Double diaphragm pump and related methods

• US 20070077156A1
• Filed: 07/11/2006
• Published: 04/05/2007
• Est. Priority Date: 07/13/2005
• Status: Active Grant

• Current Assignee: Baxter Healthcare SA (Baxter International Inc.), Baxter International Inc., Purity Solutions ,LLC
• Original Assignee: Purity Solutions ,LLC
• Inventors: Orr, Troy
• Granted Patent: US 7,717,682 B2
• Time in Patent Office: Days
• US Class Current: 417/395
• CPC Class Codes: F04B 43/0736 with two or more pumping chambers in parallel
• CPC Class Codes: F04B 53/109 inlet and outlet valve forming one unit
• CPC Class Codes: F04B 7/02 the valving being fluid-actuated

Abstract

A pump for transferring a process fluid has a first pump chamber and a second pump chamber. A motive fluid actuates the pump chambers and control flow valves. The direction of process fluid flow is controlled by varying the amounts of pressure or the use of a vacuum. The control flow valves utilize diaphragms for actuation.

Claims

1. A pump for moving a process fluid, the pump comprising:

a first inlet pressure-activated diaphragm valve, a first outlet pressure-activated diaphragm valve, a second inlet pressure-activated diaphragm valve, and a second outlet pressure activated diaphragm valve,

a first pump chamber comprising a pressure-activated diaphragm, wherein the first pump chamber achieves fluid communication with an input line via the first inlet pressure-activated diaphragm valve, and wherein the first pump chamber achieves fluid communication with an outlet line via the first outlet pressure-activated diaphragm valve, and

a second pump chamber comprising a pressure-activated diaphragm, wherein the second pump chamber achieves fluid communication with the input line via the second inlet pressure-activated diaphragm valve, and wherein the second pump chamber achieves fluid communication with the outlet line via the second outlet pressure-activated diaphragm valve,

wherein the diaphragm of the first inlet pressure-activated diaphragm valve and the diaphragm of the first pump chamber are simultaneously moved by a first motive fluid, and

wherein the diaphragm of the second inlet pressure-activated diaphragm valve and the diaphragm of the second pump chamber are simultaneously moved by a second motive fluid.

2. A pump as defined in claim 1,

wherein the first pump chamber and the first inlet pressure-activated diaphragm valve are in fluid communication with the second outlet pressure-activated diaphragm valve, and

wherein the second pump chamber and the second inlet pressure-activated diaphragm valve are in fluid communication with the first outlet pressure-activated diaphragm valve.

3. A pump as defined in claim 1, wherein the diaphragm of the first inlet pressure-activated diaphragm valve, the diaphragm of the first outlet pressure-activated diaphragm valve and the diaphragm of the second pump chamber comprise an integrated diaphragm media.

4. A pump as defined in claim 1, wherein the diaphragm of the second inlet pressure-activated diaphragm valve, the diaphragm of the second outlet pressure-activated diaphragm valve and the diaphragm of the first pump chamber comprise an integrated diaphragm media.

5. A pump as defined in claim 1, wherein the first motive fluid is compressed air with a pressure greater than the process fluid pressure entering the pump and the second motive fluid is a vacuum source to discharge air with a pressure less than the process fluid pressure entering the pump.

6. A pump as defined in claim 1, further comprising a first motive fluid plate, a second motive fluid plate, and a process fluid body between the first motive fluid plate and the second motive fluid plate.

7. A pump as defined in claim 6, wherein the input line extends within the process fluid body and is in fluid communication with the first and second inlet pressure-activated diaphragm valves and the output line extends within the process fluid body and is in fluid communication with the first and second outlet pressure-activated diaphragm valves.

8. A pump as defined in claim 6,

wherein the first inlet pressure-activated diaphragm valve and the first outlet pressure-activated diaphragm valve are both defined by the second motive fluid plate and the process fluid body, and

wherein the second inlet pressure-activated diaphragm valve and the second outlet pressure-activated diaphragm valve are both defined by the first motive fluid plate and the process fluid body,

9. A pump as defined in claim 6, wherein each pressure-activated diaphragm valve comprises its diaphragm which moves within a valve chamber in response to fluid pressure, and wherein each valve chamber comprises a valve seat defined by the process fluid body and an actuation cavity defined by one of the motive fluid plates.

10. A pump as defined in claim 6,

wherein the first pump chamber comprises an actuation cavity defined by the first motive fluid plate and a first pump chamber cavity defined by the process fluid body, and

wherein the second pump chamber comprises an actuation cavity defined by the second motive fluid plate and a second pump chamber cavity defined by the process fluid body.

11. A pump as defined in claim 10,

wherein the first inlet pressure-activated diaphragm valve comprises a first inlet valve chamber and the diaphragm of the first inlet pressure-activated diaphragm valve moves within the first inlet valve chamber in response to fluid pressure, wherein the first inlet valve chamber comprises an actuation cavity defined by the second motive fluid plate and a first inlet valve seat defined by the process fluid body,

wherein the first outlet pressure-activated diaphragm valve comprises a first outlet valve chamber and the diaphragm of the first outlet pressure-activated diaphragm valve moves within the first outlet valve chamber in response to fluid pressure, wherein the first outlet valve chamber comprises an actuation cavity defined by the second motive fluid plate and a first outlet valve seat defined by the process fluid body,

wherein the second inlet pressure-activated diaphragm valve comprises a second inlet valve chamber and the diaphragm of the second inlet pressure-activated diaphragm valve moves within the second inlet valve chamber in response to fluid pressure, wherein the second inlet valve chamber comprises an actuation cavity defined by the first motive fluid plate and a second inlet valve seat defined by the process fluid body, and

wherein the second outlet pressure-activated diaphragm valve comprises a second outlet valve chamber and the diaphragm of the second outlet pressure-activated diaphragm valve moves within the second outlet valve chamber in response to fluid pressure, wherein the second outlet valve chamber comprises an actuation cavity defined by the first motive fluid plate and a second outlet valve seat defined by the process fluid body.

12. A pump as defined in claim 1,

wherein a first inlet chamber channel extends from the first pump chamber cavity to the first inlet valve seat to provide fluid communication between the first pump chamber and the first inlet pressure-activated diaphragm valve for movement of a process fluid into the first pump chamber from the input line,

wherein a first outlet chamber channel extends from the first pump chamber cavity to the first outlet valve seat to provide fluid communication between the first pump chamber and the first outlet pressure-activated diaphragm valve for movement of a process fluid from the first pump chamber to the output line,

wherein a second inlet chamber channel extends from the second pump chamber cavity to the second inlet valve seat to provide fluid communication between the second pump chamber and the second inlet pressure-activated diaphragm valve for movement of a process fluid into the second pump chamber from the input line, and

wherein a second outlet chamber channel extends from the second pump chamber cavity to the second outlet valve seat to provide fluid communication between the second pump chamber and the second outlet pressure-activated diaphragm valve for movement of a process fluid from the second pump chamber to the output line.

13. A pump as defined in claim 1, wherein a flow restrictor is positioned to restrict the flow of the process fluid out of the outlet line.

14. A pump for moving a process fluid, the pump comprising:

a first inlet pressure-activated diaphragm valve, a first outlet pressure-activated diaphragm valve, a second inlet pressure-activated diaphragm valve, and a second outlet pressure activated diaphragm valve,

a first pump chamber comprising a pressure-activated diaphragm, wherein the first pump chamber achieves fluid communication with an input line via the first inlet pressure-activated diaphragm valve, and wherein the first pump chamber achieves fluid communication with an outlet line via the first outlet pressure-activated diaphragm valve, and

a second pump chamber comprising a pressure-activated diaphragm, wherein the second pump chamber achieves fluid communication with the input line via the second inlet pressure-activated diaphragm valve, and wherein the second pump chamber achieves fluid communication with the outlet line via the second outlet pressure-activated diaphragm valve,

wherein the diaphragm of each valve and each pump chamber is pre-formed from a uniform thickness film.

15. A pump as defined in claim 14, wherein the diaphragm of the first inlet pressure-activated diaphragm valve, the diaphragm of the first outlet pressure-activated diaphragm valve and the diaphragm of the second pump chamber comprise an integrated diaphragm media.

16. A pump as defined in claim 14, wherein the diaphragm of the second inlet pressure-activated diaphragm valve, the diaphragm of the second outlet pressure-activated diaphragm valve and the diaphragm of the first pump chamber comprise an integrated diaphragm media.

17. A pump as defined in claim 14, further comprising a first motive fluid plate, a second motive fluid plate, and a process fluid body between the first motive fluid plate and the second motive fluid plate.

18. A pump as defined in claim 17, wherein the input line and the output line extend within the process fluid body.

19. A pump as defined in claim 17,

wherein the first inlet pressure-activated diaphragm valve and the first outlet pressure-activated diaphragm valve are both defined by the second motive fluid plate and the process fluid body, and

wherein the second inlet pressure-activated diaphragm valve and the second outlet pressure-activated diaphragm valve are both defined by the first motive fluid plate and the process fluid body.

20. A pump as defined in claim 17, wherein each pressure-activated diaphragm valve comprises its diaphragm which moves within a valve chamber in response to fluid pressure, and wherein each valve chamber comprises a valve seat defined by the process fluid body and an actuation cavity defined by one of the motive fluid plates.

21. A pump as defined in claim 17,

wherein the first pump chamber comprises an actuation cavity defined by the first motive fluid plate and a first pump chamber cavity defined by the process fluid body, and

wherein the second pump chamber comprises an actuation cavity defined by the second motive fluid plate and a second pump chamber cavity defined by the process fluid body.

22. A pump for moving a process fluid, the pump comprising:

a first inlet pressure-activated diaphragm valve, a first outlet pressure-activated diaphragm valve, a second inlet pressure-activated diaphragm valve motive, and a second outlet pressure activated diaphragm valve, wherein each valve comprises a diaphragm in a chamber and each chamber comprises an actuation cavity and a valve seat

a first pump chamber which achieves fluid communication with an input line via first inlet pressure-activated diaphragm valve and which achieves fluid communication with an outlet line via the first outlet pressure-activated diaphragm valve,

a second pump chamber which achieves fluid communication with the input line via the second inlet pressure-activated diaphragm valve and which achieves fluid communication with the outlet line via the second outlet pressure-activated diaphragm valve,

wherein a diaphragm is positioned in each pump chamber,

wherein the diaphragm of the first inlet pressure-activated diaphragm valve and the diaphragm of the first pump chamber are simultaneously moved by a first motive fluid,

wherein the diaphragm of the second inlet pressure-activated diaphragm valve and the diaphragm of the second pump chamber are simultaneously moved by a second motive fluid, and

wherein the diaphragm of each pressure activated diaphragm valve is configured to open and close the valve at the same motive fluid pressure used to actuate the diaphragm of the pump chamber.

23. A pump as defined in claim 22,

wherein the first inlet valve and the first outlet valve are each in fluid communication with the first chamber via separate channels,

wherein the second inlet valve and the second outlet valve are each in fluid communication with the second chamber via separate channels,

wherein the first inlet valve and the second inlet valve are each in fluid communication with the inlet line via separate portals;

and

wherein the first outlet valve and the second outlet valve are each in fluid communication with the outlet line via separate portals.

24. A pump as defined in claim 23, wherein the thickness of each valve diaphragm and the sizes of the channels and portals prevents the diaphragms from being substantially drawn into a channel or portal.

25. A pump for moving a process fluid, the pump comprising:

a process fluid body between a first motive fluid plate and a second motive fluid plate,

a first inlet pressure-activated diaphragm valve, a first outlet pressure-activated diaphragm valve, a second inlet pressure-activated diaphragm valve and a second outlet pressure-activated diaphragm valve, wherein the first inlet pressure-activated diaphragm valve and the first outlet pressure-activated diaphragm valve are each defined by one of the motive fluid plates and the process fluid body while the second inlet pressure-activated diaphragm valve and the second outlet pressure-activated diaphragm valve are each defined by the other motive fluid plate and the process fluid body,

a first pump chamber and a second pump chamber, wherein the first pump chamber is defined by one of the motive fluid plates and the process fluid body define and second pump chamber is defined by the other motive fluid plate and the process fluid body,

wherein the first pump chamber achieves fluid communication with an input line via the first inlet pressure-activated diaphragm valve and wherein the first pump chamber achieves fluid communication with an outlet line via the first outlet pressure-activated diaphragm valve,

wherein the second pump chamber achieves fluid communication with the input line via the second inlet pressure-activated diaphragm valve and wherein the second pump chamber achieves fluid communication with the outlet line via the second outlet pressure-activated diaphragm valve,

wherein a diaphragm is positioned in each pump chamber and each valve,

wherein the diaphragm in the first inlet valve and the diaphragm in the first pump chamber are simultaneously moved by a first motive fluid source, and

wherein the diaphragm in the second inlet valve and the diaphragm in the second pump chamber are simultaneously moved by a second motive fluid source.

26. A liquid pumping system comprising:

a pump for moving a process fluid, comprising;

a first pump chamber, a first inlet pressure-activated diaphragm valve, a first outlet pressure-activated diaphragm valve, a second pump chamber, a second inlet pressure-activated diaphragm valve, a second outlet pressure activated diaphragm valve, a diaphragm positioned in each pump chamber and each valve, an input line for movement of a process fluid into the pump, and an output line for movement of a process fluid out of the pump,

wherein the first inlet and first outlet pressure-activated diaphragm valves respectively permit a process fluid to be moved into the first pump chamber via the first inlet pressure-activated diaphragm valve and out of the first pump chamber via the first outlet pressure-activated diaphragm valve,

wherein the second inlet and second outlet pressure-activated diaphragm valves respectively permit a process fluid to be moved into the second pump chamber via the second inlet pressure-activated diaphragm valve and out of the second pump chamber via the second outlet pressure-activated diaphragm valve, and

a first manifold for fluid communication via the first pump chamber, the first inlet pressure-activated diaphragm valve, and the second outlet pressure-active diaphragm valve of a first motive fluid or a second motive fluid, and

a second manifold for fluid communication via the second pump chamber, the second inlet pressure-activated diaphragm valve, and the first outlet pressure-activated diaphragm valve of a first motive fluid or a second motive fluid;

a switch for alternating delivery of a first motive fluid and a second motive fluid to the first manifold and the second manifold; and

a first pressure regulator operatively connected to the pump to regulate the pressure of a first motive fluid and a second pressure regulator operatively connected to the pump to regulate the pressure of a second motive fluid.

27. A system as defined in claim 26, wherein the first motive fluid is under positive pressure and the second motive fluid is under negative pressure.

28. A system as defined in claim 26, further comprising:

a positive pressure fluid source for supplying the first motive fluid under a pressure greater than process fluid source pressure; and

a negative pressure fluid source for supplying the second motive fluid under a pressure less than the process fluid source pressure.

29. A system as defined in claim 26,

wherein the diaphragm of the first pump chamber, the diaphragm of the first inlet pressure-activated diaphragm valve, and the diaphragm of the second outlet pressure-activated diaphragm valve are simultaneously moved by a first motive fluid, and

wherein the diaphragm of the second pump chamber, the diaphragm of the second inlet pressure-activated diaphragm valve, and the diaphragm of the first outlet pressure-active diaphragm valve are simultaneously moved by a second motive fluid.

30. A system as defined in claim 29, wherein the system enables delivery of the first motive fluid to be actuated independent of the actuation of the delivery of the second motive fluid.

31. A method of pumping a process fluid comprising:

coupling an input line of a pump for movement of a process fluid into the pump,

coupling an output line of the pump for movement of the process fluid out of the pump,

establishing a first flow mode comprising a first stroke achieved by supplying positive pressure to a first motive fluid to simultaneously move a diaphragm of a first pump chamber, a diaphragm of a first inlet pressure-activated diaphragm valve, and a diaphragm of a second outlet pressure-active diaphragm valve while supplying negative pressure to a second motive fluid to simultaneously move a diaphragm of a second pump chamber, a diaphragm of a second inlet pressure-activated diaphragm valve, and a diaphragm of a first outlet pressure-active diaphragm valve,

establishing a second flow mode comprising a second stroke achieved by supplying negative pressure to a first motive fluid to simultaneously move a diaphragm of a first pump chamber, a diaphragm of a first inlet pressure-activated diaphragm valve, and a diaphragm of a second outlet pressure-active diaphragm valve while supplying negative pressure to a second motive fluid to simultaneously move a diaphragm of a second pump chamber, a diaphragm of a second inlet pressure-activated diaphragm valve, and a diaphragm of a first outlet pressure-activated diaphragm valve,

wherein the first stroke delivers the process fluid from the first pump chamber to the output line and pulls the process fluid from the input line into the second pump chamber and wherein the second stroke delivers the process fluid from the second pump chamber to the output line and pulls the process fluid from the input line into the first pump chamber, and

switching in succession between the first flow mode and the second flow mode so that fluid flow from a source into the input line is essentially continuous.

32. A method as defined in claim 31, wherein the diaphragm of the first inlet pressure-activated diaphragm valve, the diaphragm of the first outlet pressure-activated diaphragm valve and the diaphragm of the second pump chamber comprise an integrated diaphragm media.

33. A method as defined in claim 31, wherein the diaphragm of the second inlet pressure-activated diaphragm valve, the diaphragm of the second outlet pressure-activated diaphragm valve and the diaphragm of the first pump chamber comprise an integrated diaphragm media.

34. A method as defined in claim 31, wherein the diaphragm of each valve and each pump chamber is pre-formed from a uniform thickness film material.

35. A method as defined in claim 31, wherein a flow restrictor is positioned to restrict the flow of the process fluid out of the outlet line.

36. A method as defined in claim 31, further comprising the step of regulating the pressure of the first motive fluid and the second motive fluid to provide a pressure regulated drive of the first motive fluid and the second motive fluid.

37. An integrated diaphragm media pre-formed to flex and move through a volume of fluid between two structures that have recesses configured such that a recess in one structure is opposite from a recess in the other structure and such that the cord length of the diaphragm region positioned in the recess is similar when the diaphragm is forced by pressure to a position adjacent to the surface that forms either recess, the diaphragm media comprising:

a polymer film having uniform thickness prior to stretching

wherein the film has at least two regions pre-formed to conform to the shapes of the recesses in the two structures such that the region seats against the recess in one of the two structures when moved by a first fluid pressure and also seats against the recess in the other structure when moved by a second fluid pressure.

38. An integrated diaphragm media as defined in claim 37, wherein the film is between 0.005 inches and 0.030 inches.

39. An integrated diaphragm media as defined in claim 37, wherein the cord length of the diaphragm media in the region of the recess stretches less than 5% when moved by fluid pressure to seat against either of the recesses in the structures.