Armstrong World Industries, Inc.

Interface Solutions, Inc.

Interface Performance Materials, Inc.

Lydall Performance Materials (us), Inc.

Lydall Performance Materials, Inc.

John S Forry

Brian C Lehr

John R Garrick

Jeffery L Barrall

Dennis M Dempsey

Christopher L Morris

Linda L Sload

Walter J Lewicki, Jr

Jerome D Wisnosky

Richard M Ringer

Nancy E Mentzer

Donald J Misselhorn

Thomas C Simonton

David S Brown

Stephen E Becker

William C Welch

Jeff Barrall

Chester W Hallett

Karl B Himmelberger

Susan M Von Stetten

A method of making a lightweight thermal shield that includes obtaining a mold having a shaped support screen with a molding surface configured to allow the passage of air and moisture therethrough, and with the mold being adapted for drawing a vacuum from behind the support screen. The method also includes applying a wet insulation material onto the molding surface of the support screen and drawing a vacuum to withdraw moisture through the support screen and consolidate a layer of insulation material on top the molding surface. The method further includes removing the consolidated layer of insulation material from off the molding surface, installing the consolidated layer of insulation material into an outer shell layer, and drying the consolidated layer of insulation material within the outer shell layer to form a lightweight core insulation layer.

Lightweight thermal shield

An edge coated gasket includes a base sheet made of compressible gasket material and having opposed faces and an interior edge surrounding and defining an aperture. An edge coating of polymer or other material is disposed on and seals the interior edge of the base sheet and may project beyond the facial planes of the base sheet to define protruding rims extending around the aperture. Face coatings may also be applied to one or more of the faces extending in relatively narrow strips around the aperture of the base sheet. When clamped between flange surfaces, the edge coating engages, conforms to, and seals against the flange surfaces to provide a seal against both interfacial and intersticial migration of fluid past the gasket. At the same time, the inherently good compression failure resistance of the compressible gasket material of the base sheet is preserved. Thus, a gasket with enhanced sealability and compression failure resistance is provided. A unique method of making such an edge coated gasket is also disclosed.

Edge coated gaskets and method of making same

A gasket with selectively positioned seal enhancement zones located in the web of the gasket is provided. The gasket is formed of a base sheet of gasket material cut to define an interior aperture bounded by an interior edge and webs. Slots are formed at selected locations within the seal enhancement zones and the slots are bounded by edges. An edge coating of polymeric material is applied to the slot edges and, in one embodiment, project beyond the facial planes of the base sheet to form raised rims. An edge coating also may be formed on the interior edge bounding the aperture of the gasket. When clamped between a pair of flange surfaces, the polymeric edge coatings on the slot edges engage and seal against the flange surfaces within the seal enhancement zones to provide an enhanced seal against leakage in these zones.

Gasket with selectively positioned seal enhancement zones

An improved gasket ( ) for sealing the joint between a pair of flange surfaces is provided. In one embodiment, the gasket ( ) is an edge coated gasket and the edge coating ( ) also exhibits surface adhesion to enhance the seal provided by the gasket. In another embodiment, compressible sealing members ( ) are coated with a coating material ( ) that exhibits surface adhesion properties.

Gaskets with controlled flange surface adhesion properties

Gaskets with selectively positioned seal enhancement zones

A gasket having two opposed faces and an edge disposed therebetween is given a wide coating on the edge. The coating is sufficiently wide so that it goes from corner to corner on the edge and protrudes past the corner on at least one side of the gasket in a direction perpendicular to a facial plane of the gasket. The coating protrudes in an amount effective to give the gasket a sealing ability which is better than the sealing ability of the same gasket if it had a coating merely extending from corner to corner without protruding. A process for coating the gasket edges which are around the aperture comprises placing the gasket sheets together so that a cavity is formed by the apertures, the sides of the cavity are the aperture edges to be coated. The coating material is put into the cavity and contacts the edges to be coated to form the coated edges.

Method of fabricating high sealing gaskets

A gasket which is compression-failure resistant, even at operating flange pressures in the range of from about 3,000 to about 15,000 PSI and also has a good sealing ability, comprises a soft gasket material having two opposed, facial surfaces and an aperture with an edge perpendicular to the facial surfaces, wherein the edge of the aperture has a polymer coating (coating A) on the edge for a good sealing ability. In this embodiment, except for coating A, the gasket is otherwise not coated which makes the gasket compression-failure resistant. In embodiments which need even better sealing ability, at least one of the opposed, facial surfaces has polymer coating B, which may abut both the edge and polymer coating A, wherein polymer coating B on the facial, opposed surface leaves the gasket uncoated for sealing ability in an amount effective to give the gasket compression failure resistance.

High-pressure compression-failure resistant and high sealing gasket

A gasket having two opposed faces and an edge disposed therebetween is given a wide coating on the edge. The coating is sufficiently wide so that it goes from corner to corner on the edge and protrudes past the corner on at least one side of the gasket in a direction perpendicular to a facial plane of the gasket. The coating protrudes in an amount effective to give the gasket a sealing ability which is better than the sealing ability of the same gasket if it had a coating merely extending from corner to corner without protruding.

High sealing gaskets

A compressible gasket is provided which has at least one bolt area with a tapered densification. The tapered densification puts the lowest porosity at a center area of the bolt area. The center area is that part of the bolt area which surrounds and abuts the bolt aperture itself, and in use is covered by the bolt head. Two embodiments are provided. In one the gasket will have a substantially uniform porosity throughout the center area underneath the bolt head. In the more preferred embodiment, the densification gradually decreases in a porosity gradient beginning at the aperture and going through the center area.

Gasket structure with tapered bolt area densification

A print and fusion process is used to fabricate ceramic elements that are subsequently utilized to generate a composite including a fibrous mat and discrete ceramic elements. The composite may include a substrate and a flexible or rigid non-ceramic composition between the discrete ceramic elements and/or the substrate. A ceramic ink preferably partially penetrates the fibrous mat to form the discrete elements or a continuous layer.

Growing community of inventors

Lancaster, PA, United States of America

John S Forry