Coated flanged coupling

Abstract

An improved coupling system for joining two items together, typically in the form of copper pipes, to other copper pipes, or in the form of other fittings, includes a pair of flange couplings, each of which is independently secured to one of the items to be joined together so that when the two flange couplings are securely joined to each other by suitable fasteners received through fastening apertures in the two flange couplings, the two items are sealingly joined to one another to form a substantially water tight junction. The improvement being that the bare metal parts of the ferrous components of the coupling are coated with a protective coating, such as a copper coating, so that there is no direct contact between two dissimilar metals thereby inhibiting or preventing corrosion of the metal components of the coupling due to electrolytic or galvanic action arising from direct contact between the two dissimilar metals.

Claims

1. A connector in the form of a coupling for joining two conduit members to one another, the coupling comprising a first conduit member made from a first metallic material, a second conduit member, a first coupling element made from a second metallic material, and a second coupling element made from the second material, the second coupling element being associated with the second conduit member, the first and second metallic materials having different positions on the Anodic Index, said first and second coupling elements each having an external coating of the first material, wherein when the first and second coupling elements are arranged with respect to each other so that the first coupling element is associated with the first conduit member and the second coupling element is associated with the second conduit member so as to join the first conduit member to the second conduit member by the coupling, the coating of the first coupling element is in intimate contact with the first conduit member for reducing and/or preventing an electrolytic or galvanic cell being formed between the first conduit member and the first coupling element.

2. A connector according to claim 1 in which when the first conduit member is joined to the second conduit member by the first and second coupling elements cooperatively engaging with one another, there is no direct intimate contact between the first conduit member and the second material of an uncoated part of the surface of the first coupling element and no direct intimate contact between the second conduit member and the second material of an uncoated part of the surface of the second coupling element, so that corrosion occurring between the first conduit member and the first coupling element and/or between the second conduit member and the second coupling element due to the first and second metallic materials having different positions on the Anodic Index, is inhibited or prevented.

3. A connector according to claim 1 in which the coupling is a flange coupling or flange connector, or a pair of flange couplings or joining rings.

4. A connector according to claim 3 in which the flange coupling is provided with a centrally located or oriented orifice or opening, aperture, bore, hole, cavity or base for receiving therethrough one of the conduit members in which the size of the aperture is slightly greater than the outside diameter of the conduit member.

5. A connector according to claim 4 in which the conduit member is an insert or sleeve or is provided with an insert or sleeve in which the insert or sleeve is received within the orifice or opening, of the connector or flange coupling.

6. A connector according to claim 5 in which one end of the conduit member, insert or sleeve is received through one coupling and abuts against a wall of the other coupling, such that one of the ends of the insert, sleeve or pipe is located intermediate the two flange couplings when joined to one another.

7. A connector according to claim 6 in which the conduit member is joined to the sleeve or insert mechanically or by a chemical bonding agent or similar such as by being soldered, crimped or welded.

8. A connector according to claim 1 in which the conduit member is a pipe made from copper or a copper containing alloy.

9. A connector according to claim 1 in which the coating is applied to the external surface of the flange coupling wherein the coating is made from or deposited as a metallic coating in which the metal of the coating is a non ferrous metal or contains a non ferrous metal, in which the non ferrous metal is copper, nickel, or chromium, including alloys or combinations thereof.

10. A connector according to claim 9 in which the external metallic coating is a mono layer or is a dual layer, or is a multi-layer of metal or metal containing material.

11. A connector according to claim 10 in which the metallic coating is a laminate or layered structure of two or more coatings or layers of the same or different materials.

12. A connector according to claim 11 in which the metallic coating comprises at least one inner layer and at least one outer layer in which the inner layer is in direct intimate contact with the metal from which the flange coupling is made.

13. A connector according to claim 12 in which the outer layer is made of a metal of a composition having a position on the Anodic Index which is the same as the position on the Anodic Index of the composition of the metal from which one or both of the conduit members are manufactured.

14. A connector according to claim 12 in which the flange coupling is made from a ferrous material and the coating or the outer layer of the coating is copper or a copper containing material.

15. A connector according to claim 12 in which there is direct intimate contact of at least part of the exterior copper coated flange coupling and at least a part of the exterior surface of the copper insert or sleeve or pipe.

16. A connector according to claim 12 in which the coating includes an inner layer of chromium or nickel which is directly adhered to the surface of the steel from which the coupling is made and the outer layer is a copper layer or made from a copper containing material applied to the nickel or chromium layer so as to alter the electrolytic or galvanic characteristics of the flange coupling.

17. A connector according to claim 16 in which the layer is deposited as a layer of copper plating in which the copper plating is by electroplating, by alkaline complexed bath or acid bath.

18. A connector according to claim 17 in which the thickness of the copper layer is from about 0.5 to about 100, preferably from about 1 to about 80, more preferably from about 5 to about 50, most preferably from about 10 to about 50.

19. A connector according to claim 18 in which the layer changing the electrolytic characteristic or galvanic characteristic of the connector is a copper layer, copper alloy layer, brass layer, bronze layer or similar, which is applied by electroplating, chemical vapour deposition, spluttering or other electroplating and/or deposition techniques including electroless plating using chemical reactions to cover the bare exposed metal surfaces of the flange coupling or connector.

20. A connector according to claim 17 in which the layer of chromium or nickel is from about 0.1 to about in excess of 100.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the connector and/or coupling will now be described to illustrate forms of the coupling by way of example only with reference to the accompanying drawings in which:

(2) FIG. 1 is an exploded view of the component parts of one form of the coupling connector.

(3) FIG. 2 is a perspective view of the coupling/connector of FIG. 1 in a connected configuration in use for joining two pipes to one another.

(4) FIG. 3 is an exploded view of one form of fastener for joining two flange couplings or connectors to one another.

(5) FIG. 4 is an enlarged view of circle A of FIG. 5 showing the layered structure of the external coating applied to the flange connector.

(6) FIG. 5 is a partial cross-sectional view/partial side elevation view of the connector showing the layered arrangement of the external coating applied to all exposed surfaces of the flange connector.

(7) FIG. 6 is an exploded view of another embodiment of the connector for joining a port of a valve to a pipe.

DETAILED DESCRIPTION OF AN EMBODIMENT

(8) In the drawings, there is shown various views of one form of a connector system useful for joining two pipes to one another. It is to be noted that in this embodiment, the connector is being used to join two substantially identical pipes together. Other embodiments are used to connect a pipe to a fitting, such as for example, a valve or tap, or more particularly, the inlet and/or outlet of the valve or tap for admitting liquid to or discharging liquid from the valve or tap. One alternative is shown in FIG. 6. Also, it is to be noted that the described embodiment is illustrated with respect to joining two sleeves together in which the pipes are received in the sleeves. Other embodiments include joining a pipe and sleeve combination to another type of fitting, such as a valve or tap, including the conduit portions of the valve or tap.

(9) In one form, there is a first flange coupling, generally denoted as 12, located at or towards the left hand side of FIG. 1. Flange coupling 12 is generally circular in shape being of an annular form having a centrally located relatively large size orifice 14 of a size, shape and profile corresponding to the size, shape and profile of a first sleeve 32, particularly the external diameter of the body 36 of the sleeve 32, which is received within orifice 14 in preparation of joining two conduit members to one another. It is to be noted that a pipe 33 (not shown for clarity in FIGS. 1 to 3, but shown in FIGS. 4 and 5,) is received within sleeve 32. In one form, pipe 33 and sleeve 32 combination, is one form of one conduit, typically the first conduit. There are other forms of the first conduit, such as for example, the sleeve, or the pipe, or both.

(10) Flange coupling 12 is generally cylindrical having a first surface, referred to as an obverse face 16 located on one side and facing outwardly in use. Flange coupling 12 has a second surface, referred to as a reverse face 18 located on the opposite side facing inwardly toward a second flange coupling 62 to which first flange coupling 12 is connected in use to join the two conduit members.

(11) Flange coupling 12 is provided with a circumferentially curved outer side wall 20, generally referred to as the thickness of the flange coupling, extending between the first surface 16 and the second surface 18 and with an inner curved side wall 22 forming the inner surface of centrally located orifice 14. In one form, all of surfaces 16, 18, 20, 22 are generally smooth. However, the surfaces may be treated to assist application of a protective covering thereover as will be described in more detail later.

(12) In one form, flange coupling 12 is provided with eight relatively small diameter apertures 24a, 24b, 24c, 24d, 24e, 24f, 24g, 24h located at regularly spaced apart locations around the perimeter of the circular faces 16, 18 of coupling 12 to form fastening apertures to assist in joining flange couplings 12, 62 to one another to be described in more detail later in the specification. In one form, flange couplings 12, 62 are made from steel or other essentially ferrous materials.

(13) Flange couplings 12, 62 are each made from steel as indicated by 92 of FIG. 4, such as for example, a mild steel or other steel material, and are provided with an external coating 94 to provide a protective coating or covering over the entire outer surface including the inside walls of circular orifice 14 and the inside walls of fastening apertures 24 to provide a more or less substantially uniform coating over the entire exposed steel surface of each flange coupling 12, 62. In one form, the coating is a copper coating or a coating containing copper or an alloy of copper, herein referred to as being the copper coating for ease of reference. In one form, there is an inner coating (not shown). Typically, the inner coating is a chromium coating, a chromium-containing coating or a coating of a chromium alloy or the like whereas the outer coating is the copper coating.

(14) A first conduit member in the form of a sleeve 32 is provided contiguously with first flange coupling 12. In one form, sleeve 32 comprises a flange 34 located at one end thereof and a body portion 36 extending from flange 34 to the other end of sleeve 32. In one form, sleeve 32 is formed with body 36 and flange 34 being integrally arranged such that flange 34 is formed at the end of body 36 by spinning the metal at the end of sleeve 32 to form flange 34. It is to be noted that the outside diameter of body 36 of sleeve 32 is about the same as the internal diameter of orifice 14 of flange coupling 12 so as to be received in or through orifice 14 when joining two pipes together. In one form, sleeve 32 is made from copper or a copper-containing alloy. Pipe 33, also made from copper, is received in sleeve 32 as shown more particularly in FIGS. 4 and 5.

(15) A first generally plug shaped hollow insert 38, typically made from a plastics or other non metallic material, having a generally annular transverse cross-section is provided in each fastener aperture 24a to 24h from the obverse face of coupling 12. Insert 38 has a lengthwise extending body or shank portion 40 in the shape of a hollow cylinder and an enlarged head portion 42 in the form of an annular disc integrally formed with hollow shank 40. It is to be noted that the external diameter of shank portion 40 is about the same or slightly smaller than the internal diameter of fastening aperture 24 so as to be securely located in aperture 24 to protect the coated surfaces of flange coupling 12, particularly around each aperture 24 and the wall of the bores of apertures 24 from coming into contact with the exposed bare surface of a bolt 46 received within the opening 24 of insert 38. Bolt 46 is usually made from steel or other ferrous material. Bolt 46 is provided with a shaft 48 having a threaded section 50 located at or towards the one end around the external circumference and a hexagonal shaped head 52 located at the other end. A washer 54 typically made from the same material as nut 46, such as steel or other ferrous material, or insert 38 such as for example, made from a plastics material, such as nylon or other engineering plastic material, is located between head 52 of bolt 46 and head 42 of insert 38.

(16) A similar arrangement is provided on the right hand side of the connector system where there is second flange coupling 62 having an obverse face 64, a reverse face 66, a curved outer circumferentially extending side wall 68, a curved inner side wall 70, surrounding a centrally located orifice 72 for use with a second conduit member. Coupling 62 is made from a steel based material, such as for example, mild steel 92, and is coated with a copper or copper alloy coating 94, having the same composition as the second conduit which in this embodiment, is a copper sleeve 78 so as to inhibit galvanic corrosion through direct contact of two dissimilar metals.

(17) Flange coupling 62 is provided with eight fastener apertures 74a to 74h, located at regularly spaced apart locations circumferentially around the perimeter of the flange.

(18) In one form, a second conduit in the form of sleeve 78 is provided with a flange 80 located around the inboard end in use and a body section 82 corresponding to the diameter of sleeve 78. A pipe 79, (not shown in FIGS. 1 to 3 of the drawings for clarity, but shown in FIGS. 4 and 5) is received within the bore of sleeve 78. Pipe 79 is received within sleeve 78 as shown more particularly in FIGS. 4 and 5. Sleeve 78 is made from copper as is pipe 79. Pipe 79 when received in sleeve 78, is crimped or otherwise fastened to sleeve 78 so as to secure the pipe and sleeve into a single water tight unit.

(19) A set of second inserts 84 having hollow shanks 86 and enlarged annular disc-like heads 88, are received in fastening apertures 74 of second flange coupling 62 in a similar manner to inserts 38 being received in fastening apertures 24 of the first flange coupling 12. Washers 90 are provided intermediate head 88 of insert 84 on the inboard side of nut 76.

(20) Instead of having threaded bolts 46 received through inserts 38 and apertures 24, internally threaded nuts 76 are provided to threadingly engage the externally treated portion 50 of bolt 46 to securely connect the flange couplings 12, 62 to one another with flanges 34, 80 of sleeves 32, 78 sandwiched therebetween the two flange couplings 12, 62 to form a fluid tight seal between flanges 34, 80 of the two pipes 33, 79.

(21) It is to be noted that mostly, nuts 76 and bolts 46 are made from ferrous materials, mainly steel. However, they can be made from other materials such as brass, bronze or the like for selected applications.

(22) In a second embodiment as shown in FIG. 6, there is shown an embodiment in which a pipe is joined to another form of fitting, such as for example, to the outlet of a valve or tap in which the flange coupling is integrally formed with the tap or valve on an outwardly extending projection.

(23) In the embodiment shown in FIG. 6, the same reference numerals are used to denote the same or similar features of the embodiment shown in FIGS. 1 to 5.

(24) In the embodiment of FIG. 6, valve 110 has a handle 112 and two flange couplings 114, 116 located at either opposite end thereof at the end of respective outwardly extending projections. Thus, body 36 of sleeve 32 is received through orifice 14 of coupling 16 to extend outwardly from coupling 16 to receive one end of pipe 33 which is crimped or otherwise fastened to body 36 of sleeve 32. Flange 34 is located intermediate the inwardly directed face 18 of coupling 16, and the outwardly directed face of coupling 116, which is integrally formed at one end of valve 110 to join pipe 33 to valve 110. Coupling 116 is the same as coupling 62 of FIGS. 1 to 5 except that it is formed integrally as part of valve 110, rather than being an individual component. Bolts 46 are received through aligned apertures 24 provided in coupling 116 to threadingly engage with nuts 76. Inserts 38 are provided in apertures 24 to prevent contact of bolts 46 with the copper coating of flange coupling 116. Flange coupling 114, 116 can be copper coated to match the copper of insert 32 so as to inhibit corrosion caused by a galvanic cell of similar metals being established.

(25) In other embodiments, valve 110 can be replaced with any other fitting having a flange which is the same as or similar to flange couplings 16, 62, 116.

(26) By coating all of the exposed metal surfaces of the flange coupling with a copper coating to match the copper of the pipes, there is no direct intimate contact of two dissimilar metals to set up an electrolytic or galvanic cell for causing corrosion. Instead, the metal parts of the coupling system or arrangement including the couplings in intimate direct touching contact with each other, are all of the same or substantially the same metal, most notably copper, so that there is a considerably reduced chance that corrosion will result due to the electrochemical potential difference of the two dissimilar metals forming an electrolytic or galvanic cell or circuit of the type responsible for corrosion.

ADVANTAGES OF THE INVENTION

(27) Copper coating of steel flange is UV resistant, more durable, scratchproof. Having a copper coating reduces or prevents the need to have other forms of protection, such as for example, washers, gaskets or the like. Pipes and couplings can be buried underground without additional adverse corrosive effects. No insulator/gasket required to provide protection so that there is no need to check to see if an insulator gasket is present or is the correct size for receiving a pipe or other conduit. The plastic inserts can be preinstalled at the factory where the couplings are being made and/or packaged so that there is virtually complete isolation between dissimilar metals. The copper coating process tends to be more reliable at providing protection. The copper coating process tends to be more of a failsafe way of providing protection. Pre-cleaning of the components forming the coupling and/or coupling system can occur in situ rather than during installation or assembly of the pipe line or similar. No heat required to be applied to the coupling, connector or other parts during installation of the coupling. Reproducible coating thicknesses is possible, and thus uniform protection provided.

(28) The described arrangement has been advanced by explanation and many modifications may be made without departing from the spirit and scope of the invention which includes every novel feature and novel combination of features herein disclosed.

(29) Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope.