BIAXIAL PTFE GASKET MATERIAL WITH HIGH PURITY FILLER
A gasket material comprising polytetrafluoroethylene (PTFE) and high purity filler is described. The gasket material can include from 50 to 60 wt % PTFE and from 40 to 50 wt % high purity filler. The high purity filler can be high purity quartz, such as wherein the filler comprises greater than or equal to 99.996% quartz as the primary filler material. The PTFE can be full density PTFE. The gasket material can be provided in the form of a sheet, and can exhibit biaxial material properties. A core metal sheet can be encapsulated within the gasket material sheet, such as a corrugated metal sheet. Annular gasket seals can be formed from the gasket material sheet.
1 . A gasket material comprising:
50 to 60 wt % polytetrafluoroethylene; and
40 to 50 wt % filler, wherein the filler includes greater than or equal to 99.996% of primary filler material and less than or equal to 0.004% contaminants.
2 . The gasket material of claim 1 , wherein the polytetrafluoroethylene is full density polytetrafluorethylene.
3 . The gasket material of claim 2 , wherein the primary filler material is quartz.
4 . The gasket material of claim 3 , wherein the gasket material consists of the polytetrafluorethylene and the filler.
5 . The gasket material of claim 3 , wherein the polytetrafluorethylene is in the form of a matrix and the filler is homogenously dispersed throughout the polytetrafluoroethylene matrix.
6 . The gasket material of claim 3 , wherein the filler is at least 99.999% quartz.
7 . The gasket material of claim 3 , further comprising zirconia microballoons.
8 . The gasket material of claim 3 , wherein the gasket material is manufactured in a manner that results in the gasket material having biaxial material properties.
9 . The gasket material of claim 3 , wherein the gasket material is provided in the form of an annular gasket seal.
10 . A method of manufacturing an annular gasket seal comprising:
providing a sheet of gasket material comprising:
50 to 60 wt % full density polytetrafluoroethylene; and
40 to 50 wt % filler, wherein the filler comprises greater than or equal to 99.996% primary filler material;
cutting a series of arcs from the sheet of gasket material;
arranging the series of arcs in a circle; and
thermally bonding the ends of adjacent arcs.
11 . The method claim 10 , wherein the primary filler material is quartz.
12 . The method of claim 10 , wherein prior to cutting arcs from the sheet of gasket material, the sheet of gasket material is calendared in a manner that provides the gasket material sheet with biaxial material properties.
13 . The method of claim 10 , wherein thermally bonding the ends of the adjacent arcs is carried out in the absence of adhesive.
14 . A system for manufacturing high purity polysilicon, comprising:
a first system component;
a second system component abutting and in fluid communication with the first system component; and
a gasket seal disposed between the first system component and the second system component, the gasket seal comprising:
50 to 60 wt % full density polytetrafluoroethylene; and
40 to 50 wt % filler, wherein the filler comprises greater than or equal to 99.996% primary filler material;
15 . The system of claim 14 , wherein the primary filler material is quartz.
16 . The system of claim 14 , wherein the first system component is a pipe segment and the second system component is a reaction chamber.
17 . The system of claim 14 , wherein the first system component is one half of a dome-shaped reaction chamber and the second system component is a second half of the dome-shaped reaction chamber.