System and method for a pump with reduced form factor

• US 20070128050A1
• Filed: 11/20/2006
• Published: 06/07/2007
• Est. Priority Date: 11/21/2005
• Status: Active Grant

• Current Assignee: Entegris Incorporated
• Original Assignee: Entegris Incorporated
• Inventors: Cedrone, James, Gonnella, George, Gashgaee, Iraj
• Granted Patent: US 8,087,429 B2
• Time in Patent Office: Days
• US Class Current: 417/244
• CPC Class Codes: F04B 13/00 Pumps specially modified to deliver fixed or variable measured quantities
• CPC Class Codes: F04B 2201/0201 Position of the piston
• CPC Class Codes: F04B 2201/0601 Opening times
• CPC Class Codes: F04B 2205/03 Pressure in the compression chamber
• CPC Class Codes: F04B 23/06 the pumps being all of reciprocating positive-displacement type
• CPC Class Codes: F04B 43/04 Pumps having electric drive
• CPC Class Codes: F04B 49/065 and making use of computers
• CPC Class Codes: F04B 53/06 Venting
• CPC Class Codes: F04B 53/16 Casings; Cylinders; Cylinder liners or heads; Fluid connections
• CPC Class Codes: F04B 53/22 Arrangements for enabling ready assembly or disassembly
• CPC Class Codes: F04B 7/0076 the members being actuated by electro-magnetic means
• CPC Class Codes: F04B 9/02 the means being mechanical
• CPC Class Codes: Y10T 137/87885 Sectional block structure
• CPC Class Codes: Y10T 29/49236 Fluid pump or compressor making

Abstract

Embodiments of the present invention provide pumps with features to reduce form factor and increase reliability and serviceability. Additionally, embodiments of the present invention provide features for gentle fluid handling characteristics. Embodiments of the present invention can include a pump having a motor driven feed stage pump and a motor driven dispense stage pump. The feed stage motor and the feed stage motor can include various types of motors and the pumps can be rolling diaphragm or other pumps. According to one embodiment, a dispense block defining the pump chambers and various flow passages can be formed out of a single piece of material.

Claims

1. A multi-stage pump comprising:

an pump inlet flow path;

a pump outlet flow path;

a feed pump in fluid communication with the pump inlet flow path comprising;

a feed stage diaphragm movable in a feed chamber;

a feed piston to move the feed stage diaphragm;

a feed motor coupled to the feed piston to reciprocate the feed piston;

a dispense pump in fluid communication with the feed pump and the pump outlet flow path, the dispense pump comprising;

a dispense diaphragm movable in a dispense chamber, wherein the dispense diaphragm comprises a dispense rolling diaphragm;

a dispense piston to move the dispense diaphragm;

a dispense motor coupled to the dispense piston to reciprocate the dispense piston;

a set of valves to selectively allow fluid flow through the multi-stage pump.

2. The multi-stage pump of claim 1, wherein the feed stage diaphragm is a feed stage rolling diaphragm.

3. The multi-stage pump of claim 2, wherein the feed motor is a first brushless DC motor and the dispense motor is a second brushless DC motor.

4. The multi-stage pump of claim 2, wherein the feed motor is a stepper motor and the dispense motor is a brushless DC motor.

5. The multi-stage pump of claim 4, further comprising:

a first lead screw connected the feed piston and movable by the feed motor; and

a second lead screw connected to the dispense piston movable by the dispense motor.

6. The multi-stage pump of claim 4, further comprising:

a feed stage outlet flow path in fluid communication with the feed chamber;

a dispense stage inlet flow path in fluid communication with the dispense chamber; and

a filter in fluid communication with the feed stage outlet flow path and the dispense stage inlet flow path such that fluid flowing from the feed stage pump to the dispense pump passes through the filter.

7. The multi-stage pump of claim 6, further comprising a vent flow path in fluid communication with to the filter.

8. The multi-stage pump of claim 6, further comprising a purge flow path in fluid communication with the dispense chamber.

9. The multi-stage pump of claim 8, wherein the purge flow path leads from the dispense chamber to the feed chamber.

10. The multi-stage pump of claim 9, further comprising a dispense block formed of a single piece of material defining at least a portion of the feed chamber and at least a portion of the dispense chamber.

11. The multi-stage pump of claim 10, wherein the dispense block further defines a first and second portion of the pump inlet flow path, a first and second portion of the feed stage outlet flow path, a first and second portion of the dispense stage inlet flow path, a first and second portion of the vent flow path, a first and second portion of the purge flow path and at least a portion of the pump outlet flow path.

12. The multi-stage pump of claim 11, wherein:

the first portion of the pump inlet flow path leads from an inlet to an inlet valve and the second portion of the pump inlet path leads from the inlet valve to the feed chamber;

the first portion of the feed stage outlet flow path leads from the feed chamber to an isolation valve and the second portion of the feed stage outlet flow path leads to the filter;

the first portion of the dispense stage inlet flow path leads from the filter to a barrier valve and the second portion of the dispense stage inlet flow path leads from the barrier valve to the dispense chamber;

the first portion of the vent flow path leads from the filter to a vent valve and the second portion of the vent flow path leads from the vent valve to a vent outlet;

the first portion of the purge flow path leads from the dispense chamber to a purge valve and the second portion of the purge flow path leads from the purge valve to the feed chamber.

13. The multi-stage pump of claim 12, further comprising a valve plate coupled to the dispense block, the valve plate and dispense block defining valve chambers for the inlet valve, isolation valve, barrier valve and purge valve.

14. The multi-stage pump of claim 13, further comprising a sheet of elastomeric material coupled between the valve plate and the dispense block.

15. The multi-stage pump of claim 12, further comprising:

an electronics housing;

a manifold positioned in the electronics housing, the manifold in fluid communication with the inlet valve, vent valve, isolation valve, barrier valve and purge valve, the manifold comprising one or more solenoid valves.

16. The multi-stage pump of claim 15, wherein the electronics housing is partially defined by a surface of the dispense block and the manifold is positioned at a distal location in the electronics housing from the surface of the dispense block.

17. The multi-stage pump of claim 15, further comprising a PCB board disposed in the electronics housing, wherein the PCB board is configured with one or more heat generating components on an opposite side of the PCB board from the surface of the dispense block.

18. The multi-stage pump of claim 17, further comprising a back plate, wherein the manifold and PCB board are coupled to the back plate and wherein the back plate is formed of a material selected to dissipate heat from the PCB board and the manifold.

19. The multi-stage pump of claim 10, wherein the multi-stage pump further comprises an electronics housing and wherein the dispense block comprises a sloped feature to guide drips away from the electronics housing.

20. The multi-stage pump of claim 10, wherein the dispense block further comprises a flange located at an edge of the dispense block that contacts a top cover of the electronics housing.

21. The multi-stage pump of claim 20, wherein a top surface of the top cover is flush with a top surface of the flange.

22. The multi-stage pump of claim 21, wherein a side surface of the top cover is inwardly inset from an outer edge of the flange.

23. The multi-stage pump of claim 22, further comprising:

a back plate partially defining the electronics housing;

a seal between the back plate and the top cover.

24. The multi-stage pump of claim 19, further comprises one or more covers, wherein each vertical surface of the one or more covers is inwardly offset from corresponding vertical surfaces of the dispense block.

25. The multi-stage pump of claim 1, further comprising a pressure sensor positioned to read pressure in the dispense chamber.

26. A multi-stage pump comprising:

a pump inlet flow path;

a pump outlet flow path;

a single piece dispense block defining at least a portion of a dispense chamber in fluid communication with the pump outlet flow path and at least a portion of a feed chamber in fluid communication with the pump inlet flow path;

a filter in fluid communication with the feed chamber and the dispense chamber;

a feed stage diaphragm movable in the feed chamber;

a feed piston to move the feed stage diaphragm;

a feed motor coupled to the feed piston to reciprocate the feed piston;

a dispense diaphragm movable in the dispense chamber;

a dispense piston to move the dispense diaphragm; and

a dispense motor coupled to the dispense piston to reciprocate the dispense piston.

27. The multi-stage pump of claim 26, wherein the dispense block further defines a first and second portion of the pump inlet flow path, a first and second portion of the feed stage outlet flow path, a first and second portion of the dispense stage inlet flow path, a first and second portion of a vent flow path, a first and second portion of a purge flow path and at least a portion of the pump outlet flow path.

28. The multi-stage pump of claim 27, wherein:

the first portion of the pump inlet flow path leads from an inlet to an inlet valve and the second portion of the pump inlet path leads from the inlet valve to the feed chamber;

the first portion of the feed stage outlet flow path leads from the feed chamber to an isolation valve and the second portion of the feed stage outlet flow path leads to the filter;

the first portion of the dispense stage inlet flow path leads from the filter to a barrier valve and the second portion of the dispense stage inlet flow path leads from the barrier valve to the dispense chamber;

the first portion of the vent flow path leads from the filter to a vent valve and the second portion of the vent flow path leads from the vent valve to a vent outlet;

the first portion of the purge flow path leads from the dispense chamber to a purge valve and the second portion of the purge flow path leads from the purge valve to the feed chamber.

29. The multi-stage pump of claim 28, further comprising a valve plate coupled to the dispense block, the valve plate and dispense block defining valve chambers for the inlet valve, isolation valve, barrier valve and purge valve.

30. The multi-stage pump of claim 29, further comprising a sheet of elastomeric material coupled between the valve plate and the dispense block.

31. The multi-stage pump of claim 29, further comprising:

an electronics housing;

a manifold positioned in the electronics housing, the manifold in fluid communication with the inlet valve, vent valve, isolation valve, barrier valve and purge valve, the manifold comprising one or more solenoid valves.

32. The multi-stage pump of claim 31, wherein the electronics housing is partially defined by a surface of the dispense block and the manifold is positioned at a distal location in the electronics housing from the surface of the dispense block.

33. The multi-stage pump of claim 31, further comprising a PCB board disposed in the electronics housing, wherein the PCB board is configured with one or more heat generating components on an opposite side of the PCB board from the surface of the dispense block.

34. The multi-stage pump of claim 33, further comprising a back plate, wherein the manifold and PCB board are coupled to the back plate and wherein the back plate is formed of a material selected to dissipate heat from the PCB board and the manifold.

35. The multi-stage pump of claim 26, wherein the multi-stage pump further comprises an electronics housing and wherein the dispense block comprises a sloped feature to guide drips away from the electronics housing.

36. The multi-stage pump of claim 35, wherein the dispense block further comprises a flange located at an edge of the dispense block that contacts a top cover of the electronics housing.

37. The multi-stage pump of claim 36, wherein a top surface of the top cover is flush with a top surface of the flange.

38. The multi-stage pump of claim 37, wherein a side surface of the top cover is inwardly inset from an outer edge of the flange.

39. The multi-stage pump of claim 36, further comprising:

a back plate partially defining the electronics housing;

a seal between the back plate and the top cover.

40. The multi-stage pump of claim 26, wherein the multi-stage pump further comprises one or more covers, wherein each vertical surface of the one or more covers is inwardly offset from a corresponding vertical surface of the dispense block.

41. The multi-stage pump of claim 26, further comprising a pressure sensor positioned to read pressure in the dispense chamber.

42. A multi-stage pump method comprising:

forming a dispense block of a single piece of material, the dispense block at least partially defining a feed chamber, a dispense chamber, a pump inlet flow path and a pump outlet flow path;

mounting a dispense rolling diaphragm between the dispense block and a dispense pump piston housing;

mounting a feed stage rolling diaphragm between the dispense block and a feed pump piston housing;

coupling a feed pump piston to a feed pump motor via a feed pump lead screw;

coupling a dispense pump piston to a dispense pump motor via a dispense pump lead screw;

coupling the feed motor to the feed pump piston housing; and

coupling the dispense motor to the dispense motor piston housing;

coupling a filter to the dispense block such that the filter is in fluid communication with the dispense chamber and the feed chamber.

43. The method of claim 42, wherein the feed motor and dispense motors are brushless DC motors.

44. The method of claim 42, wherein the feed motor is stepper motor and the dispense motor is a brushless DC motor.

45. The method of claim 42, wherein the dispense block further defines a first and second portion of the pump inlet flow path, a first and second portion of the feed stage outlet flow path, a first and second portion of the dispense stage inlet flow path, a first and second portion of a vent flow path, a first and second portion of a purge flow path and at least a portion of the pump outlet flow path.

46. The method of claim 45, wherein:

the first portion of the pump inlet flow path leads from an inlet to an inlet valve and the second portion of the pump inlet path leads from the inlet valve to the feed chamber;

the first portion of the feed stage outlet flow path leads from the feed chamber to an isolation valve and the second portion of the feed stage outlet flow path leads to the filter;

the first portion of the dispense stage inlet flow path leads from the filter to a barrier valve and the second portion of the dispense stage inlet flow path leads from the barrier valve to the dispense chamber;

the first portion of the vent flow path leads from the filter to a vent valve and the second portion of the vent flow path leads from the vent valve to a vent outlet;

the first portion of the purge flow path leads from the dispense chamber to a purge valve and the second portion of the purge flow path leads from the purge valve to the feed chamber.

47. The method of claim 46, further comprising coupling a valve plate to the dispense block, wherein the valve plate at least partially defines one or more valves.

48. The method of claim 47, wherein the valve plate partially defines the inlet valve, vent valve, isolation valve, barrier valve, and purge valve.

49. The method of claim 48, further comprising selectively directing vacuum pressure to the inlet valve, vent valve, isolation valve, barrier valve, and purge valve.

50. The method of claim 42, comprising:

inserting a set of metal rods with screw holes into the dispense block, wherein the screw holes are aligned such that each rod is orthogonal to screws screwed in the screw holes of that rod; and

screwing screws into the screw holes to couple one or more components to the dispense block.

51. The method of claim 50, wherein the one or more components comprise the dispense piston housing and dispense motor.

52. The method of claim 50, wherein the one or more components comprise the feed piston housing and the feed motor.

53. A pump comprising:

a pump inlet flow path;

a pump outlet flow path;

a single piece dispense block defining at least a portion of a pump chamber in fluid communication with the pump outlet flow path and the pump inlet flow path;

a diaphragm movable in the feed chamber;

a piston to move the diaphragm; and

a motor coupled to the piston to reciprocate the piston.

54. The pump of claim 53, wherein the dispense block further defines a first and second portion of the pump inlet flow path, a first and second portion of a purge flow path and at least a portion of the pump outlet flow path.

55. The pump of claim 54, wherein:

the first portion of the pump inlet flow path leads from an inlet to an inlet valve and the second portion of the pump inlet path leads from the inlet valve to the pump chamber;

the first portion of the purge flow path leads from the pump chamber to a purge valve and the second portion of the purge flow path leads to a purge outlet.

56. The pump of claim 55, further comprising a valve plate coupled to the dispense block, the valve plate and dispense block defining valve chambers for the inlet valve and purge valve.

57. The pump of claim 56, further comprising a sheet of elastomeric material coupled between the valve plate and the dispense block.

58. The pump of claim 56, further comprising:

an electronics housing; and

a manifold positioned in the electronics housing, the manifold in fluid communication with the inlet valve and the purge valve, the manifold comprising one or more solenoid valves.

59. The pump of claim 58, wherein the electronics housing is partially defined by a surface of the dispense block and the manifold is positioned at a distal location in the electronics housing from the surface of the dispense block.

60. The pump of claim 59, further comprising a PCB board disposed in the electronics housing, wherein the PCB board is configured with one or more heat generating components on an opposite side of the PCB board from the surface of the dispense block.

61. The pump of claim 60, further comprising a back plate, wherein the manifold and PCB board are coupled to the back plate and wherein the back plate is formed of a material selected to dissipate heat from the PCB board and the manifold.

62. The pump of claim 53, wherein the multi-stage pump further comprises an electronics housing and wherein the dispense block comprises a sloped feature to guide drips away from the electronics housing.

63. The pump of claim 62, wherein the dispense block further comprises a flange located at an edge of the dispense block that contacts a top cover of the electronics housing.

64. The pump of claim 63, wherein a top surface of the top cover is flush with a top surface of the flange.

65. The pump of claim 64, wherein a side surface of the top cover is inwardly inset from an outer edge of the flange.

66. The pump of claim 65, further comprising:

a back plate partially defining the electronics housing;

a seal between the back plate and the top cover.

67. The pump of claim 66, wherein the pump further comprises one or more covers, wherein each vertical surface of the one or more covers is inwardly offset from a corresponding vertical surface of the dispense block.

68. The pump of claim 67, further comprising a pressure sensor positioned to read pressure in the dispense chamber.