Non-metallic high pressure high temperature high chemical compatibility flange isolation gasket

Abstract

A non-metallic flange isolation gasket kit sealing flanged pipeline connections and flanged vessel connections while providing electrical isolation protection between flanges suited for high-pressure and high-temperature cathodic protection applications is presented. The invention protects flange faces from media induced corrosion and mitigates flange rotation induced fatigue and failures. The invention comprises of a retainer, a seal, and a seal pre-load structural ring. The seal pre-load structural ring is inserted into the seal, and seal outer diameter surface is joined to the retainer inner diameter surface. A second embodiment comprises of a composite gasket blank, comprising of a retainer and a seal, and a seal pre-load structural ring. The seal outer diameter surface and the retainer inner diameter surface are joined by thermal fusion bonding. The invention may further comprise one or more gasket seating stress stabilizers and/or a centering ring. Tapered retainer upper and lower surfaces decrease flange rotation.

I claim: 
     
         1 . A process for making cured composite material, which comprises the steps of:
 (a) chemically etching a tube shape compression molded fluoropolymer outer diameter surface of a tube shape compression molded fluoropolymer;   (b) inserting the tube shape compression molded fluoropolymer over a mandrel;   (c) over-molding a first layer of material onto the tube shape compression molded fluoropolymer outer diameter surface while spinning the mandrel;   (d) over-molding a second layer of material onto the first layer of material while spinning the mandrel;   (e) removing the mandrel from the over-molded material;   (f) curing the over-molded material in an oven.   
     
     
         2 . The process for making cured composite material as recited in  claim 1 ,
 (a) where the first layer of material comprises of impregnated composite fiber filaments,   (b) where the second layer of material comprises of semi-cured impregnated composite fabric matrix.   
     
     
         3 . The process for making cured composite material as recited in  claim 1 ,
 (a) where the first layer of material comprises of semi-cured impregnated composite fabric matrix;   (b) where the second layer of material comprises of impregnated composite fiber filaments.   
     
     
         4 . The process for making cured composite material as recited in  claim 1 , further comprising:
 (a) a step of: over-molding a third layer of material onto the second layer of material after step (d) and prior to step (e) while spinning the mandrel.   
     
     
         5 . The process for making cured composite material as recited in  claim 4 ,
 (a) where the first layer of material comprises of impregnated composite fiber filaments,   (b) where the second layer of material comprises of semi-cured impregnated composite fabric matrix.   (c) where the third layer of material comprises of impregnated composite fiber filaments;   
     
     
         6 . The process for making cured composite material as recited in  claim 4 ,
 (a) where the first layer of material comprises of semi-cured impregnated composite fabric matrix;   (b) where the second layer of material comprises of impregnated composite fiber filaments.   (c) where the third layer of material comprises of semi-cured impregnated composite fabric matrix.   
     
     
         7 . The process for making cured composite material as recited in  claim 1 , wherein the step of curing the over-molded material in an oven comprises the steps of:
 (a) ramping the oven temperature to a pre-flow temperature;   (b) waiting for the over-molded material inside the oven to reach the pre-flow temperature;   (c) waiting for the temperature of the over-molded material inside the oven to be uniform through-out the over-molded material;   (d) ramping the oven temperature to the thermal fusion bonding temperature;   (e) holding the oven temperature at the thermal fusion bonding temperature while the over-molded material diffuses across the interface between the tube shape compression molded fluoropolymer and the first layer of material;   (f) ramping down the oven temperature at a steady rate when sufficient over-molded material has diffused across the interface between the tube shape compression molded fluoropolymer and the first layer of material.   
     
     
         8 . An improved flange isolation gasket kit for sealing flanged pipeline connections, comprising:
 (a) a composite gasket blank, comprising:
 (i) a retainer, comprising,
 (1) a tapered upper surface; 
 (2) a tapered lower surface; 
 (3) a retainer outer diameter surface; 
 (4) a retainer inner diameter surface; 
 (5) a retainer thickness; and 
 (6) a central bore; 
 (7) where the retainer thickness tapers from the retainer inner diameter surface towards the retainer outer diameter surface, 
 
 (ii) a seal, comprising,
 (1) a seal outer diameter surface; 
 (2) a seal inner diameter surface, comprising:
 (a) an upper facing surface; 
 (b) a lower facing surface; and 
 (c) a seal pre-load cavity; 
 (d) where the seal pre-load cavity forms an indentation within the seal inner diameter surface concentric to the seal central axis, 
 
 (3) a seal upper surface; 
 (4) a seal lower surface; and 
 (5) a seal thickness; 
 
   (b) a seal pre-load structural ring;
 (i) where the seal pre-load structural ring is made out of materials with elastic properties, 
 (ii) where the seal pre-load structural ring is inserted within the seal pre-load cavity, 
   (c) where the retainer inner diameter surface is joined to the seal outer diameter edge by thermal fusion bonding.   (d) where the retainer is made from one or more layers of cured filament wound material and one or more layers of cured convolute wrapped pre-preg material,   (e) wherein the composite gasket blank is made by the process in  claim 1 .   
     
     
         9 . An improved flange isolation gasket kit for sealing flanged pipeline connections, comprising:
 (a) a composite gasket blank, comprising:
 (i) a retainer, comprising,
 (1) a tapered upper surface; 
 (2) a tapered lower surface; 
 (3) a retainer outer diameter surface; 
 (4) a retainer inner diameter surface; 
 (5) a retainer thickness; and 
 (6) a central bore; 
 (7) where the retainer thickness tapers from the retainer inner diameter surface towards the retainer outer diameter surface, 
 
 (ii) a seal, comprising,
 (1) a seal outer diameter surface; 
 (2) a seal inner diameter surface, comprising:
 (a) an upper facing surface; 
 (b) a lower facing surface; and 
 (c) a seal pre-load cavity; 
 (d) where the seal pre-load cavity forms an indentation within the seal inner diameter surface concentric to the seal central axis, 
 
 (3) a seal upper surface; 
 (4) a seal lower surface; and 
 (5) a seal thickness; 
 
   (b) a seal pre-load structural ring;
 (i) where the seal pre-load structural ring is made out of materials with elastic properties, 
 (ii) where the seal pre-load structural ring is inserted within the seal pre-load cavity, 
   (c) where the retainer inner diameter surface is joined to the seal outer diameter edge by thermal fusion bonding.   (d) where the retainer is made from one or more layers of cured filament wound material and one or more layers of cured convolute wrapped pre-preg material,   (e) wherein the composite gasket blank is made by the process in  claim 7 .   
     
     
         10 . The improved flange isolation gasket kit of  claim 8 , the improved flange isolation gasket kit further comprising:
 (a) A gasket seating stress stabilizer, comprising:
 (i) A gasket seating stress stabilizer hole; 
   (b) where the gasket seating stress stabilizer secures the composite gasket blank.   
     
     
         11 . The improved flange isolation gasket kit of  claim 10 , wherein the gasket seating stress stabilizer comprises a gasket seating stress bushing. 
     
     
         12 . The improved flange isolation gasket kit of  claim 10 , wherein the gasket seating stress stabilizer comprises a gasket seating stress annular block. 
     
     
         13 . The improved flange isolation gasket kit of  claim 10 , wherein the gasket seating stress stabilizer comprises a plurality of gasket seating stress annular block segments. 
     
     
         14 . The improved flange isolation gasket kit of  claim 8 , the improved flange isolation gasket kit further comprising:
 (a) a centering ring,   (b) a gasket seating stress stabilizer, comprising:
 (i) A gasket seating stress stabilizer hole; and 
   (c) where the centering ring secures the composite gasket blank,   (d) where the gasket seating stress stabilizer secures the centering ring.   
     
     
         15 . The improved flange isolation gasket kit of  claim 14  above, wherein the gasket seating stress stabilizer comprises a gasket seating stress bushing. 
     
     
         16 . The improved flange isolation gasket kit of  claim 14 , wherein the gasket seating stress stabilizer comprises a gasket seating stress annular block. 
     
     
         17 . The improved flange isolation gasket kit of  claim 14 , wherein the gasket seating stress stabilizer comprises a plurality of gasket seating stress annular block segments.