extending axially along said set of axially aligned openings from said substantially flat portion of said second outer layer to a distal end of said second outer layer which is located inside of said set of axially aligned openings and approximately at said middle of said overall axial thickness of said gasket near said core layer; and

wherein said first and second outer layer flanges are in direct contact with one another only in a limited region at or near their respective distal ends with said limited region being substantially smaller than said overall axial thickness of said gasket and located more axially proximate said middle of said overall axial thickness of said gasket than axially proximate to either of said substantially flat portions of said first and second outer layers, wherein said direct contact at said limited region provides a gas tight seal around said set of axially aligned openings for protecting said facing layers from gasses flowing through said set of axially aligned openings.

2. The gasket assembly as set forth in claim 1 wherein said first and second outer layer flanges overlap one another in said axial direction.

3. The gasket assembly as set forth in claim 1 wherein said distal ends of said first and second outer layers are in contact with one another.

4. The gasket assembly as set forth in claim 1 wherein each of said first and second outer layers is curved by approximately ninety degrees at said set of aligned openings.

5. The gasket assembly as set forth in claim 1 wherein there are a plurality of sets of axially aligned openings.

6. The gasket assembly as set forth in claim 1 wherein said core layer includes an upper surface and a lower surface, and said core layer is perforated to present a plurality of tangs on said upper and lower surfaces.

7. The gasket assembly as set forth in claim 6 wherein said first and second facing layers are engaged with said tangs on said core layer.

8. The gasket assembly as set forth in claim 1 wherein said first and second outer layers are made of stainless steel.

9. The gasket assembly as set forth in claim 1 wherein said core layer is made of steel.

10. A method of making the gasket assembly according to claim 1 , the method comprising:

making said gasket assembly of claim 1 and including the steps of:

preparing said core layer;

engaging said first facing layer and said second facing layer with the core layer;

bending said first outer layer of metal to present said first outer layer flange;

bending said second outer layer of metal to present said second outer layer flange; and

positioning said first outer layer on said outer facing surface of said first facing layer facing away from said core layer, and positioning said second outer layer on said outer facing surface of said second facing layer facing away from said core layer facing layer.

11. The method of making the gasket assembly of claim 1 , as set forth in claim 10 , wherein the bending steps of said first and second outer layers are blanking operations.

12. The method of making the gasket assembly of claim 1 , as set forth in claim 10 , wherein said core layer includes a plurality of tangs on said one side of said core layer and on said opposite side of said core layer thereof, and wherein the first and second facing layers are engaged by the tangs during the engaging step.

13. The method of making the gasket assembly of claim 1 , as set forth in claim 10 , wherein the step of bending the first outer layer is further defined as bending said first outer layer of metal by approximately ninety degrees.

14. The method of making the gasket assembly of claim 1 , as set forth in claim 10 , wherein the step of bending the second outer layer is further defined as bending said second outer layer of metal by approximately ninety degrees.