A spirally wound gasket is described. The gasket includes a sealing strip ( 11 ) wound into a spiral and a support strip ( 10 ) wound into a spiral in such a manner that the spiral of the sealing strip is formed interposed between the coils of the supporting strip. The sealing strip comprises a resilient material, the resilient material comprising a CEV component in a proportion of at least 25% w/w of the sealing strip. The CEV component is at least partially derived from dry CEV, and the sealing strip does not include a carrier strip in one aspect. In another aspect, the CEV component is at least partially derived from dry CEV, and the sealing strip has a moisture level of between 3–20% w/w of the sealing strip resilient material during winding into the said gasket. A method of producing a sealing strip is also described.
1. A spirally wound gasket comprising a sealing strip wound into a spiral wherein the sealing strip is in the form of a single layer, and a support strip wound into a spiral in such a manner that the spiral of the sealing strip is formed interposed between the coils of the support strip, the spiral of the sealing strip contacting and extending uninterruptedly between the coils of the support strip, the sealing strip comprising a resilient material, the resilient material comprising a chemically exfoliated vermiculite (CEV) component in a proportion of at least 25% w/w of the sealing strip, the said CEV component being at least partially derived from dry CEV.
2. A spirally wound gasket comprising a sealing strip wound into a spiral wherein the sealing strip is in the form of a single layer, and a support strip wound into a spiral in such a manner that the spiral of the sealing strip is formed interposed between the coils of the support strip, the spiral of the sealing strip contacting and extending uninterruptedly between the coils of the support strip, the sealing strip comprising a resilient material, the resilient material comprising a chemically exfoliated vermiculite (CEV) component in a proportion of at least 25% w/w of the sealing strip, the said CEV component being at least partially derived from dry CEV, wherein the resilient material also comprises a hydrolysis resistant polymer to improve the water resistance of said sealing strip, the proportion of said polymer not exceeding 20% w/w of the sealing strip.
3. A spirally wound gasket according to claim 1 , wherein the resilient material further comprises a plate like filler material.
4. A spirally wound gasket according to claim 1 , wherein the sealing strip has a small moisture content during spiral winding.
5. A spirally wound gasket according to claim 1 , wherein the sealing strip has a small moisture content during removal from a forming sheet on which the sealing strips or layers are formed.
6. A spirally wound gasket according to claim 1 , wherein the moisture level of the sealing strip during winding is between 3–20% w/w of the resilient material of the sealing strip.
7. A spirally wound gasket according to claim 1 , wherein the resilient material further comprises a hydrolysis resistant polymer to improve the water resistance of said sealing strip, the proportion of said polymer not exceeding 20% w/w of the sealing strip.
8. A spirally wound gasket according to claim 1 , wherein the chemically exfoliated vermiculite component of the present invention includes sufficient dry CEV, to provide a wet sealing layer dough with a reduced water content which is capable of being dried before substantial skinning has occurred.
9. A spirally wound gasket according to claim 1 , wherein the moisture level of the sealing strip during winding is between 2–10% w/w of the resilient material of the sealing strip.
10. A spirally wound gasket according to claim 1 , wherein the sealing strip comprises at least 80% resilient material.
11. A gasket according to claim 1 , wherein the relative ratio of non-dry derived CEV to dry CEV in the dried sealing strip component is between 0.01:1 and 20:1.
12. A gasket according to claim 1 , wherein the particle size of at least 90% of the CEV is more than 50μm.
13. A gasket according to claim 1 , wherein the resilient material is mechanically bonded to the support strip.
14. A gasket according to claim 1 which includes, as a plate-like, filler, vermiculite material comprising a plurality of particles with at least 90% of the particles having a plate size in the range 50–300 μm.
15. A gasket according to claim 1 , wherein the sealing layer comprises 5–80% plate like filler in the dried sealing layer.
16. A gasket comprising:
a support strip; and
a sealing strip comprising a resilient material, the sealing strip having:
a partially-wound configuration in which:
at least a portion of the support strip is spirally wound to define a first plurality of coils,
a portion of the sealing strip is spirally wound in such a manner that the spiral of the portion of the sealing strip is formed interposed between the coils of the first plurality of coils, and
the moisture level of the sealing strip is 2–20% w/w of the sealing strip resilient material; and
a fully-wound configuration in which:
the entire support strip is spirally wound to define a second plurality of coils, and
the entire sealing strip is spirally wound in such a manner that the spiral of the entire sealing strip is formed interposed between the coils of the second plurality of coils.
17. The gasket of claim 16 wherein the moisture level reduces the brittleness of the sealing strip.
18. The gasket of claim 16 wherein the moisture level increases the cohesion of the sealing strip.
19. The gasket of claim 16 wherein the resilient material comprises a hydrolysis resistant polymer to improve the water resistance of the sealing strip, the proportion of the polymer not exceeding 20% w/w of the sealing strip.
20. The gasket of claim 16 wherein the resilient material comprises means for strengthening the sealing strip to prevent breakage of the sealing strip due to the spiral winding of the sealing strip.
21. The gasket of claim 20 wherein the sealing strip is in the form of a single layer, and wherein the spiral of the sealing strip contacts and extends uninterruptedly between the coils of the second plurality of coils in the fully-wound configuration.
22. The gasket of claim 20 wherein the strengthening means comprises a chemically exfoliated vermiculite (CEV) component in a proportion of at least 25% w/w of the sealing strip, the CEV component being at least partially derived from dry CEV.
23. The gasket of claim 22 wherein the relative ratio of non-dry derived CEV to dry CEV in the sealing strip is between 0.01:1 and 20:1.
24. A gasket comprising:
a sealing strip wound into a spiral, wherein the sealing strip is in the form of a single layer; and
a support strip wound into a spiral in such a manner that the spiral of the sealing strip is formed interposed between the coils of the support strip, the spiral of the sealing strip contacting and extending uninterruptedly between the coils of the support strip;
wherein the sealing strip comprises a resilient material, the resilient material comprising means for strengthening the sealing strip to prevent breakage of the sealing strip due to the spiral winding of the sealing strip; and
wherein the strengthening means comprises a chemically exfoliated vermiculite (CEV) component in a proportion of at least 25% w/w of the sealing strip, the CEV component being at least partially derived from dry CEV.
25. The gasket of claim 24 wherein the relative ratio of non-dry derived CEV to dry CEV in the sealing strip is between 0.01:1 and 20:1.
26. A gasket comprising:
a sealing strip wound into a spiral, wherein the sealing strip is in the form of a single layer; and
a support strip wound into a spiral in such a manner that the spiral of the sealing strip is formed interposed between the coils of the support strip, the spiral of the sealing strip contacting and extending uninterruptedly between the coils of the support strip;
wherein the sealing strip comprises a resilient material, the resilient material comprising means for strengthening the sealing strip to prevent breakage of the sealing strip due to the spiral winding of the sealing strip; and
wherein the resilient material further comprises a hydrolysis resistant polymer to improve the water resistance of the sealing strip, the proportion of the polymer not exceeding 20% w/w of the sealing strip.
27. A gasket comprising:
a support strip; and
a sealing strip comprising a resilient material, the sealing strip having:
a partially-wound configuration in which:
at least a portion of the support strip is spirally wound to define a first plurality of coils,
a portion of the sealing strip is spirally wound in such a manner that the spiral of the portion of the sealing strip is formed interposed between the coils of the first plurality of coils, and
the resilient material comprises means for reducing the brittleness of the sealing strip; and
a fully-wound configuration in which:
the entire support strip is spirally wound to define a second plurality of coils, and
the entire sealing strip is spirally wound in such a manner that the spiral of the entire sealing strip is formed interposed between the coils of the second plurality of coils;
wherein the resilient material further comprises means for strengthening the sealing strip to prevent breakage of the sealing strip due to the spiral winding of the sealing strip; and
wherein the strengthening means comprises a chemically exfoliated vermiculite (CEV) component in a proportion of at least 25% w/w of the sealing strip, the CEV component being at least partially derived from dry CEV.
28. The gasket of claim 27 wherein the reducing means comprises moisture in such an amount that the moisture level of the sealing strip is 3–20% w/w of the sealing strip resilient material in the partially-wound configuration.
29. The gasket of claim 27 wherein the reducing means comprises moisture in such an amount that the moisture level of the sealing strip is 2–10% w/w of the sealing strip resilient material in the partially-wound configuration.
30. The gasket of claim 27 wherein the sealing strip is in the form of a single layer, and wherein the spiral of the sealing strip contacts and extends uninterruptedly between the coils of the second plurality of coils in the fully-wound configuration.
31. The gasket of claim 27 wherein the relative ratio of non-dry derived CEV to dry CEV in the sealing strip is between 0.01:1 and 20:1.
32. The gasket of claim 27 wherein the resilient material further comprises a hydrolysis resistant polymer to improve the water resistance of the sealing strip, the proportion of the polymer not exceeding 20% w/w of the sealing strip.