High-Flow Valve Block Layout to Protect the Diaphragm
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Solution Overview
Problem
Current valve designs for simulated moving bed (SMB) chromatography face issues such as reliability problems due to fluid and solute mixtures affecting moving parts, over-stretching of flexible diaphragms, and unacceptably high pressure and fluid linear velocity at required flow rates.
Innovation Solution
The development of a valve block system that includes a fluid-transfer plate, a pressure plate, and a diaphragm, where the diaphragm is sandwiched between the two plates and the sizing and number of inlet and outlet bores are optimized to avoid deleterious deformation of the diaphragm and control the required pressure for fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional valve designs are used in SMB chromatography, then the system can operate with simple structure, but the reliability deteriorates due to fluid and solute mixtures affecting moving parts and causing diaphragm over-stretching
Solution Approach 1:
The valve block is segmented into multiple functional plates (fluid-transfer plate, plate with recesses) that can be assembled together, allowing the diaphragm to be sandwiched between them. This segmentation enables independent optimization of each component and improves reliability by isolating the diaphragm from direct exposure to fluid mixtures while maintaining a relatively simple overall structure.
Solution Approach 2:
The diaphragm acts as an intermediary element sandwiched between the fluid-transfer plate and the plate with recesses. This intermediary structure protects the diaphragm from direct contact with harmful fluid and solute mixtures, preventing degradation and over-stretching while still allowing it to perform its flow control function effectively.
2Productivity
If larger bore sizes are used to accommodate higher flow rates, then the productivity increases, but the diaphragm undergoes deleterious deformation
Solution Approach 1:
Instead of using a single large bore, the design segments the flow path into multiple smaller inlet bores (four or more per inlet channel) and outlet bores. This segmentation allows the system to handle higher total flow rates while each individual bore remains small enough to prevent excessive diaphragm deformation, thus maintaining diaphragm structural integrity.
Solution Approach 2:
The inlet and outlet channels are designed with specific sizing and numbering of bores to create local quality variations in the flow distribution. This ensures that pressure and flow are evenly distributed across the diaphragm surface, preventing localized over-stretching and deformation while accommodating the required overall flow rate.
3Stress or pressure
If the number of inlet and outlet bores is increased to control pressure, then the manufacturing complexity increases, but the pressure control improves
Solution Approach 1:
Multiple inlet bores are merged into common inlet channels, and multiple outlet bores are merged into common outlet channels. This merging approach allows for effective pressure control through multiple bores while simplifying the manufacturing process by reducing the total number of individual bore openings that need to be precisely located and sized.
Solution Approach 2:
The plate with recesses serves multiple functions: it provides structural support for the diaphragm, creates the valve sealing surfaces, and defines the flow paths. This multi-functionality reduces the need for additional separate components, thereby simplifying manufacturing while still achieving the required pressure control through the configured bore arrangement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables the valve block to accommodate higher flow rates (up to 2.5 liters per minute) and pressures (up to 290 pounds per square inch) while preventing excessive deformation of the diaphragm, thus enhancing the reliability and performance of SMB chromatography systems.
Implementation Method 1
The diaphragm is configured to prevent flow of a fluid from the plurality of inlet bores to the plurality of outlet bores if the recess is filled with the material. The diaphragm is further configured to allow flow of the fluid from the plurality of inlet bores to the plurality of outlet bores if the recess is filled with a material having a pressure less than a pressure of the fluid.
Data Source
AI summary
An illustrative valve block includes a plate, a fluid transfer block, and a diaphragm. The plate includes a channel configured to receive a first fluid and a recess connected to the channel. The fluid transfer block includes an inlet connection configured to receive a second fluid and an outlet connection. The fluid transfer block also includes a plurality of valve inlet bores connected to the inlet connection. The plurality of valve inlet bores are distributed along at least part of a first curved shape. The fluid transfer block further includes a plurality of valve outlet bores each fluidly connected to the outlet connection. The plurality of valve outlet bores are distributed along at least part of a second curved shape. The diaphragm is between the pressure plate and the fluid transfer block. The plurality of valve inlet bores and the plurality of valve outlet bores adjoin the recess.