Fluid connector configured for corrosion detection, continuous flow reactor comprising such a fluid connector, and method of using such a fluid connector

Abstract

A fluid connector configured for corrosion detection is disclosed. The fluid connector comprises a body that extends along a central axis between opposed end faces thereof. The body comprises a first body section with a first contact surface and a second body section with a second contact surface joined to the first contact surface at a first bond joint comprising bonding material. The fluid connector further comprises a connector passage that extends through the body and opens to the opposed end faces. The first bond joint intersects the connector passage and extends from the connector passage to a peripheral surface of the body for a detection distance. A continuous flow reactor is also disclosed. The continuous flow reactor comprises a flow module and the fluid connector. The connector passage of the fluid connector and the module passage of the flow module are fluidically connected via a flow path.

Description

FLUID CONNECTOR CONFIGURED FOR CORROSION DETECTION, CONTINUOUS FLOW REACTOR COMPRISING SUCH A FLUID CONNECTOR, AND METHOD OF USING SUCH A FLUID CONNECTORCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of French Patent Application Serial No. FR2405639 filed on May 30, 2024, the content of which is incorporated herein by reference in its entirety.FIELD

[0002] The present disclosure relates to corrosion detection. In particular, the present disclosure relates to fluid connectors configured to detect corrosion in continuous flow reactors configured to convey fluids that are corrosive to components of the reactors.BACKGROUND

[0003] Continuous flow reactors can include flow modules that have bond joints formed from bonding material. The continuous flow reactors may process fluids that are corrosive to the bonding material of the bond joints, and the bond joints may be exposed to the corrosive fluids. While the corrosion performance of some bonding materials is known, the corrosion performance of some other bonding materials is not known. Consequently, it would be advantageous to provide a fluid connector with a bond joint that is formed from the same bonding material as that of the flow modules, that can be exposed to the same corrosive fluids as that of the flow modules, and that is configured to show evidence of corrosion before such corrosion affects the safety and / or performance of the flow modules of the continuous flow reactors.SUMMARY

[0004] According to aspect (1), a fluid connector is provided. The fluid connector comprises: a body extending along a central axis between opposed end faces thereof, the body comprising a first body section with a first contact surface and a second body section with a second contact surface joined to the first contact surface at a first bond joint comprising bonding material; and a connector passage extending through the body and opening to theopposed end faces, wherein the first bond joint intersects the connector passage and extends from the connector passage to a peripheral surface of the body for a detection distance.

[0005] According to aspect (2), the fluid connector of aspect (1) is provided, wherein the first and second contact surfaces are coextensive with a plane along which the first bond joint extends through the body.

[0006] According to aspect (3), the fluid connector of aspect (2) is provided, wherein the first bond joint extends entirely through the body along the plane.

[0007] According to aspect (4), the fluid connector of aspect (2) or aspect (3) is provided, wherein the first bond joint is aligned with the central axis such that the first and second body sections are configured as first and second longitudinal body sections.

[0008] According to aspect (5), the fluid connector of aspect (2) or aspect (3) is provided, wherein the first bond joint is perpendicular to the central axis such that the first and second body sections are configured as first and second axial body sections.

[0009] According to aspect (6), the fluid connector of aspect (5) is provided, wherein the first bond joint is disposed at an approximate midpoint between the opposed end faces of the body.

[0010] According to aspect (7), the fluid connector of any one of aspects (1) to (6) is provided, wherein the connector passage is concentric with the central axis.

[0011] According to aspect (8), the fluid connector of any one of aspects (1) to (7) is provided, further comprising: a threaded bore extending through at least a portion of the first and second body sections and oriented transversely with respect to the first and second contact surfaces; and a fastener threadedly engaged with the threaded bore.

[0012] According to aspect (9), the fluid connector of aspect (8) is provided, wherein the threaded bore comprises a plurality of threaded bores, and the fastener comprises a plurality of fasteners each configured to threadedly engage a corresponding threaded bore.

[0013] According to aspect (10), the fluid connector of aspect (9) is provided, wherein each threaded bore opens on one side to the peripheral surface, and wherein at least two threaded bores open to the peripheral surface in opposite directions.

[0014] According to aspect (11), the fluid connector of any one of aspects (1) to (10) is provided, wherein the bonding material comprises one or more of a carbide material and a nitride material.

[0015] According to aspect (12), the fluid connector of aspect (11) is provided, wherein the bonding material comprises a boron carbide material.

[0016] According to aspect (13), the fluid connector of aspect (11) or aspect (12) is provided, wherein the carbide material and the nitride material are formed via heating a carbide powder and a nitride powder, respectively, to a bonding temperature for a bonding time.

[0017] According to aspect (14), the fluid connector of any one of aspects (1) to (13) is provided, wherein the body of the fluid connector comprises metal.

[0018] According to aspect (15), the fluid connector of aspect (14) is provided, wherein the metal is stainless steel.

[0019] According to aspect (16), the fluid connector of any one of aspects (1) to (15) is provided, wherein the peripheral surface has a circular shape when viewed in a cross section oriented substantially normal to the central axis.

[0020] According to aspect (17), the fluid connector of any one of aspects (1) to (16) is provided, wherein each end face of the body has one or more surface portions oriented substantially normal to the central axis.

[0021] According to aspect (18), the fluid connector of aspect (17) is provided, wherein the one or more surface portions are annular surface portions that encircle the central axis.

[0022] According to aspect (19), the fluid connector of aspect (17) or aspect (18) is provided, wherein the one or more surface portions comprise an inner surface portion disposed proximate to the connector passage and an outer surface portion radially spaced from the inner surface portion and disposed proximate to the peripheral surface.

[0023] According to aspect (20), the fluid connector of aspect (19) is provided, wherein the inner surface portion and the outer surface portion define an annular groove therebetween.

[0024] According to aspect (21), a continuous flow reactor is provided. The continuous flow reactor comprises: the fluid connector of any one of aspects (1) to (20); and a flow module comprising (i) first and second plates joined together at a second bond joint comprising the bonding material and (ii) a module passage disposed within the flow module, wherein the second bond joint intersects the module passage and extends therefrom for at least a critical distance, wherein the connector passage of the fluid connector and the module passage of the flow module are fluidically connected via a flow path along which fluid that is corrosive to the bonding material is configured to be conveyed in a process direction through the continuousflow reactor, thereby exposing the bonding material of the first and second bond joints to the corrosive fluid, wherein the detection distance of the first bond joint is shorter than the critical distance of the second bond joint.

[0025] According to aspect (22), the continuous flow reactor of aspect (21) is provided, wherein the detection distance is less than or equal to approximately 80% of the critical distance.

[0026] According to aspect (23), the continuous flow reactor of aspect (21) is provided, wherein the detection distance is less than or equal to approximately 60% of the critical distance.

[0027] According to aspect (24), the continuous flow reactor of any one of aspects (21) to (23) is provided, wherein the critical distance is in a range of about 5 mm to about 15 mm.

[0028] According to aspect (25), the continuous flow reactor of any one of aspects (21) to (23) is provided, wherein the critical distance is in a range of about 7 mm to about 13 mm.

[0029] According to aspect (26), the continuous flow reactor of any one of aspects (21) to(25) is provided, wherein the flow module comprises a module port extending between opposed major outer surfaces of the first and second plates and intersecting the module passage, and wherein one of the opposed end faces of the fluid connector is configured to abut the major outer surface of one of the first and second plates and directly connect the connector passage of the fluid connector to the module passage of the flow module.

[0030] According to aspect (27), the continuous flow reactor of any one of aspects (21) to(26) is provided, further comprising a further flow module configured in the same manner as the flow module, the further flow module arranged downstream from the flow module along the flow path, wherein the fluid connector is configured to be positioned along the flow path any of (i) upstream from the flow module, (ii) between the flow module and the further flow module, and (iii) downstream from the further flow module.

[0031] According to aspect (28), the continuous flow reactor of aspect (27) is provided, further comprising a further fluid connector configured in the same manner as the fluid connector, the further fluid connector positioned along the flow path differently than the fluid connector is positioned along the flow path.

[0032] According to aspect (29), a method for detecting corrosion in the continuous flow reactor of any one of aspects (21) to (28) is provided. The method comprises: operating thecontinuous flow reactor by flowing the fluid along the flow path through the fluid connector and the flow module; monitoring the peripheral surface of the fluid connector for indicia of the fluid leaking through the first bond joint during the flowing; and detecting corrosion in the continuous flow reactor when the indicia is present on the peripheral surface.

[0033] According to aspect (30), the method of aspect (29) is provided, further comprising: ceasing operation of the continuous flow reactor when corrosion is detected via the fluid connector; and inspecting the flow module for corrosion.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Various exemplary embodiments of the present disclosure are described in detail below with reference to the following drawings. The drawings are provided for purposes of illustration only and merely depict exemplary embodiments of the present disclosure to facilitate the understanding of the present disclosure. Therefore, the drawings should not be considered as limiting of the breadth, scope, or applicability of the present disclosure. It should be noted that for clarity and ease of illustration these drawings are not necessarily drawn to scale.

[0035] FIG. 1 is a perspective view of a fluid connector with a longitudinal bond joint comprising bonding material according to one or more embodiments;

[0036] FIG. 2 is a perspective view of another fluid connector with a longitudinal bond joint comprising bonding material according to one or more embodiments;

[0037] FIG. 3 is an exploded view of the fluid connector of FIG. 2;

[0038] FIG. 4 is a perspective view of still another fluid connector with an axial bond joint comprising bonding material according to one or more embodiments;

[0039] FIG. 5 is an exploded view of the fluid connector of FIG. 4;

[0040] FIG. 6 is an axial cross section through the fluid connector of FIG. 1 showing a first configuration of threaded bores;

[0041] FIG. 7 is an axial cross section through the fluid connector of FIG. 1 showing a second configuration of threaded bores;

[0042] FIG. 8 is a digital image of a separated preform to illustrate a step of a method for fabricating a fluid connector with a bond joint comprising bonding material according to one or more embodiments;

[0043] FIG. 9 is a digital image illustrating another step of the method of FIG. 8 showing discrete preform body sections clamped together via threaded bores and corresponding fasteners;

[0044] FIG. 10 is a schematic depiction of modified first and second preform body sections that can be used during a subsequent bonding step when threaded bores are not provided in the preform body sections;

[0045] FIG. 11 is a schematic depiction of a fixture that can be used during a subsequent bonding step when threaded bores are not provided in the preform body sections;

[0046] FIG. 12 is a digital image of two fluid connectors that have been finish machined to obtain target or final dimensions thereof in accordance with one or more embodiments;

[0047] FIG. 13 is an exploded perspective view schematically illustrating aspects of a flow module with a bond joint comprising bonding material according to one or more embodiments;

[0048] FIG. 14-16 are schematic cross-sectional representations comparing a bond joint without corrosion issues to bond joints with corrosions issues;

[0049] FIG. 17 schematically depicts a continuous flow reactor comprising the fluid connector of any one of FIGS. 1-7 fluidically connected to one or more flow modules; and

[0050] FIG. 18 is a flow diagram of an embodiment of a method for detecting corrosion in the continuous flow reactor of FIG. 17.DETAILED DESCRIPTION

[0051] For the purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the disclosure is thereby intended. It is further understood that the present disclosure includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles disclosed herein as would normally occur to one skilled in the art to which this disclosure pertains.

[0052] As used herein, the term “and / or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and / or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.

[0053] In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0054] As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and / or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term “about” is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites “about,” the numerical value or end-point of a range is intended to include two embodiments: one modified by “about,” and one not modified by “about.” It will be further understood that the end-points of each of the ranges are significant both in relation to the other end-point, and independently of the other end-point.

[0055] Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range was explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also to include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4, the sub ranges such as from 1-3, from 2-4, from 3-5, etc., as well as 1, 2, 3, 4, and 5 individually. The same principle applies to ranges reciting only one numerical value as a minimum or maximum. Furthermore,such an interpretation should apply regardless of the breadth of the range or the characteristics being described by the range.

[0056] The terms “substantial,” “substantially,” and variations thereof as used herein, unless defined elsewhere in association with specific terms or phrases, are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. In some embodiments, “substantially” may denote values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.

[0057] Directional terms as used herein — for example up, down, right, left, front, back, top, bottom, above, below, and the like — are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0058] As used herein the terms "the," "a," or "an," mean "at least one," and should not be limited to "only one" unless explicitly indicated to the contrary. Thus, for example, reference to "a component" includes embodiments having two or more such components unless the context clearly indicates otherwise.

[0059] FIGS. 1-7 depict various embodiments of a fluid connector 100 configured for corrosion detection. For the purpose of distinguishing the embodiments, elements of the fluid connector embodiments that are the same or substantially similar are identified with the same reference number and appended with a letter (e.g., a, b, c, etc.) to indicate the embodiment. For example, a first embodiment can use the letter "a," a second embodiment can use the letter "b," and so on. In contrast, elements of the fluid connector embodiments that are different or unique from embodiment to embodiment can be identified with a unique reference number with or without a letter indicating the embodiment appended thereto.

[0060] FIGS. 1, 6, and 7 depict a first embodiment 100a of the fluid connector 100, FIGS. 2 and 3 depict a second embodiment 100b of the fluid connector 100, and FIGS. 4 and 5 depicts a third embodiment 100c of the fluid connector 100. As shown in FIGS. 1-5, the fluid connector 100, 100a, 100b, 100c comprises a body 104, 104a, 104b, 104c that extends along a central axis 108 between opposed end faces 112, 112a, 112b, 112c thereof. In aspects, the body 104, 104a, 104b, 104c of the fluid connector 100, 100a, 100b, 100c comprises a metal, ceramic, glass, or plastic material. In aspects in which the fluid connector 100, 100a, 100b, 100c, comprises a metal or a metal material, the metal is stainless steel, such as 316L stainless steel,which has high corrosion performance and is readily available in various thicknesses and sizes. Other stainless-steel metals can be used as well including Hastelloy®, as well as still other metals.

[0061] The body 104, 104a, 104b, 104c of the fluid connector 100, 100a, 100b, 100c comprises a first body section 116, 116a, 116b, 116c with a first contact surface 120, 120a, 120b, 120c and a second body section 124, 124a, 124b, 124c with a second contact surface 128, 128a, 128b, 128c. The first contact surface 120, 120a, 120b, 120c and the second contact surface 128, 128a, 128b, 128c are joined at a first bond joint 132, 132a, 132b, 132c. As described later in this disclosure, the first bond joint 132, 132a, 132b, 132c comprises a bonding material, such as a flux or an adhesive, that is bonded to and / or between the first contact surface 120, 120a, 120b, 120c and the second contact surface 128, 128a, 128b, 128c.

[0062] As used herein, the term "bonding material" refers to any material that can join or unite separate bodies or surfaces together in a sufficient manner so that the bodies or surfaces can perform their intended functions. In aspects, the bonding material can have at least two states, such as a first or initial (unbonded) state and a second or final (bonded) state. In the initial unbonded state, the bonding material is configured (or can be configured by combination with other materials and / or changes to the environment, such as heating) to be readily applied to the bodies or surfaces to be joined or united. For example, the bonding material in the initial unbonded state can be in the form of (i) loose powder, particulate, or particles, (ii) a viscous paste, (iii) a (curable) liquid, and other forms. In the final bonded state, the bonding material is configured to be a substantially fixed, solid or relatively solid volume of material that is firmly adhered to itself and to the bodies or surfaces on which it had been applied so as to permanently or semi-permanently join or unite the bodies or surfaces together.

[0063] Different techniques can be used to change the bonding material from the initial unbonded state to the final bonded state. In aspects, an adhesive can be changed from the initial unbonded state to the final bonded state by exposure to one or more of air, heat, humidity, or other environmental conditions. In aspects, an ultraviolet (UV) curable liquid can be changed from the initial unbonded state to the final bonded state by exposure to a UV light source. In aspects, such as described later in this disclosure with respect to the method for fabricating the fluid connector, flux (e.g., carbide powder) can be changed from the initial unbonded state to the final bonded state by exposure to heat and pressure such that the flux is thermally-bonded to and / or between the features, such as the first and second contact surfaces.

[0064] Whether or not the bonding material being described is in the initial unbonded state or the final bonded state should be apparent by the context in which the term is used in the disclosure. For example, apparatus claims that refer to the bonding material can be presumed to be referring to the bonding material in the final bonded state unless described otherwise in the claims. In contrast, method claims that refer to the bonding material may refer to the bonding material in either the initial unbonded state or the final bonded state. Reference to bonding material and / or surfaces that is / are "bonded" or "joined" typically refers to bonding material in the final bonded state unless described otherwise.

[0065] As best shown in FIGS. 3 and 5, the first body section 116, 116a, 116b, 116c and the second body section 124, 124a, 124b, 124c are separate (e.g., discrete) structures before being joined by the bonding material at the first bond joint 132, 132a, 132b, 132c. The first body section 116, 116a, 116b, 116c and the second body section 124, 124a, 124b, 124c form a unitary structure after being joined by the bonding material at the first bond joint 132, 132a, 132b, 132c.

[0066] Referring again to FIGS. 1-5, the fluid connector 100, 100a, 100b, 100c comprises a connector passage 136 that extends through the body 104, 104a, 104b, 104c and opens to the opposed end faces 112, 112a, 112b, 112c. In aspects, the connector passage 136 is concentric with the central axis 108 as shown in FIGS 1-5. In aspects, the connector passage 136 can be radially offset from the central axis 108. In aspects, the connector passage 136 can extend transversely relative to the central axis 108.

[0067] In aspects, the first contact surface 120, 120a, 120b, 120c and the second contact surface 128, 128a, 128b, 128c are coextensive with a plane 140 (FIGS. 3 and 5) along which the first bond joint 132, 132a, 132b, 132c extends through the body 104, 104a, 104b, 104c. In aspects, the first bond joint 132, 132a, 132b, 132c extends entirely through the body 104, 104a, 104b, 104c along the plane 140, such as depicted in FIGS. 1, 2, and 4.

[0068] Referring still to FIGS. 1-5, the first bond joint 132, 132a, 132b, 132c intersects the connector passage 136 and extends (e.g., continuously) from the connector passage 136 to a peripheral surface 144, 144a, 144b, 144c of the body 104, 104a, 104b, 104c for a detection distance 148. In aspects, the peripheral surface 144, 144a, 144b, 144c has a circular shape when viewed in a cross section oriented substantially normal to the central axis 108. In aspects, the peripheral surface 144, 144a, 144b, 144c can have other cross-sectional shapes, such as oval, square, rectangular, and others. In aspects, such as shown in FIG. 1, the peripheral surface 144,144a can comprises a radial groove 146 that encircles the central axis 108. In aspects, an annular seal such as an O-ring (not shown) can be installed in the radial groove 146.

[0069] As used herein, the "detection distance" is the distance or length of the first bond joint 132, 132a, 132b, 132c between the connector passage 136 and the peripheral surface 144, 144a, 144b, 144c measured in a direction perpendicular to the connector passage 136. In other words, the detection distance 148 is the shortest distance along the first bond joint 132, 132a, 132b, 132c between the connector passage 136 and the peripheral surface 144, 144a, 144b, 144c. The detection distance 148 does not include features of the opposed end faces 112, 112a, 112b, 112c, such as the surface portion(s), the protrusion(s), and the annular groove(s) described later in this disclosure.

[0070] In aspects, such as depicted in FIGS. 1-3, the first bond joint 132, 132a, 132b is aligned with the central axis 108 (e.g., the first bond joint and the central axis are coextensive) such that the first body section 116, 116a, 116b and the second body section 124, 124a, 124b are configured as a first longitudinal body section and a second longitudinal body section, respectively. In such aspects, as best shown in FIG. 3, the detection distance 148 is approximately the same over the extent of the body 104, 104a, 104b, 104b along the central axis 108, which can lead to more consistent corrosion detection.

[0071] In aspects, such as depicted in FIGS. 4 and 5, the first bond joint 132, 132c is perpendicular to the central axis 108 such that the first body section 116, 116c and the second body section 124, 124c are configured as a first axial body section and a second axial body section, respectively. In such aspects, as shown in FIGS. 4 and 5, the first bond joint 132, 132c can be disposed at an approximate midpoint (e.g., an equidistant position) between the opposed end faces 112, 112c of the body 104, 104c. In such aspects, the first bond joint 132, 132c can be disposed at any position between the opposed end faces 112, 112c of the body 104, 104c as long as there is sufficient material thickness for fabricating and bonding the preforms, as described later in this disclosure.

[0072] In aspects in which first bond joint 132, 132c is perpendicular to the central axis 108, such as depicted in FIGS. 4 and 5, the peripheral surface 144, 144c preferably has a crosssection shape that is circular so that the detection distance 148 (e.g., measured in a radial direction between the connector passage and the peripheral surface) is approximately the same at any position on the peripheral surface 144, 144c. In such aspects, if the peripheral surface 144, 144c has a cross-sectional shape that is not circular, a circular groove (not shown) that isco-located with the first bond joint 132, 132c can be formed in the peripheral surface 144, 144c so that the detection distance 148 is approximately the same at any position along the surface of the groove. Alternatively, a plurality of spaced-apart depressions could be formed in the peripheral surface 144, 144c (e.g., about the periphery of the body 104, 104c) and co-located with the first bond joint 132, 132c such that the detection distance 148 is approximately the same at each depression.

[0073] Referring now to FIGS. 1, 6, and 7, the fluid connector 100, 100a can comprise a threaded bore 152 and a fastener 156 threadedly engaged with the threaded bore 152. FIG. 6 is a cross-sectional view of the fluid connector 100, 100a along a section plane passing through the radial groove 146 (FIG. 1). As shown in FIG. 6, the threaded bore 152 extends through at least a portion of the first body section 116, 116a and the second body section 124, 124a and opens to the peripheral surface 144, 144a on one side (e.g., the second body section 124, 124a in the embodiment shown in FIG. 6). In aspects, the threaded bore 152 is oriented transversely with respect to the first contact surface 120, 120a and the second contact surface 128, 128a (e.g., the threaded bore is oriented transversely with respect to the first bond joint). In aspects, as show in FIG. 6, the threaded bore 152 is oriented perpendicularly with respect to the first contact surface 120, 120a and the second contact surface 128, 128a (e.g., the threaded bore is oriented perpendicularly with respect to the first bond joint).

[0074] As shown in FIG. 6, the fastener 156 is threadedly engaged with the threaded bore 152 such that the fastener 156 draws the first contact surface 120, 120a of the first body section 116, 116a and the second contact surface 128, 128a of the second body section 124, 124a towards each other (and into compression) when the fastener 156 is tightened in the threaded bore 152. Such tightening (and the resulting compression therefrom) is used in connection with joining the first contact surface 120, 120a and the second contact surface 128, 128 with the bonding material, as described later in this disclosure.

[0075] In aspects, as shown in FIGS. 6 and 7, the threaded bore comprises a plurality of threaded bores 152, and the fastener comprises a plurality of fasteners 156 each of which is configured to threadedly engage a corresponding threaded bore 152. In aspects, as shown in FIG. 6, the threaded bores 152 can open to the peripheral surface 144, 144a on the same side of the fluid connector 100, 100a (e.g., both threaded bores 152 open from the second body section 124, 124a). In aspects, as shown in FIG. 7, the threaded bores 152 can open to the peripheral surface 144, 144a on different (e.g., opposite) sides of the fluid connector 100, 100a (e.g., one threaded bore 152 opens from the first body section 116, 116a and the other threadedbore 152 opens from the second body section 124, 124a). In such aspects as shown in FIG. 7, the threaded bores 152 disposed in opposite directions can enable tighter assembly as the clearances in the threads will operate in opposition rather than cumulatively.

[0076] Referring again to FIGS. 1-5, the opposed end faces 112, 112a, 112b, 112c of the fluid connector 100, 100a, 100b, 100c can have features that facilitate implementation of the fluid connector in a continuous flow reactor, such as the continuous flow reactor 200 shown in FIGS. 11 and 15 and described later in this disclosure. For example, each end face 112, 112a, 112b, 112c can have one or more surface portions 160, 160a, 160b, 160c oriented substantially normal to the central axis 108. In aspects, the surface portions 160, 160a, 160b, 160c are annular surface portions that encircle the central axis 108.

[0077] In aspects, the surface portions 160, 160a, 160b, 160c can comprises an inner surface portion disposed proximate to the connector passage 136 and an outer surface portion radially spaced from the inner surface portion and disposed proximate to the peripheral surface 144, 144a, 144b, 144c. In aspects, the inner and outer surface portions 160, 160a, 160b, 160c define an annular groove 164, 164a, 164b, 164c therebetween. In aspects, an annular seal such as an O-ring (not shown) can be installed in the annular groove 164,164a, 164b, 164c. In aspects, the surface portions 160, 160a, 160b, 160c are configured to abut corresponding surfaces of the continuous flow reactor 200 for sealing the fluid connector 100, 100a, 100b, 100c against components of the continuous flow reactor 200.

[0078] In aspects, as shown in FIG. 2, each end face 112, 112b can have a protrusion 168, 168b that surrounds the connector passage 136 and extends outwardly from the body 104, 104b (e.g., the inner surface portion 160, 160b) along the central axis 108. In aspects, the protrusions 168, 168b are arranged concentrically with respect to the connector passage 136. In aspects, the protrusions 168, 168b can be attached to the body 104, 104b of the fluid connector 100, 100b after the first body section 116, 116b and the second body section 124, 124b are joined so that the first bond joint 132, 132b does not pass through the protrusions 168, 168b (e.g., the protrusions are monolithic). In aspects, the protrusions 168, 168b are configured to be received in ports of the continuous flow reactor 200 for positioning the fluid connector 100, 100b relative to components of the continuous flow reactor 200.

[0079] It should be appreciated that the various features and / or aspects described herein with reference to the different embodiments of the fluid connector 100, 100a, 100b, 100c should be considered interchangeable with one another and not limiting if not expresslydisclosed in connection with a specific embodiment. For example, the threaded bore(s) and the fastener(s) can be included in any embodiment, or the threaded bore(s) and the fastener(s) can be omitted in any embodiment as long as appropriate fixturing and / or clamping is utilized during the fabrication and bonding of the preforms, as described later in this disclosure. Similarly, the features and / or aspects described with reference to the opposed end faces of the different embodiments of the fluid connect 100, 100a, 100b, 100c can be the same or different depending how the fluid connector will be integrated in the continuous flow reactor.

[0080] An embodiment of a method for fabricating the fluid connector 100 is now described with reference to FIGS. 8-10. In the following description of the method, reference may also be made to the various embodiments of the fluid connector 100, 100a, 100b, 100c described herein with reference to FIGS. 1-7. The method comprises fabricating a preform 304 in the general shape of the fluid connector 100. In aspects, the preform 304 can be fabricated by a subtractive process such as turning or computer numerical control (CNC) machining. In aspects, the preform 304 can be fabricated by an additive process, such as three-dimensional (3D) printing. In aspects, the preform 304 can be fabricated by a molding process, such as metal injection molding (MIM).

[0081] In aspects, the preform 304 has external dimensions that are larger than target or final external dimensions of the fluid connector 100. For example, the preform 304 can have preform opposed end faces 312 that are larger than the corresponding opposed end faces 112 of the fluid connector 100. Similarly, the preform 304 can have a preform peripheral surface 344 that is larger than the corresponding peripheral surface 144 of the fluid connector 100. In aspects, the preform 304 also has internal dimensions that are smaller than target or final internal dimensions of the fluid connector 100. For example, the preform 304 can have a preform connector passage 336 that is smaller than the corresponding connector passage 136 of the fluid connector 100.

[0082] After the preform 304 is fabricated, the method optionally comprises forming one or more threaded bores 152 in the preform 304. The threaded bores 152 can be positioned and oriented as described above with reference to FIGS. 6 and 7. After the threaded bores 152 are optionally formed in the preform 304, the method comprises separating the preform 304 into a first preform body section 316 corresponding generally to the first body section 116 (FIGS. 1- 7) and a second preform body section 324 corresponding generally to the second body section 124 (FIGS. 1-7). The preform 304 can be separated by any process that can accurately section the preform 304, leaving substantially mirror symmetrical contact surfaces 120, 128 withminimal or no post-processing (e.g., no grinding or polishing). In aspects, the preform 304 can be separated using wire electrical discharge machining (EDM).

[0083] In aspects, as an alternative to fabricating a monolithic preform (e.g., the preform 304) and thereafter separating the preform, the method can comprise fabricating the first and second preform body sections 316, 324 as discrete bodies such that there is no need to perform a separating step. In such aspects, if the discrete first and second preform body sections 316, 324 will comprise the two threaded bores 152 disposed on opposite sides of the (final) fluid connector, the first and second preform body sections 316, 324 can be fabricated as identical sections, which can provide a manufacturing cost advantage.

[0084] After the preform 304 is separated (or the first and second preform body sections 316, 324 are fabricated as discrete bodies), the method comprises applying bonding material to the contact surfaces 120, 128 of the first and second preform body sections 316, 324. The contact surfaces 120, 128 should be smooth and flat before applying the bonding material. In aspects, the bonding material applied to the contact surfaces 120, 128 of the first and second preform body sections 316, 324 is the same bonding material used to join the plates of the flow module(s) of the continuous flow system 200 described later in this disclosure so that the corrosion performance of the fluid connector 100 can be used to predict the corrosion performance of the flow module(s) of the continuous flow system 200. In aspects, when the fluid connector material is a metal, the bonding material can be carbide powder, which can be used to preserve the chemical resistance of the flow module(s) of the continuous flow system 200. Any carbide powder (e.g., silicon carbide, boron carbide, hafnium carbide, etc.), or mixtures thereof, can be used as the bonding material. In aspects, nitride powder (e.g., silicon nitride) can also be used as the bonding material since such powder can bond as well.

[0085] In aspects, the carbide powder or carbide powder mixture is applied (e.g., deposited, sprinkled, etc.) onto one or both of the contact surfaces 120, 128 so that there is complete coverage. In aspects, after deposition, the carbide powder or carbide powder mixture forms a layer on the contact surface 120, 128 that has a monolayer-like thickness, which approximates the thickness of a single layer of the powder particles that form the bonding material. In aspects, the layer of carbide powder or carbide powder mixture can be deposited to a thickness that is greater than the monolayer-like thickness.

[0086] In aspects, the bonding material can be provided as a water-based mixture comprising the carbide powder or carbide powder mixture. The mixture can be applied to thecontact surfaces 120, 128, for example, via brushing, rolling, spraying, or the like such that the mixture remains approximately in place on the contact surface thereafter.

[0087] After the bonding material is applied to the contact surfaces 120, 128, the method comprises pressing the first and second preform body sections 316, 324 together so as to compress the bonding material between the contact surfaces 120, 128. In embodiments in which the threaded bores 152 are formed in the preform 304, fasteners 156 (e.g., threaded screws) can be installed in the threaded bores 152 and tightened in order to clamp the first and second preform body sections 316, 324 together, in particular during a possible subsequent thermal bonding step. The threaded bores 152 and the fasteners 156 are also configured set and hold the alignment of the first and second preform body sections 316, 324 relative to one another during the subsequent thermal bonding step. FIG. 9 is a digital image that shows the first and second preform body sections 316, 324 assembled together with the fasteners 156 and with the bonding material disposed between the contact surfaces 120, 128 at the first bond joint 132 (e.g., prior to the thermal bonding step).

[0088] In embodiments in which the preform 304 does not include the threaded bores 152, the first and second preform body sections 316, 324 with the bonding material applied to the contact surfaces 120, 128 thereof can be placed in a fixture configured to hold the first and second preform body sections 316, 324 in alignment and press the first and second preform body sections 316, 324 together during the subsequent thermal bonding step. FIGS. 10 and 11 are schematic depictions of a fixture 350 and modified first and second preform body sections 316', 324' that can be used during the subsequent thermal bonding step when threaded bores 152 are not provided. As shown in FIGS. 10 and 11, the contact surfaces 120', 128' of the modified first and second preform body sections 316', 324' comprise a self-centering feature 354 configured to position the first and second preform body sections in near-concentric alignment with one another when the contact surfaces 120', 128' thereof are pressed together. In aspects, the self-centering feature 354 can comprises a centering protrusion 358 protruding from one of the contact surfaces 120', 128' and corresponding depression 362 recessed into the other of the contact surfaces 120', 128' and configured to receive the centering protrusion 358 therein with virtually no radial clearance therebetween.

[0089] Referring now to FIG. 11, the fixture 350 can include a pair of plates 366 configured to abut the preform opposed end faces 312 and sandwich the modified first and second preform sections 316', 324' therebetween while a force (arrow 370) is applied to one or both the plates 366. The plates 366 can be formed from a material configured to withstand the bondingpressure and the bonding temperature used to thermally bond the bonding material between the contact surfaces 120', 128'. The material of the plates 366 is also configured to not adhere to the modified first and second preform body sections 316', 324' during the subsequent thermal bonding. In aspects, the plates 350 can be formed from graphite or oxide ceramics, such as alumina or cordierite.

[0090] In aspects, after the first and second preform body sections 316, 324 are pressed together, the method comprises heating the first and second preform body sections 316, 324 and the bonding material to a bonding temperature for a bonding time to thermally bond the bonding material to and / or between the contact surfaces 120, 128 and form the first bond joint 132. In aspects, the heating takes place in a non-oxidizing or in an inert atmosphere (argon, vacuum, etc.). For carbide powders, the bonding time can be 120 minutes, 110 minutes, 100 minutes, 90 minutes, or less at the (peak) bonding temperature. The bonding temperature depends on the bonding material and can be in a range of from about 1100 °C to about 1500 °C, from about 1200 °C to about 1400 °C, or from about 1200 °C to about 1350 °C. In aspects, the bonding material is boron carbide since its bonding temperature of approximately 1210 °C is lower than the bonding temperature of other carbide powders. For example, the bonding temperature of silicon carbide is approximately 1340 °C. After the heating, the bonding material at the first bond joint 132 comprises one or more of a (thermally-bonded) carbide material and a (thermally-bonded) nitride material.

[0091] After the first and second preform body sections 316, 324 and the bonding material are heated to thermally bond the bonding material to and / or between the contact surfaces 120, 128 and form the first bond joint 132, the method comprises finish machining the body 104 to obtain the target or final dimensions of the fluid connector 100 and provide clean surfaces. FIG. 12 is a digital image of two fluid connectors 100, 100a that have been finish machined to obtain target or final dimensions thereof.

[0092] Referring now to FIGS. 13-17, embodiments of a continuous flow reactor 200 that comprises the fluid connector 100 and a flow module 201 are shown. The flow module 201 is made of the same material as the fluid connector 100. FIG. 13 is an exploded perspective view schematically illustrating aspects of the flow module 201. As shown in FIG. 13, the flow module 201 includes a first plate 202 with a first major (inner) surface 204 and a second plate 206 with a second major (inner) surface 208. The first plate 202 has a third major (outer) surface 210 that is opposed to the first major surface 204. The second plate 206 has a fourth major (outer) surface 212 that is opposed to the second major surface 208. The second plate206 has one or more flow channels 214 defined at least in part in the second major surface 208. The first plate 202 in some embodiments also has one or more flow channels 216 (FIG. 14) defined at least in part in the first major surface 204. The flow channels 214 alone or together with the flow channels 216 form a (common) module passage 218 that is disposed within the flow module 201.

[0093] In aspects, the flow module 201 comprises a plurality of module ports 217 some of which are configured to extend between the third and fourth major (outer) surfaces 210, 212 of the first and second plates 202, 206 and intersect the module passage 218. In aspects, module passage 218 can comprise two inputs 219 and an output 220 as shown in FIG. 13.

[0094] As best shown in FIG. 17, the first and second plates 202, 206 are joined together at a second bond joint 222 that comprises the bonding material bonded to and / or between contacting portions of the first and second major (inner) surfaces 204, 208. As used herein, “contacting portions” means those portions of the referenced surfaces that would be in contact absent the bonding material when the referenced surfaces are positioned against one another. Specifically, the contacting portions are those portions of the respective first and second major surfaces 204, 208 that would be in contact absent the bonding material when the first major surface 204 is positioned against the second major surface 208.

[0095] In aspects, the bonding material applied to the contacting portions of the first and second major surfaces 204, 208 of the first and second plates 202, 206 of the flow module 201 is the same bonding material used to join the first and second contact surfaces 120, 128 of the first and second body sections 116, 124 of the fluid connector 100 described hereinabove. In aspects, the bonding material is thermally bonded to and / or between the contacting portions of the first and second major (inner) surfaces 204, 208 of the flow module 201 using essentially the same bonding process (e.g., bonding temperature, bonding time, pressure during bonding, etc.) used in connection with the fluid connector 100. An exemplary thermal bonding process for bonding the metal plates of a flow module is described in U.S. Patent Publication No. US 2023 / 0150050 Al, filed on March 29, 2021, which is incorporated by reference herein in its entirety.

[0096] Referring now to FIGS. 14-16, schematic cross sections of portions of reference flow modules are shown to illustrate issues that may arise when continuous flow reactors process fluid that is corrosive to the bonding material used to join the plates of the respective flow modules. FIG. 14 illustrates a first reference flow module 201refi with a module passage218 defined by portions of the first and second major surfaces 204, 208 of the first and second plates 202, 206. Two adjacent portions of the module passage 218 are shown in FIG. 14 with the adjacent portions having a spacing 224 therebetween. In aspects, the spacing 224 is about 10 mm, but such spacing can be lesser or greater in other aspects. The second bond joint 222 intersects the adjacent portions of the module passage 218. As schematically illustrated in FIG. 14, the second bond joint 222 of the first reference flow module 201refi is unaffected by corrosion and fully intact between (i) the adjacent portions of the module passage 218 and (ii) each adjacent portion of the module passage 218 and a peripheral (outer) surface of the flow module 201refi.

[0097] FIG. 15 illustrates a second reference flow module 201ref2 that is configured in the same manner as the first reference flow module 201refi except that second bond joint 222 of the second reference flow module 201ref2 is affected by corrosion. For example, as schematically illustrated in FIG. 15, the second bond joint 222 is fully corroded between the adjacent portions of the module passage 218 (e.g., as shown via the open channel 226 that provides a bypass between the adjacent portion of the module passage 218), thereby leading to performance and / or safety issues during operation of the second reference flow module 201ref2.

[0098] FIG. 16 illustrates a third reference flow module 201refi with a module passage 218 defined by portions of the first and second major surfaces 204, 208 of the first and second plates 202, 206. A single portion of the module passage 218 is shown in FIG. 16. The second bond joint 222 intersects the single portion of the module passage 218. As schematically illustrated in FIG. 16, the second bond joint 222 is affected by corrosion such that lateral portions of the module passage 218 proximate the second bond joint 222 have formed open areas 228 due to the corrosion. Such open areas 228 can act as dead zones (e.g., areas containing fluid of lower velocity) for the reaction fluid and degrade the residence time distribution. Furthermore, dead zones are known to create a risk of runaway for some reactions, such as nitration reactions.

[0099] In view these and other corrosion-related issues known to affect the safe and efficient operation of continuous flow reactors using bonded flow modules, the continuous flow reactor 200 disclosed herein utilizes a critical distance that corresponds to a (maximum) allowable delamination of the second bond joint 222 (e.g., due to corrosion) that extends (perpendicularly) from the module passage 218 into the bulk of flow module 201.

[0100] Referring now to FIGS. 1, 2, 4, 13, and 17, the connector passage 136 of the fluid connector 100 and the module passage 218 of the flow module 201 are fluidically connectedvia a flow path (e.g., dashed arrows in FIG. 17) along which fluid that is corrosive to the bonding material is configured to be conveyed in a process direction through the continuous flow reactor 200, thereby exposing the bonding material of the first bond joint 132 and the second bond joint 222 to the corrosive fluid.

[0101] In aspects, the detection distance 148 of the first bond joint 132 of the fluid connector 100 is shorter than the critical distance of the second bond joint 222 of the flow module 201 such that the fluid connector 100 will exhibit indicia of the (corrosive) fluid leaking through the first bond joint 132 during operation of the continuous flow reactor 200 before performance and / or safety issues arise with respect to the second bond joint 222 of the flow module 201.

[0102] In aspects, the detection distance 148 is less than or equal to approximately 80% (e.g., 75%, 70%, 65%, 60%, 55%, 50%, or less) of the critical distance. In aspects, the critical distance is in a range of about 5 mm to about 15 mm, about 7 mm to about 13 mm, or about 8 mm to about 12 mm.

[0103] In aspects, one of the opposed end faces 112 of the fluid connector 100 is configured to abut the major (outer) surface 210, 212 of one of the first and second plates 202, 206 and directly connect the connector passage 136 of the fluid connector 100 to the module passage 218 of the flow module 201.

[0104] In aspects, the continuous flow reactor 200 comprises a further flow module 201' configured in the same manner as the flow module 201. As shown in FIG. 17, the further flow module 201' is arranged downstream from the flow module 201 along the flow path. In aspects, the fluid connector 100 is configured to be positioned along the flow path any of (i) upstream from the flow module 201 (e.g., the fluid connector 100i), (ii) between the flow module 201 and the further flow module 201' (e.g., the fluid connector IOO2), and (iii) downstream from the further flow module 201' (e.g., the fluid connector IOO3). In aspects, the continuous flow reactor 200 comprises a further fluid connector configured in the same manner as the fluid connector 100. The further fluid connector is positioned along the flow path differently than the fluid connector 100 is positioned along the flow path. For example, the continuous flow reactor 200 can comprise the fluid connector 100i and the fluid connector IOO2, which are positioned differently relative to each other.

[0105] It should be appreciated that the continuous flow reactor 200 can have numerous different configurations including additional flow modules and additional fluid connectors. Inaspects, each additional flow module can have the same configuration or different configurations than the flow module 201 and the further flow module 201' depicted in FIG. 17. For example, the additional flow modules can have heat exchangers attached to one or both major (outer) surfaces thereof. Moreover, the continuous flow reactor 200 can utilize a multitude of different inserts to define various process fluid flow paths through the reactor, such as the metal inserts disclosed in (Applicant Docket No. SP22-281).

[0106] Referring now to FIG. 18, a flow chart depicting steps of an exemplary method 400 for detecting corrosion in the continuous flow reactor 200 is shown. In a first step 402, the method 400 comprises operating the continuous flow reactor 200 by flowing the (corrosive) fluid along the flow path through the fluid connector 100 and the flow module 201. In a second step 404, the method 400 comprises monitoring the peripheral surface 144 of the fluid connector 100 for indicia of the fluid leaking through the first bond joint 132 during the flowing. The indicia can comprise fluid present and / or actively emerging from the first bond joint 132 at the peripheral surface 144. In aspects, the indicia may include staining of the peripheral surface 144 of the fluid connector 100 proximate to the first bond joint 132. For example, such staining may result from (reactive) gas(es) escaping through the first bond joint 132 due to partial corrosion of the first bond joint 132 and high pressure within the flow module 201.

[0107] In a third step 406, the method 400 comprises determining if the indicia is present on the peripheral surface 144 of the fluid connector 100 so as to detect corrosion in the continuous flow reactor 200. If the indicia is not present (e.g., "NO"), the method 400 returns to the second (monitoring) step 404. If the indicia is present (e.g., "YES"), the method 400 comprises (possibly) detecting corrosion in the continuous flow reactor 200 and proceeding to the next step. In a fourth step 408, the method 400 comprises ceasing operation of the continuous flow reactor 200 when corrosion is detected via the fluid connector 100. In a fifth step 410, the method 400 comprises inspecting the flow module 200 for corrosion. Such inspecting can include proof-testing and / or non-destructive control methods such as acoustic microscopy.

[0108] While the disclosure has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications, and further applications that come within the spirit of the disclosure are desired to be protected.

Claims

CLAIMSWhat is claimed is:

1. A fluid connector, comprising: a body extending along a central axis between opposed end faces thereof, the body comprising a first body section with a first contact surface and a second body section with a second contact surface joined to the first contact surface at a first bond joint comprising bonding material; and a connector passage extending through the body and opening to the opposed end faces, wherein the first bond joint intersects the connector passage and extends from the connector passage to a peripheral surface of the body for a detection distance.

2. The fluid connector of claim 1, wherein the first and second contact surfaces are coextensive with a plane along which the first bond joint extends through the body.

3. The fluid connector of claim 2, wherein the first bond joint extends entirely through the body along the plane.

4. The fluid connector of claim 2 or claim 3, wherein the first bond joint is aligned with the central axis such that the first and second body sections are configured as first and second longitudinal body sections.

5. The fluid connector of claim 2 or claim 3, wherein the first bond joint is perpendicular to the central axis such that the first and second body sections are configured as first and second axial body sections.

6. The fluid connector of claim 5, wherein the first bond joint is disposed at an approximate midpoint between the opposed end faces of the body.

7. The fluid connector of any one of claims 1-6, wherein the connector passage is concentric with the central axis.

8. The fluid connector of any one of claims 1-7, further comprising: a threaded bore extending through at least a portion of the first and second body sections and oriented transversely with respect to the first and second contact surfaces; and a fastener threadedly engaged with the threaded bore.

9. The fluid connector of claim 8, wherein the threaded bore comprises a plurality of threaded bores, and the fastener comprises a plurality of fasteners each configured to threadedly engage a corresponding threaded bore.

10. The fluid connector of claim 9, wherein each threaded bore opens on one side to the peripheral surface, and wherein at least two threaded bores open to the peripheral surface in opposite directions.

11. The fluid connector of any one of claims 1-10, wherein the bonding material comprises one or more of a carbide material and a nitride material.

12. The fluid connector of claim 11, wherein the bonding material comprises a boron carbide material.

13. The fluid connector of claim 11 or claim 12, wherein the carbide material and the nitride material are formed via heating a carbide powder and a nitride powder, respectively, to a bonding temperature for a bonding time.

14. The fluid connector of any one of claims 1-13, wherein the body of the fluid connector comprises metal.

15. The fluid connector of claim 14, wherein the metal is stainless steel.

16. The fluid connector of any one of claims 1-15, wherein the peripheral surface has a circular shape when viewed in a cross section oriented substantially normal to the central axis.

17. The fluid connector of any one of claims 1-16, wherein each end face of the body has one or more surface portions oriented substantially normal to the central axis.

18. The fluid connector of claim 17, wherein the one or more surface portions are annular surface portions that encircle the central axis.

19. The fluid connector of claim 17 or claim 18, wherein the one or more surface portions comprise an inner surface portion disposed proximate to the connector passage and an outer surface portion radially spaced from the inner surface portion and disposed proximate to the peripheral surface.

20. The fluid connector of claim 19, wherein the inner surface portion and the outer surface portion define an annular groove therebetween.

21. A continuous flow reactor, comprising: the fluid connector of any one of claims 1-20; and a flow module comprising (i) first and second plates joined together at a second bond joint comprising the bonding material and (ii) a module passage disposed within the flow module, wherein the second bond joint intersects the module passage and extends therefrom for at least a critical distance, wherein the connector passage of the fluid connector and the module passage of the flow module are fluidically connected via a flow path along which fluid that is corrosive to the bonding material is configured to be conveyed in a process direction through the continuous flow reactor, thereby exposing the bonding material of the first and second bond joints to the corrosive fluid, wherein the detection distance of the first bond joint is shorter than the critical distance of the second bond joint.

22. The continuous flow reactor of claim 21, wherein the detection distance is less than or equal to approximately 80% of the critical distance.

23. The continuous flow reactor of claim 21, wherein the detection distance is less than or equal to approximately 60% of the critical distance.

24. The continuous flow reactor of any one of claims 21-23, wherein the critical distance is in a range of about 5 mm to about 15 mm.

25. The continuous flow reactor of any one of claims 21-23, wherein the critical distance is in a range of about 7 mm to about 13 mm.

26. The continuous flow reactor of any one of claims 21-25, wherein the flow module comprises a module port extending between opposed major outer surfaces of the first and second plates and intersecting the module passage, and wherein one of the opposed end faces of the fluid connector is configured to abut the major outer surface of one of the first and second plates and directly connect the connector passage of the fluid connector to the module passage of the flow module.

27. The continuous flow reactor of any one of claims 21-26, further comprising a further flow module configured in the same manner as the flow module, the further flow module arranged downstream from the flow module along the flow path, wherein the fluid connector is configured to be positioned along the flow path any of (i) upstream from the flow module, (ii) between the flow module and the further flow module, and (iii) downstream from the further flow module.

28. The continuous flow reactor of claim 27, further comprising a further fluid connector configured in the same manner as the fluid connector, the further fluid connector positioned along the flow path differently than the fluid connector is positioned along the flow path.

29. A method for detecting corrosion in the continuous flow reactor of any one of claims 21-28, the method comprising: operating the continuous flow reactor by flowing the fluid along the flow path through the fluid connector and the flow module; monitoring the peripheral surface of the fluid connector for indicia of the fluid leaking through the first bond joint during the flowing; and detecting corrosion in the continuous flow reactor when the indicia is present on the peripheral surface.

30. The method of claim 29, further comprising: ceasing operation of the continuous flow reactor when corrosion is detected via the fluid connector; and inspecting the flow module for corrosion.

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