Abstract:
A thin flange for insertion between two ultra-high vacuum flanges includes opposing, parallel sealing surfaces. The sealing surfaces can be surrounded by mounting surfaces having mounting holes therein alignable with holes in the flanges. Forces applied by bolts inserted through the aligned holes are distributed by the flanges so that the thin flange is subjected only to symmetric, compressive forces. Since no deforming forces are applied to the thin flange, the thickness of the thin flange can be less than previously attained, and can be less than 15% of its diameter, or even less than 6.5%. The thickness of the thin flange can be less than 0.28 inches or less than 0.16 inches. Knife edges on the sealing surfaces pressed against soft metal gaskets can form vacuum seals. The thin flange can include a feature such as an inward-facing mounting groove, a threaded mounting bore, and/or an electrical feed-through.

Description:
RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 10/934,833, filing date Sep. 3, 2004, which is a continuation-in-part of U.S. patent application Ser. No. 10/014,164, filing date Oct. 26, 2001, now abandoned, which claims the benefit of U.S. provisional application No. 60/243,526, filing date Oct. 26, 2000. Each of these applications is herein incorporated by reference in its entirety for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to ultra-high vacuum systems and, specifically, to a system for the insertion of components on a reduced thickness flange between two standard thickness flanges. 
     BACKGROUND OF THE INVENTION 
     Vacuum systems find wide applications in research, education, product development, and production. Typical systems comprise independent and interchangeable components. Such components may include testing chambers, pumps, gauges, valves, specimen manipulators, testing apparatus, radiation sources, particle detectors, heating and cooling systems, and other components known in the industry. 
     Processes or experiments that require high or ultrahigh vacuum (UHV) currently employ all metal vacuum joints. A typical flange  20  for an all-metal joint is illustrated in  FIG. 1 . Such a joint is comprised of at least two flanges  20 ,  24  illustrated in  FIG. 2 . Each of the flanges  20 ,  24  includes an annular recess  26 ,  28  and an annular knife edge  30 ,  32 . The flanges  20 ,  24  are configured for mating using a soft, metallic gasket  34  (e.g. a copper gasket). The opposing knife edges  30 ,  32  are pressed into the gasket  34  when the flanges  20 ,  24  are compressed together by tightening bolts  38 . The knife edges  30 ,  32  in combination with the gasket  34  form a UHV seal. 
     The force of the tightened bolts  38  is transferred to the gasket  34  through the thickness of the flanges  20 ,  24 . The bolt holes  36  are disposed on a diameter that is outside that of the knife edge  30 ,  32 . If the standard flange  20 ,  24  is not of appropriate thickness, the flanges  20 ,  24  may deform as depicted in  FIGS. 3 and 4 . The deformed flange  25 A in  FIG. 3  is considered a dish-shaped deformation and results from the flange  25 A bowing around the perimeter of the gasket. The deformed flange  25 B in  FIG. 4  is a wave-like deformation and results from deflection of the flange  25 B between bolts in the all-metal joint. The bowing of the flange  25 A occurs due to the moment arm between the knife edge  30 ,  32  and the bolt  38 . In the case of a deflection or deformation, such as those illustrated in  FIGS. 3 and 4 , the seal may leak if the force placed on the gasket  34  between the adjacent bolts  38  is less than the force required to press the knife edges  30 ,  32  sufficiently into the gasket  34  to form a seal. Only an appropriate thickness of the flange provides adequate resistance to deformation in this situation. 
     Thus, a heretofore unaddressed need exists in the industry to address the aforementioned deficiencies and inadequacies. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present invention provide a system and method for providing a thin flange. 
     Briefly described, in architecture, one embodiment of the system, among others, can be implemented as follows. A thin flange, for use with a vacuum system, includes a member having a diameter and a thickness. The member has a first face having a first sealing surface. The member has a second face opposed and substantially parallel to the first face. The second face has a second sealing surface. The thickness of the member is less than previously attained. In some designs, the thickness of the member is less than 0.28 inches. In other designs, the thickness of the member is less than fifteen percent of the diameter of the member. 
     One general aspect of the present invention is a thin flange configured for installation in a vacuum system between a first thick flange and a second thick flange. The thin flange includes a first face having a first sealing surface surrounded by a substantially planar first clamping surface, the first sealing surface being bounded by a first inner sealing perimeter and a first outer sealing perimeter. The thin flange further includes a second face opposed to and substantially parallel to the first face, the second face having a second sealing surface surrounded by a substantially planar second clamping surface, the second sealing surface being bounded by a second inner sealing perimeter and a second outer sealing perimeter, the second clamping surface being in at least partly overlapping relationship with the first clamping surface, the first clamping surface and the second clamping surface being separated by a clamping thickness. In addition, the thin flange includes a plurality of mounting holes, each of the mounting holes penetrating the thin flange through both the first clamping surface and the second clamping surface, each of the mounting holes being alignable with a corresponding hole disposed in the first thick flange and with a corresponding hole disposed in the second thick flange, such that when the thin flange is disposed between the two thick flanges and bolts are inserted through the aligned holes, all clamping forces applied by the bolts are distributed by the two thick flanges and are applied only as a symmetric, compressive force to the thin flange. 
     In some embodiments, the first sealing surface comprises a knife edge and the second sealing surface comprises a knife edge. 
     In various embodiments, the thin flange includes at least one mounting feature disposed within at least one of the inner sealing perimeters. In some of these embodiments the at least one mounting feature includes at least one groove formed in an inward facing surface of the thin flange. In other of these embodiments the at least one mounting feature includes at least one threaded bore. 
     Certain embodiments further include at least one electrical feed-through configured to provide electrical but not gas communication between a region outside of the outer sealing perimeters and a region inside of the inner sealing perimeters. 
     In some embodiments the mounting thickness is less than 15% of an outer diameter of the thin flange. In other embodiments, the mounting thickness is less than 6.5% of an outer diameter of the thin flange. 
     In various embodiments the mounting thickness is less than 0.75 inches. In certain embodiments the mounting thickness is less than 0.28 inches. And in other embodiments the mounting thickness is less than 0.16 inches. In some embodiments an outer diameter of the thin flange is less than five inches. 
     Another general aspect of the present invention is a method for coupling a first thick vacuum flange to a second thick vacuum flange, the first thick flange and the second thick flange being alignable so as to enable alignment of corresponding holes in the first and second thick flanges. The method includes providing a thin flange having a thickness, the thin flange including a first face having a first sealing surface bounded by a first inner sealing perimeter and a first outer sealing perimeter, a second face opposed to and substantially parallel to the first face, the second face having a second sealing surface bounded by a second inner sealing perimeter and a second outer sealing perimeter. 
     The method further includes locating the thin flange between the first thick flange and the second thick flange, aligning the holes in the first thick flange with the holes in the second thick flange, inserting bolts through the aligned holes, and tightening the bolts so as to apply forces which compresses the thick flanges together, the thin flange being sandwiched therebetween, the thick flanges thereby distributing the forces applied by the bolts in a symmetric manner which applies only a compressive force to the thin flange. 
     In various embodiments, the first sealing surface includes a first knife edge and the second sealing surface comprises a second knife edge, the method further comprising locating a first soft, metallic gasket between the first sealing surface and the first thick flange and locating a second soft, metallic gasket between the second sealing surface and the second thick flange, so that the knife edges are pressed into the soft metal gaskets when the thick flanges and the thin flange are compressed together by the bolts. 
     In some embodiments at least one of the holes in the thick flanges is a threaded hole, and tightening the bolts includes threading a bolt into the threaded hole. In other embodiments, inserting the bolts includes passing at least one of the bolts completely through holes in the thick flanges and the thin flange, so that a threaded end of the bolt extends beyond one of the thick flanges, and tightening the bolts includes tightening a nut onto the extending threaded end of the bolt. 
     In certain embodiments the thin flange includes at least one mounting feature disposed within at least one of the inner sealing perimeters. In some of these embodiments, the at least one mounting feature includes at least one groove formed in an inward facing surface of the thin flange. In other of these embodiments, the at least one mounting feature comprises at least one threaded bore. 
     In various embodiments the thin flange includes at least one electrical feed-through configured to provide electrical but not gas communication between a region outside of the outer sealing perimeters and a region inside of the inner sealing perimeters. 
     In some embodiments, the thickness of the thin flange is less than 15% of an outer diameter of the thin flange. In other embodiments, the thickness of the thin flange is less than 6.5% of an outer diameter of the thin flange. In various embodiments, the thickness of the thin flange is less than 0.75 inches. In other embodiments the thickness of the thin flange is less than 0.28 inches. In still other embodiments the thickness of the thin flange is less than 0.16 inches. And in certain embodiments an outer diameter of the thin flange is less than five inches. 
     Other systems, methods, and advantages of the present invention will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present invention, and be protected by the accompanying claims. The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments of the invention are set forth in the following description and shown in the drawings, wherein: 
         FIG. 1  is a perspective view of a prior art flange used for an all metal joint; 
         FIG. 2  is a partial cross-sectional view of a prior art seal; 
         FIG. 3  is a cutaway view of a prior art flange with dish-shaped deformation; 
         FIG. 4  is a perspective view of a prior art flange with wave-like deformation; 
         FIG. 5  is a graph illustrating the thickness of normal double-sided flanges, relative to diameter, as compared to the thickness of the thin flanges of the present invention and encapsulated within the graph is an image of a flange, illustrating the thickness and diameter measurements of the flange; 
         FIG. 6  is a perspective view of a first exemplary embodiment of a thin flange consistent with the present invention; 
         FIG. 7  is a sectional view of the first exemplary embodiment of the thin flange consistent with the present invention; 
         FIGS. 8 through 8C  illustrate an application of the first exemplary embodiment of the thin flange consistent with the present invention; 
         FIG. 9  is a perspective view of a second exemplary embodiment of the thin flange consistent with the present invention; 
         FIG. 9   a  is a cross-sectional view of the second exemplary embodiment of the thin flange, in accordance with  FIG. 9 ; and 
         FIG. 10  is a perspective view of a third exemplary embodiment of the thin flange consistent with the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 6 through 10 , various exemplary embodiments of double-sided thin flanges consistent with the present invention are illustrated. It should be understood that the term “thin flange”, as used herein, is not so much an absolute dimensional characterization as it is a convenient designation, indicating that the flange is not required to be thick enough to withstand the asymmetric stress and deflection imposed by the clamping bolts. The thickness of the thin flange is not needed to withstand the asymmetric stress and deflection imposed by the clamping bolts because the thin flange receives symmetric force from flanges on opposite sides of the thin flange through gaskets crushed between the thin flange and each of the other flanges. The thickness of the thin flange is rather determined primarily by the thickness required to provide the instantly desired mounting characteristics or features—i.e., mounting grooves, threaded bores, feed-throughs, etc., as discussed in the following description of the invention. 
     The present invention is based upon the innovative idea that double-sided flanges, which are generally intended to be sandwiched between two standard thickness flanges, do not need to be thick enough to withstand the stress and deflection imposed by the clamping bolts. The primary force applied to the standard thickness flanges is applied asymmetrically at the interspersed bolt holes. Therefore, as previously described, the standard thickness flanges must be strong enough and, thereby, thick enough to avoid deformation of the standard thickness flange due to the uneven forces applied at the area around the bolt holes and the area of the standard thickness flange between consecutive bolt holes. The thin flanges of the present invention, however, do not receive a primary force at the bolt hole location because, in part, the bolts do not attach to the thin flange and therefore, do not apply any force directly to the thin flange. Instead, the force applied by tightening the bolts is communicated directly to the standard thickness flanges and the standard thickness flanges apply symmetric compressive force directly to the gaskets, which apply symmetric compressive force to the thin flange. Because the force applied from the standard thickness flanges, through the gaskets, to the thin flange is spread substantially equally across a sealing surface of each of the standard thickness flanges, the thin flanges do not need to be made thick to avoid deformation from asymmetric forces. 
       FIG. 5  is a graph that further illustrates the improvements of the present invention. The graph plots the minimum thickness available for industry standard flanges and for the thin flanges of the present invention against the corresponding diameter of the flanges, with the thickness T and diameter D illustrated in an image of a flange  40  within the graph of  FIG. 5 . The graph shows that a typical line of industry standard flanges has an increase in thickness as the diameter of the industry standard flanges increase. One of the motivations for this increase is durability, specifically the ability to avoid deformation. The present invention is based on the finding that flanges do not need to be made thicker to be durable. For all industry standard flange diameters shown, the present invention is capable of maintaining a thickness of 0.155 inches, as shown on the graph, which is presently the thickness required to maintain the two sealing surfaces. Should a sealing surface be designed that requires less thickness than those currently known, the present invention would be capable of maintaining a thickness below 0.155. 
     The present invention is also capable of maintaining any thickness between 0.155 inches and those thicknesses previously available. The present invention is capable of maintaining a thickness of 0.28 inches or below for any diameter double-sided flange. The present invention is capable of maintaining a thickness that is less than approximately 6.5% of the diameter of the double-sided flange. For double-sided flanges with a diameter of less than five inches, the present invention is capable of maintaining a thickness that is less than approximately 15% of the diameter of the double-sided flange. For double-sided flanges with a diameter of greater than five inches, the present invention is capable of maintaining a thickness of 0.75 inches or less. 
       FIGS. 6 through 8C  show details of a first exemplary embodiment of a thin flange  40  having a first face  41  on which is located a first sealing surface  42  to crush a metallic gasket  44 A against a standard thickness flange  48  for forming an all-metal joint. The thin flange  40  further features second face  49  on which is located a second sealing surface  50  to crush a metallic gasket  44 B against a standard thickness flange  54  for forming the all-metal joint. A plurality of bolt holes  46  are located outside of a perimeter of the sealing surfaces  42 ,  50  to provide an access way for securing the standard thickness flanges  48 ,  54  with the bolts  45 . The bolt holes  46  provide alignment of the thin flange  40  relative to the standard thickness flanges  48 ,  54  prior to sealing. Once the seal is formed, by tightening the bolts  45  and crushing the gaskets  44 A,  44 B, no support is provided to the thin flange  40  by the bolts  45 . 
       FIG. 6  is a prospective view of the first exemplary embodiment of the present invention.  FIG. 7  is a cross-sectional view of the thin flange  40  shown in  FIG. 6 . This cross-section shows the details of the sealing surfaces  42 ,  50 , which are knife edges in this embodiment. Consistent with the present invention, internal vacuum components may be mounted using equipment-mounting grooves  52 . These specific equipment mounting grooves  52  permit the mounting of internal vacuum system components (not shown). As illustrated, the equipment-mounting grooves  52  are disposed in a region of the thin flange  40  located within the perimeter of the sealing surfaces  42 ,  50 . Accordingly, components may be mounted extending out of the confines of the thin flange  40 . Consistent with this configuration, components may be mounted to the vacuum system over a shorter distance than previously possible because the thin flange  40  eliminates the need for a tube or standard fittings or an independent structurally thick double-sided flange. Not only does the decrease in length required to mount components make the system more convenient in space-limited applications, the decrease in length also increases the conductance of the vacuum system. 
     Referring to  FIG. 8  and  FIG. 8   e , which is a partially exploded view of  FIG. 8 , there is shown an exemplary thin flange  40  mounted between two standard thickness flanges  48 ,  54 . The two standard thickness flanges  48 ,  54  are sealed against respective sides of the thin flange  40  by crushed gaskets  44 A,  44 B. When the system is sealed, by tightening the bolts  45 , the force exerted on the standard thickness flanges  48 ,  54  by the bolts  45  is effectively transferred by the rigid body of the standard thickness flanges  48 ,  54  to their respective sealing surfaces  42 ,  50  which substantially simultaneously crushes both metallic gaskets  44 A,  44 B. This, in turn, causes the crushed gaskets  44 A,  44 B to bear symmetrically against the inner side of the thin flange  40 . Accordingly, the thin flange  40  experiences only symmetrical compressive loading about its thickness. The bolt holes  46  of the thin flange  40  are under zero load. Furthermore, the thin flange  40  is not subject to any bending loads, as may be the case with the standard thickness flanges  48 ,  54 . This allows the thin flange  40  to be of a minimal thickness, only sufficient to resist the compressive forces and contain the sealing surfaces  42 ,  50 . Accordingly, a membrane, window, or small aperture can be mounted within an opening  47  formed in the thin flange  40 . Alternatively, the thin flange  40  could be constructed without an opening  47 . 
     Turning to  FIG. 9  and  FIG. 9A , there is illustrated a perspective view and a cross-sectional view of a second exemplary embodiment of the thin flange  140 . The second exemplary thin flange  140  is configured without bolt holes. This embodiment is based on the realization that thin flanges are not supported by bolts and, therefore, can be constructed without bolt holes as long as the thin flange  140  can be mounted between two standard thickness flanges without interfering with the bolts for the standard thickness flanges. The thin flange  140 , according to this embodiment, allows for arbitrary radial alignment to the mating system. The greater flexibility in radial alignment of the thin flange  140  is capable because placement of the thin flange  140  relative to the standard thickness flanges (not shown) is not restricted by the need to align bolt holes in the thin flange  140  with the bolt holes in the standard thickness flanges. As shown in  FIG. 9A , little is needed beyond a sealing surface  142 ,  150  on each face  141 ,  149  of the thin flange  140  to create the second exemplary embodiment of the present invention. The thin flange  140  consistent with this exemplary embodiment is especially beneficial when an instrument or apparatus mounted to the thin flange  140  must be precisely aligned either within the vacuum system, or relative to another instrument or apparatus. The embodiment of the thin flange  140  shown in  FIGS. 9 and 9A  is designed to have a small enough outer diameter so as to avoid interfering with bolts of standard thickness flanges. Other variations of the thin flange  140  are also contemplated that avoid interfering with bolts of standard thickness flanges without minimizing the outer diameter of the thin flange  140  and without incorporating industry standard bolt holes. 
       FIG. 10  illustrates in isometric view a third exemplary embodiment of a thin flange  240  consistent with the present invention. According to the third exemplary embodiment, the thin flange  240  comprises a series of mounting holes  262  disposed about an inner web  256 , inside the perimeter of the sealing surfaces  242  (only one sealing surface is shown) of the flange  240 . The mounting holes  262  may advantageously be configured to mount any variety of apparatus inside of the vacuum system. Accordingly, the mounting holes  262  may be arranged in a pattern that is standard to a variety of equipment, or the mounting holes  262  may be specially configured for individual pieces of apparatus. By employing a thin flange  240  as disclosed herein it is possible to align vacuum components and mating interior system components with a high level of dimensional precision. 
     In each of the above-described embodiments, the thin flange preferably is formed from a single unitary member. By machining the thin flange, including both of the sealing surfaces, from a single member it is possible to achieve very high tolerances. Additionally, it is possible to achieve a superior surface finish on the thin flange. This characteristic lends itself to higher conductance and greater cleanliness of the vacuum system, as well as accurate flange face parallelism. 
     Consistent with the above teachings, a thin flange of the present invention may be beneficially employed for mounting equipment within the vacuum system itself, as well as for an interface connecting items within the vacuum system to the exterior of the vacuum system. An exemplary application may be to conveniently provide an electrical feed-through for powering an apparatus inside the vacuum system while still maintaining the “vacuum tight” integrity of the system. Similarly, the inner web of the thin flange may be equipped with a valve, therein providing direct communication with interior of the vacuum system without decreasing the conductance of the system, which does result from typical valve mounting systems disposed on a couple or tube. 
     Further, the thin flange can mount an interior component, such as an electron gun, as well as provide an electrical feed-through. This is an improvement over having the electrical connections on a separate port of the vacuum chamber, as is conventionally the case. The advantage is that the connection does not need to be done at the location of the vacuum system since the component can be mounted within the thin flange and the electrical connections may be made as an independent subsystem. Should the component need to be removed from the vacuum system, the connection would not need to be disassembled and subsequently reassembled when the component was remounted. This configuration of components saves time, and may reduce the number of ports required on a main chamber of a vacuum system. 
     Further embodiments of the coupling flange obviously include different lengths, different industry standard flange sizes, different flange geometries, such as oval, rectangular, or other planar shape, and different interior mounting arrangements. On slightly thicker versions of the flange, radial ports may be added to increase access to internal components. The thin flanges could also be stacked, with the limit only being the twist up and stretch of the set of bolts. 
     In consideration of the various above-described embodiments and applications consistent with the present invention, it will be readily appreciated that the thin flanges consistent with the present invention may advantageously be employed in a stacked manner. Consistent with this, a plurality of thin flanges may be disposed between two standard thickness flanges, thereby providing a variety of mounting features, feed-throughs, valves, etc., while requiring only one port on the vacuum system. Because each of the thin flanges consistent with the present invention contains two sealing surfaces, any number of thin flanges may be coaxially disposed, with each pair having a soft metallic gasket disposed therebetween. Furthermore, as in the case of a single thin flange disposed between two standard thickness flanges, each of the thin flanges in the above described “stack” will experience only symmetrical forces, generally only compressive in nature, and therefore will not be subject to distortion or deflection resulting from the clamping bolts. 
     The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.