Weld Ring Gasket Layout for Reliable Flange Sealing
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Solution Overview
Problem
Existing weld ring gaskets in process technology facilities face challenges with tightness due to sensitive caulking seams, which are prone to defects under dynamic stress, making them difficult to install and maintain, especially with hazardous media, and require precise positioning that is hard to verify post-assembly.
Innovation Solution
The torus-shaped connection section is arranged radially on the inside, allowing the weld ring halves to be welded together first, then to the flanges, enabling the caulking seam to be welded outside the flange arrangement, facilitating quality control and reducing the risk of edge offset, with features like a ring gap and notch to manage force distribution and simplify disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the torus-shaped connection section is arranged radially on the outside with base sections lying radially on the inside, then the weld ring halves can be welded to flanges first, but the caulking seam becomes sensitive to defects under dynamic stress and requires precise positioning that is hard to verify post-assembly
Solution Approach 1:
The patent inverts the conventional arrangement by positioning the torus-shaped connection section radially on the inside and base sections radially on the outside. This inversion allows the caulking seam to be welded first outside the flange arrangement where quality control is easier, then the weld ring halves are welded to the flanges, resolving the contradiction between manufacturing ease and reliability.
2Reliability
If the torus-shaped connection section is arranged radially on the inside, then quality control of the caulking seam is facilitated, but the fillet welds are subject to great stress under dynamic stress
Solution Approach 1:
The patent applies preliminary action by welding the caulking seam first when the weld ring halves are still accessible outside the flange arrangement, ensuring high quality before the components are subjected to dynamic stresses during operation. This sequence allows quality control to be performed under more favorable conditions.
Solution Approach 2:
The torus-shaped connection section arranged radially on the inside acts as a cushioning element that absorbs and distributes stresses, protecting the fillet welds from the full impact of dynamic loads. The geometry of the torus section provides stress relief before forces are transmitted to the fillet welds connecting to the flanges.
3Ease of repair
If the weld ring gasket needs to be replaced, then the flange connection must be disassembled, but opening the torus-shaped connection section is required which is complex and time-consuming
Solution Approach 1:
The patent segments the weld ring gasket into distinct components: the torus-shaped connection section and the base sections. This segmentation allows the torus section to remain intact during replacement operations, while only the base sections need to be removed from the flanges, simplifying the overall replacement procedure and reducing device complexity during maintenance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration simplifies the assembly and reduces error susceptibility, ensures reliable sealing, and allows for easier replacement of the weld ring gasket without opening the torus-shaped connection section, while reducing the risk of fillet weld failure under dynamic stress.
Implementation Method 1
the weld ring halves are welded to the base section by way of a fillet weld with the flange that lies against it
Implementation Method 2
the weld ring halves are welded to one another at the torus-shaped connection section, by way of a caulking seam
Data Source
AI summary
A flange connection has two flanges and a weld ring gasket arranged between the flanges, wherein the weld ring gasket has two weld ring halves arranged one on top of the other, each having a base section and a lip arranged on it, wherein the weld ring halves are welded to the base section by way of a fillet weld with the flange that lies against it, and wherein the lips form a torus-shaped connection section having a hollow interior, and the weld ring halves are welded to one another at the torus-shaped connection section, by way of a caulking seam. The torus-shaped connection section is arranged to lie radially on the inside.