Process and apparatus for molding polymer fittings

Abstract

A method and apparatus for producing molded fluoropolymer sweep elbows with straight ends while minimizing distortion of the fitting. The invention includes a mold for creating the sweep fittings of the invention. The mold includes a mold cavity block and internal coring. The internal coring includes two symmetrical cores that shut off at a 45° miter. Each of the symmetrical cores is divided into two parts, an outside sweep core and an inside sweep core. The outside sweep core and the inside sweep core are divided on a straight plane running the length of the core. The outside sweep core molds half of the straight lumen and the greater curvature at the outside sweep surface of the bend. The inside sweep core molds the other half of the straight bore and the lesser curvature of the inside or undercut portion of the bend.

Description

RELATED APPLICATIONS [0001] This application is a continuation of application Ser. No. 10 / 706,847 filed Nov. 12, 2003, now U.S. Pat. No. 7,160,497 issued Jan. 9, 2007, entitled PROCESS AND APPARATUS FOR MOLDING POLYMER FITTINGS, which claims the benefit of U.S. Provisional Application No. 60 / 425,458 filed Nov. 2, 2002.FIELD OF THE INVENTION [0002] The invention relates to the field of molding fluid flow components. More particularly, it relates to molding sweep polymer fittings while minimizing distortion of the fitting. BACKGROUND OF THE INVENTION [0003] In semiconductor manufacturing facilities, commonly known as fabs, highly corrosive, ultra pure liquids are utilized in manufacturing operations. Conventional plastics and metallic tubing and plumbing components are highly unsuitable in these applications. The materials of choice for plumbing components are fluoropolymer plastics such as PFA and PVDF because of their chemical inertness and non-wettability. The plumbing components w...

AI Technical Summary

Benefits of technology

[0009] In a preferred embodiment, an injection molded 90° sweep fitting improves fluid dynamics of fluid transport systems by reducing pressure drop, increasing flow, reducing dead volume, decreasing turbulence and maintaining even flow through the system. In addition, the invention includes a method and apparatus for manufacturing the fitting. The invention reduces shear rate of slurries, reduces dead volume, decreases turbulence and promotes even flow throughout the entirety of fab fluid flow systems.

[0013] Moving away from the sharp corner of a standard elbow design significantly reduces turbulence as fluid rounds the corner of the sweep elbow. This improves fluid dynamics and facilitates even flow through the fitting with minimal turbulence.

Problems solved by technology

Conventional plastics and metallic tubing and plumbing components are highly unsuitable in these applications.

Uneven polishing creates unusable wafers and loss of yield.

The presence of the sharp inside corner can create a substantial pressure loss and consequently, a substantial decrease in flow rate as compared to flow through an equivalent sized straight tube.

Further, the sharp corners of a standard elbow create areas of turbulence and eddying.

Turbulence and eddy currents can cause particulate matter suspended in slurries to fall out of suspension and accumulate in areas of slow fluid flow.

Accumulated particulate matter may build up in these areas and slow the fluid flow through the conduit as well as create the possibility that lumps of particulate matter may break loose from the accumulation and be carried with the flowing fluid.

These lumps will destroy the uniformity of a polishing suspension and lead to expensive loss of yield in the wafer production process.

Sharp transitions also create increased friction between flowing fluid and the conduit.

Pressure drop within the system lowers flow rates and slows processing.

This produces the need for more powerful pumps and increases stresses on components in the portions of the system where pressures are higher increasing the risk of failure.

Turbulence also creates the possibility that cavitation will occur.

Cavitation tends to create increased wear on the surfaces of conduit walls shortening the life of components.

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