Diaphragm comprising a gamma stable composite elastomer and a thermoplastic material

Abstract

A diaphragm for a diaphragm valve includes a flange and a bellows. The flange includes a flange outer surface, a flange inner surface, a flange outer edge, and a flange inner edge. The bellows is disposed within the flange inner edge. The diaphragm is formed of a core elastomer material and at least one layer of a microporous thermoplastic material that includes a plurality of micropores. The microporous thermoplastic material is attached to at least a portion of an outer surface of the elastomer material. A combined thickness of all layers of the microporous thermoplastic material is in a first range between 0.5 pm and 12 pm. A volume ratio of the core elastomer material to the microporous thermoplastic material is in a second range between 1:1 and 100:1.

Description

[0001] Cross-references and precedence

[0002] This application claims priority from international application PCT / US2023 / 080277, filed November 17, 2023, the teachings of which are incorporated herein by reference in their entirety.

[0003] background Diaphragm valves utilize a flexible diaphragm within the valve body that connects to the valve seat to open and close the path of fluid through opposite ports. Traditionally, the diaphragm in diaphragm valves has been made of an elastomer or an elastomer made of PTFE / thermoplastic material.

[0004] During operation, the diaphragm is subjected to repeated flexing, steam, and corrosive chemicals. When repeatedly bent and / or exposed to steam or harsh chemicals, silicone, EPDM, or FKM elastomer materials may develop cracks in their sidewalls and may catastrophically break down.

[0005] Furthermore, PTFE membranes have proven difficult to sterilize for reuse. In many medical, chemical, and biological applications, it is desirable to utilize the same PTFE products, such as membranes, for multiple manufacturing processes. To avoid contamination or bacterial growth from manufacturing process to process, the elastomer and / or PTFE membrane must be sterilized before reuse. Typical sterilization methods such as steam or gamma radiation are known to degrade the PTFE material of the membrane, thereby increasing the likelihood of catastrophic failure during subsequent use.

[0006] Therefore, there is a need for an improved elastomeric diaphragm for diaphragm valves that resists cracking and repeated flexing over time and is stable during sterilization with gamma radiation or steam.

[0007] Overview

[0008] This document describes a diaphragm for a diaphragm valve. The diaphragm includes a flange and bellows. The flange has an outer flange surface, an inner flange surface, an outer flange edge, and an inner flange edge. The bellows are disposed within the inner flange edge. The diaphragm is formed of a core elastomeric material and at least one layer of a microporous thermoplastic material comprising multiple micropores. The microporous thermoplastic material is attached to at least a portion of the outer surface of the elastomeric material. The combined thickness of all layers of the microporous thermoplastic material is in a first range between 0.5 μm and 12 μm. The volume ratio of the core elastomeric material to the microporous thermoplastic material is in a second range between 1:1 and 100:1.

[0009] In some implementations, the core elastomer material may be selected from the group consisting of platinum silicone, fluorinated silicone, ethylene propylene diene monomer (EPDM) rubber, and fluorocarbon-based fluoroelastomers.

[0010] In some embodiments, the microporous thermoplastic material may be selected from the group consisting of: polytetrafluoroethylene, polypropylene, polyetheretherketone, polyurethane, polyethylene, and polyamide.

[0011] In some embodiments, the microporous thermoplastic material may include a plurality of micropores having an average pore size in the range of 0.1 μm to 15 μm.

[0012] In some implementations, a portion of the core elastomer material may extend into at least a portion of the micropores.

[0013] In some embodiments, the telescopic bladder may include a hole passing through the central axis of the telescopic bladder. In other embodiments, the telescopic bladder may include a post attached to and extending from the outer surface of the telescopic bladder at the central axis of the telescopic bladder.

[0014] In some embodiments, the flange may include multiple flange holes. When present, each flange hole allows passage from the outer surface of the flange through the inner surface of the flange.

[0015] This document also describes a diaphragm valve. A diaphragm valve may include a valve body, a diaphragm, and a valve cap assembly. The valve body has a valve inlet, a valve outlet, and a port connecting a fluid passage between the valve inlet and the valve outlet. The diaphragm has a flange and a plenum. The flange has an outer flange surface, an inner flange surface, an outer flange edge, and an inner flange edge, wherein the plenum is disposed within the inner flange edge. The inner flange surface is disposed against the top surface of the port. The valve cap assembly has a valve cap housing disposed against the outer flange surface, a compressor, and an actuator mechanically connected to the compressor.

[0016] The diaphragm in the diaphragm valve is formed of a core elastomer material and at least one layer of microporous thermoplastic material comprising multiple micropores. The microporous thermoplastic material is attached to at least a portion of the outer surface of the elastomer material. The combined thickness of all layers of the microporous thermoplastic material is in a first range between 0.5 μm and 12 μm. The volume ratio of the core elastomer material to the microporous thermoplastic material is in a second range between 1:1 and 100:1.

[0017] In some embodiments of the diaphragm valve, the core elastomer material may be selected from the group consisting of platinum silicone, fluorinated silicone, ethylene propylene diene monomer (EPDM) rubber, and fluorocarbon-based fluoroelastomers.

[0018] In some embodiments of the diaphragm valve, the microporous thermoplastic material may be selected from the group consisting of: polytetrafluoroethylene, polypropylene, polyetheretherketone, polyurethane, polyethylene, and polyamide.

[0019] In some embodiments of the diaphragm valve, the microporous thermoplastic material may include a plurality of micropores having an average pore size in the range of 0.1 μm to 15 μm.

[0020] In some embodiments of the diaphragm valve, a portion of the core elastomer material may extend into at least a portion of the micropores.

[0021] In some embodiments of the diaphragm valve, the bladder may include a hole passing through the central axis of the bladder. In other embodiments, the bladder may include a post attached to and extending from the outer surface of the bladder at the central axis of the bladder.

[0022] In some embodiments of the diaphragm valve, the flange may include multiple flange holes. When present, each flange hole allows passage from the outer surface of the flange through the inner surface of the flange.

[0023] In some embodiments of diaphragm valves, the fluid passage may include a weir.

[0024] In some embodiments of the diaphragm valve, the actuator may be selected from the group consisting of: knobs and screws, hydraulic actuators, pneumatic actuators, electric actuators, piezoelectric actuators, and electromagnetic actuators. Brief description of the attached figures

[0025] Figure 1 This is a perspective view of the diaphragm used in diaphragm valves.

[0026] Figure 2 This is a side view of the diaphragm used in a diaphragm valve.

[0027] Figure 3 This is a side view of a multilayer diaphragm used in diaphragm valves.

[0028] Figure 4 This is a perspective view of an embodiment of a diaphragm used in a diaphragm valve.

[0029] Figure 5 This is a perspective view of an embodiment of a diaphragm used in a diaphragm valve.

[0030] Figure 6 This is an exploded perspective view of a diaphragm valve.

[0031] Figure 7 This is a cross-sectional view of the diaphragm valve assembly.

[0032] Detailed description

[0033] This document discloses a diaphragm for a diaphragm valve. As described herein and in the claims, the following figures refer to the following structures indicated in the figures.

[0034] 10 refers to the diaphragm valve.

[0035] 100 refers to the diaphragm.

[0036] 110 refers to the flange.

[0037] 111 refers to the outer surface of the flange.

[0038] 112 refers to the inner surface of the flange.

[0039] 113 refers to the outer edge of the flange.

[0040] 114 refers to the inner edge of the flange.

[0041] 115 refers to the flange hole.

[0042] 120 refers to a retractable bladder.

[0043] 121 refers to the hole.

[0044] 122 refers to the column.

[0045] 123 refers to the outer surface of the retractable bladder.

[0046] 125 refers to the central axis of the telescopic bladder.

[0047] 200 refers to the core elastomer material.

[0048] 210 refers to the outer surface of the elastomer material.

[0049] 300 is a microporous thermoplastic material.

[0050] 400 refers to the valve body.

[0051] 410 refers to the valve inlet.

[0052] 420 refers to the valve outlet.

[0053] 430 refers to the port number.

[0054] 432 refers to the top surface of the port.

[0055] 440 refers to the fluid channel.

[0056] 442 refers to the weir body.

[0057] 500 refers to the valve cap assembly.

[0058] 510 refers to the valve cap housing.

[0059] 520 refers to the compressor.

[0060] 530 refers to the actuator.

[0061] Figure 1 A diagram for a diaphragm valve ((10)) is shown, such as Figure 6 and Figure 7 A perspective view of the diaphragm (100) shown, wherein Figure 2 The diaphragm is shown in a side view. (Example) Figure 1As shown, the diaphragm includes a flange (110) and a telescopic bladder (120). The flange has an outer edge (113) defining the periphery of the diaphragm and an inner edge (114) at the interface where the telescopic bladder connects to the flange, such that the telescopic bladder is disposed within the inner edge of the flange.

[0062] In some embodiments, such as Figure 1 As shown, the flange (110) may include a plurality of flange holes (115). When present, each flange hole will open from the outer surface of the flange ((113), as shown in the figure. Figure 2 As shown) passing through the inner surface of the flange ((114), as Figure 2 (As shown). These flange holes, when present, serve as connection points for connecting the diaphragm to the diaphragm valve ((10), as shown). Figure 6 and Figure 7 (As shown). The diaphragm can be inserted into the valve body ((400), such as by passing fasteners such as bolts, rivets, screws, etc. through one or more flange holes). Figure 6 and Figure 7 (As shown) is a part connected to the diaphragm valve. Although Figure 1 Flange holes are shown at the four corners of the flange, but the invention is not limited thereto, and other flange holes may exist at any number of locations on the flange.

[0063] Figure 3 A side view of the diaphragm (100) is shown, illustrating its material composition. (See attached image.) Figure 3 As shown, the diaphragm is formed of a core elastomeric material (200) and at least one layer of microporous thermoplastic material (300) comprising a plurality of micropores. The microporous thermoplastic material can be attached to the elastomeric material by coating the core elastomeric material with the microporous thermoplastic material. Exemplary coating processes include doctor blade coating on rollers, gravure coating, roll-to-roll coating, and ultrasonic spraying.

[0064] The number of microporous thermoplastic material layers (300) can vary depending on the application. Typically, the diaphragm will comprise at least one layer of microporous thermoplastic material. However, there will be embodiments in which the diaphragm comprises at least two layers of microporous thermoplastic material, at least five layers of microporous thermoplastic material, at least ten layers of microporous thermoplastic material, or at least twenty-five layers of microporous thermoplastic material. As used herein, micropore refers to the average pore size of the thermoplastic material mentioned herein. The microporous thermoplastic material combining all layers will have a thickness that can be selected from the group consisting of: between 0.5 μm and 12 μm, between 0.5 μm and 10 μm, between 0.5 μm and 7.5 μm, between 0.5 μm and 5.0 μm, between 1.0 μm and 12 μm, between 1.0 μm and 10 μm, between 1.0 μm and 7.5 μm, between 1.0 μm and 5.0 μm, between 2.0 μm and 12 μm, between 2.0 μm and 10 μm, between 2.0 μm and 7.5 μm, and between 2.0 μm and 7.5 μm.

[0065] When incorporated into the diaphragm (100), the core elastomer material (200) and the microporous thermoplastic material (300) will have a volume ratio. The volume ratio of the core elastomer material to the microporous thermoplastic material can be in the following ranges: between 1:1 and 100:1, between 1:1 and 75:1, between 1:1 and 50:1, between 1:1 and 25:1, between 5:1 and 100:1, between 5:1 and 75:1, between 5:1 and 50:1, between 5:1 and 25:1, between 10:1 and 100:1, between 10:1 and 75:1, between 10:1 and 50:1, and between 10:1 and 25:1.

[0066] Any number of different elastomeric materials can be used for the core elastomeric material (200) of the diaphragm (100). Preferred examples of such elastomeric materials include platinum silicone, fluorinated silicone, ethylene propylene diene monomer (EPDM) rubber, and fluorocarbon-based fluoroelastomers.

[0067] Any number of different microporous thermoplastic materials can be used. Preferred examples of such microporous thermoplastic materials include polytetrafluoroethylene (PTFE), polypropylene (PP), polyetheretherketone (PEEK), polyurethane, polyethylene (PE), and polyamide.

[0068] The micropores of the microporous thermoplastic material (300) will have an average pore size. Preferably, the average pore size will be within the range selected from the group consisting of: between 0.1 μm and 15 μm, between 0.1 μm and 10 μm, between 0.1 μm and 7.5 μm, between 0.1 μm and 5.0 μm, between 1.0 μm and 15 μm, between 1.0 μm and 10 μm, between 1.0 μm and 7.5 μm, between 1.0 μm and 5.0 μm, between 2.0 μm and 15 μm, between 2.0 μm and 10 μm, between 2.0 μm and 7.5 μm, and between 2.0 μm and 5.0 μm. The thermoplastic material can be provided in the form of micropores, for example, as a film of material comprising micropores, or as an open braid of thermoplastic material that is heat-set to attach to a core elastomeric material, thereby forming micropores in the process. Microporous thermoplastic materials can be attached to at least a portion of a core elastomer material in such a way that a portion of the elastomer material extends into at least a portion of the micropores.

[0069] Figure 4 and Figure 5 A telescopic bladder (120) for attaching the diaphragm (100) to the diaphragm drive mechanism ((500)) is shown, as... Figure 6 and Figure 7 Different embodiments are shown. (As illustrated) Figure 4 As shown, one embodiment includes a hole (121) through the central axis (125) of the telescopic bladder, through which the drive shaft of the diaphragm drive mechanism passes and is attached. Figure 5 Another embodiment shown includes a column (122) attached to and extending from the outer surface (123) of the telescopic bladder at the central axis (125). In such an embodiment, the drive shaft of the diaphragm drive mechanism may be mechanically attached to the column.

[0070] Figure 6 An exploded perspective view of a diaphragm valve (10) is shown, and embodiments of the diaphragm (100) disclosed herein can be used in the diaphragm valve (10). Figure 7 A cross-sectional view of the assembled diaphragm valve is shown. (As shown) Figure 6 As shown, a diaphragm valve may include a valve body (400), a diaphragm, and a valve cap assembly (500).

[0071] The diaphragm (100) can be of any type disclosed herein. Typically, the diaphragm may include a flange (110) and a bladder (120). The flange has an outer edge (113) defining the periphery of the diaphragm and an inner edge (114) at the interface where the bladder is connected to the flange, such that the bladder is disposed within the inner edge of the flange.

[0072] In some embodiments, such as Figure 6As shown, the flange (110) may include a plurality of flange holes (115). When present, each flange hole extends from the outer surface (113) of the flange through the inner surface (114) of the flange. These flange holes, when present, serve as attachment points for connecting the diaphragm to the valve body (400). The diaphragm (100) can be connected to the valve body by passing fasteners (which may or may not be molded into place) – such as bolts, rivets, screws, etc. – through one or more of the flange holes and into a portion of the valve body (particularly through corresponding holes on the surface of the port (430) of the valve body). Although Figure 6 Flange holes are shown at the four corners of the flange, but the invention is not limited thereto, and other flange holes may exist at any number of locations on the flange.

[0073] like Figure 6 and Figure 7 As shown, the valve body (400) may include a valve inlet (410), a valve outlet (420), a port (430), and a fluid passage (440). The valve inlet refers to a fitting, hose connection, or other opening that allows fluid from outside the valve body to enter the fluid passage. The valve outlet refers to a fitting, hose connection, or other opening that allows fluid from the fluid passage to exit the pump body.

[0074] like Figure 6 and Figure 7 As further shown, the valve cap assembly (500) may include a valve cap housing (510), a compressor (520), and an actuator (530). The valve cap housing is disposed against an outer surface (111) of a flange, wherein an inner surface of the flange is disposed against a top surface (432) of a port, such that a diaphragm is sandwiched between the valve cap housing and the port. The actuator passes through a hole in the valve cap housing and is mechanically connected to the compressor, which itself is mechanically connected to the telescopic bladder (120).

[0075] In operation, the actuator (530) operates linearly on the compressor (520), which causes the telescopic bladder (120) to expand from a position such that... Figure 7 The retracted position shown is moved to the extended position. When in the extended (or partially extended) position, the bladder blocks (or reduces) the flow of fluid through the fluid channel (440). In some embodiments, the fluid channel will include a weir (442), which, when present, helps to precisely control the amount of fluid that can flow through the fluid channel.

[0076] The diaphragm disclosed herein is composed of a core elastomer material and a microporous thermoplastic or PTFE material. Compared with known silicone elastomer diaphragms, the diaphragm disclosed herein has been observed to achieve improved resistance to cracking over time and repeated flexural stress. Furthermore, the diaphragm disclosed herein is gamma-stabilized. That is, the diaphragm disclosed herein can be sterilized using gamma radiation without degrading the core elastomer material.

[0077] Although the diaphragm has been described as having one or more exemplary designs, the diaphragm can be further modified within the spirit and scope of this disclosure. Therefore, this application is intended to cover any variations, uses, or adaptations of the diaphragm using its general principles.

Claims

1. A diaphragm (100) for a diaphragm valve (10), said diaphragm comprising: A flange (110) having an outer flange surface (111), an inner flange surface (112), an outer flange edge (113), and an inner flange edge (114); and The telescopic bladder (120) is disposed within the inner edge of the flange; and The diaphragm is formed of a core elastomer material (200) and at least one layer of microporous thermoplastic material (300), the microporous thermoplastic material (300) comprising a plurality of micropores, the microporous thermoplastic material being attached to at least a portion of the outer surface (210) of the elastomer material, wherein the combined thickness of all layers of the microporous thermoplastic material is in a first range between 0.5 μm and 12 μm, and wherein the volume ratio of the core elastomer material to the microporous thermoplastic material is in a second range between 1:1 and 100:

1.

2. The diaphragm according to claim 1, wherein, The core elastomer material is selected from the group consisting of: platinum silicone, fluorinated silicone, ethylene propylene diene monomer (EPDM) rubber, and fluorocarbon-based fluoroelastomer.

3. The diaphragm according to any one of claims 1 to 2, wherein, The microporous thermoplastic material is selected from the group consisting of: polytetrafluoroethylene, polypropylene, polyetheretherketone, polyurethane, polyethylene, and polyamide.

4. The diaphragm according to any one of claims 1 to 3, wherein, The microporous thermoplastic material comprises a plurality of micropores having an average pore size in the range of 0.1 μm to 15 μm.

5. The diaphragm according to claim 4, wherein, A portion of the core elastomer material extends into at least a portion of the micropores.

6. The diaphragm according to any one of claims 1 to 5, wherein, The telescopic bladder includes a hole (121) passing through the central axis (125) of the telescopic bladder.

7. The diaphragm according to any one of claims 1 to 5, wherein, The telescopic bladder includes a column (122) which is attached to and extends from the outer surface (123) of the telescopic bladder at the central axis (125).

8. The diaphragm according to any one of claims 1 to 7, wherein, The flange includes a plurality of flange holes (115), each flange hole extending from the outer surface of the flange through the inner surface of the flange.

9. A diaphragm valve (10), comprising: A valve body (400) has a valve inlet (410), a valve outlet (420) and a port (430) connected to a fluid passage (440) between the valve inlet and the valve outlet. A diaphragm (100) having a flange (110) and a telescopic bladder (120), the flange having an outer flange surface (111), an inner flange surface (112), an outer flange edge (113), and an inner flange edge (114), the telescopic bladder being disposed within the inner flange edge, and the inner flange surface being disposed abutting against the top surface (432) of the port; A valve cap assembly (500) having a valve cap housing (510) disposed abutting against the outer surface of the flange, a compressor (520), and an actuator (530) mechanically connected to the compressor; and The diaphragm is formed of a core elastomer material (200) and at least one layer of microporous thermoplastic material (300), the microporous thermoplastic material (300) comprising a plurality of micropores, the microporous thermoplastic material being attached to at least a portion of the outer surface (210) of the elastomer material, wherein the combined thickness of all layers of the microporous thermoplastic material is in a first range between 0.5 μm and 12 μm, and wherein the volume ratio of the core elastomer material to the microporous thermoplastic material is in a second range between 1:1 and 100:

1.

10. The diaphragm valve according to claim 9, wherein, The core elastomer material is selected from the group consisting of: platinum silicone, fluorinated silicone, ethylene propylene diene monomer (EPDM) rubber, and fluorocarbon-based fluoroelastomer.

11. The diaphragm valve according to any one of claims 9 to 10, wherein, The microporous thermoplastic material is selected from the group consisting of: polytetrafluoroethylene, polypropylene, polyetheretherketone, polyurethane, polyethylene, and polyamide.

12. The diaphragm valve according to any one of claims 9 to 11, wherein, The microporous thermoplastic material comprises a plurality of micropores having an average pore size in the range of 0.1 μm to 15 μm.

13. The diaphragm valve according to claim 12, wherein, A portion of the core elastomer material extends into at least a portion of the micropores.

14. The diaphragm valve according to any one of claims 9 to 13, wherein, The telescopic bladder includes a hole (121) passing through the central axis (125) of the telescopic bladder, and the compressor is attached to the hole (121).

15. The diaphragm valve according to any one of claims 9 to 13, wherein, The telescopic bladder includes a column (122) attached to and extending from the outer surface (123) of the telescopic bladder at the central axis (125) of the telescopic bladder, and the compressor is attached to the column (122).

16. The diaphragm valve according to any one of claims 9 to 15, wherein, The flange includes a plurality of flange holes (115), each flange hole extending from the outer surface of the flange through the inner surface of the flange.

17. The diaphragm valve according to any one of claims 9 to 16, wherein, The fluid channel includes a weir (442).

18. The diaphragm valve according to any one of claims 9 to 17, wherein, The actuator is selected from the group consisting of: knobs and screws, hydraulic actuators, pneumatic actuators, electric actuators, piezoelectric actuators, and electromagnetic actuators.

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