Fluid circuit with integrated electrostatic discharge mitigation

A fluid circuit (160) defining a flow path for a fluid from a fluid supply (152) toward a process stage (156). The fluid circuit may include a plurality of operative components (168) including a body portion (182) and a plurality of tubing connector fittings (186). The operative components may be connected by a plurality of tubing segments (164). Each body portion may include a non-conductive fluoropolymer portion and an outer conductor (234) that extends between each of the plurality of tubing connector fittings and that is unitary with the non-conductive fluoropolymer portion. The plurality of tubing segments may include a non-conductive fluoropolymer tubing portion (187) and an axial strip (188) of conductive polymer. The outer conductor of each body portion conductively connected with tubing segments connected thereto. Each of the connectors may include a bridging component (262) for conductively connecting the respective outer conductor of the body portion to the strip of conductive polymer of the connecting tubing segments.

TECHNICAL FIELD

Embodiments of the present disclosure are directed to fluid handling systems, and more specifically, to ultra-pure fluid handling systems with electrostatic discharge mitigation.

BACKGROUND

Fluid handling systems offering high purity standards have many uses in advanced technology applications. These applications include processing and manufacturing of solar panels, flat panel displays, and in the semiconductor industry for applications such as photolithography, bulk chemical delivery, and chemical mechanical polishing, wet etch, and cleaning. Furthermore, certain chemicals used in these applications are particularly corrosive, precluding the use of some conventional fluid handling technology due to possible corrosion of the fluid handling components and leaching of chemicals into the environment.

In order to meet the corrosion resistance and purity requirements for such applications, fluid handling systems provide tubing, fittings, valves, and other elements, that are made from inert polymers. These inert polymers include, but are not limited to, fluoropolymers such as, polytetrafluoroethylene (PTFE), perfluoroalkoxy alkane (PFA), ethylene tetrafluoroethylene (ETFE), and fluorinated ethylene propylene (FEP). In addition to providing a non-corrosive and inert construction, many fluoropolymers, such as PFA, are injection moldable and extrudable. Several types of connector fittings, made from such polymers, are available and are known, such as PRIMELOCK® fittings, PILLAR® fittings, flared fittings, and other fittings. Example fittings are illustrated by U.S. Pat. Nos. 5,154,453; 6,409,222; 6,412,832; 6,601,879; 6,758,104; and 6,776,440, each of which are incorporated herein by reference, except for express definitions and patent claims contained therein.

Electrostatic discharge (ESD) is another known issue for fluid handling systems in the semiconductor industry and in other technology applications. Frictional contact between fluid and surfaces of various operational components (e.g. piping, valves, fittings, filters, etc.) in the fluid system can result in generation of and buildup of static electrical charges. The extent of charge generation depends on various factors including, but not limited to, the nature of the components and the fluid, fluid velocity, fluid viscosity, fluid conductivity, pathways to ground, turbulence and shear in liquids, presence of free air in the liquid, and surface area. Furthermore, as the fluid flows through the system, the charge can be carried downstream in a phenomenon called a streaming charge, where charge can buildup beyond where the charge originated. Sufficient charge accumulations can cause discharges at the pipe walls, component surfaces, or even onto substrates or wafers at various process steps.

Substrates are highly sensitive and such discharges can result in damage or destruction of the substrate. For example, circuits on the substrate can be destroyed and photoactive compounds can be activated prior to regular exposure. Additionally, built up static charge can discharge from within the fluid handling system to the exterior environment, potentially damaging components in the plumbing (e.g. tubing, fittings, containers, filters, etc.), and leading to leaks, spills of fluid in the system, and diminished performance of components.

In some fluid handling systems, to reduce the buildup of static charges, certain components in fluid handling system are constructed are grounded to mitigates the buildup of static in the system as it continually disperses from the metal conductive components to ground.

For example,FIG. 1depicts a fluid handling system100of the prior art. The system100provides a flow path for fluid to flow from a fluid supply104to one or more process stages108positioned downstream. As used herein, process stage108refers to a point of use for fluid in the system100, or any intermediate point in the fluid handling system100where the fluid is utilized in a method or process. System100includes a fluid circuit112including a portion of the flow path from the fluid supply104to the one or more process stages108. The fluid circuit112includes tubing segments116and a plurality of interconnected operative components118such as elbow shaped fitting120, T-shaped fitting122, a valve124, filters126and flow sensor128.

As used herein, tubing116refers to any flexible or inflexible pipe or tube that is suitable for containing or transporting fluid therethrough. Operative components refers to any component or device having a fluid input and a fluid output and that is mateable with tubing for directing or providing for the flow of fluid. Examples of operative components include, but are not limited to, fittings, valves, filters, pumps, mixers, spray nozzles, and dispense heads. These and additional non-limiting examples of operative components are illustrated by U.S. Pat. Nos. 5,672,832; 5,678,435; 5,869,766; 6,412,832; 6,601,879; 6,595,240; 6,612,175; 6,652,008; 6,758,104; 6,789,781; 7,063,304; 7,308,932; 7,383,967; 8,561,855; 8,689,817; and 8,726,935, each of which are incorporated herein by reference, except for express definitions or patent claims contained therein.

Tubing segments116are conductive, providing an electrical pathway along the length of each tubing segment116in the fluid circuit112. Conductive tubing is primarily constructed from materials including metal or loaded polymeric material. Loaded polymeric material includes a polymer that is loaded with steel wire, aluminum flakes, nickel coated graphite, carbon fiber, carbon powder, carbon nanotubes, or other conductive material. In some instances, the tubing segments116are partially conductive, having a main portion constructed from non-conductive or low conductive material, such as perfluoroalkoxy alkane (PFA), or other suitable polymeric materials, and having a secondary unitary co-extruded conductive portion.

For example, fluid circuit112, in certain instances, can utilize FLUOROLINE®, PFA tubing, available from Entegris Inc., the owner of this application. FLUOROLINE®, PFA tubing is primarily constructed from PFA with one or more conductive strips of carbon loaded polymer that is extruded along the length of the tubing at its exterior surface. A circuit diagram132is superimposed over the fluid circuit112that illustrates the electrical pathways provided by the conductive or partially conductive tubing segments116.

Continuing to refer to Prior ArtFIG. 1, in contrast to the tubing segments116, the operative components118are each constructed primarily from non-conductive materials. For example, the operative components can be constructed from fluoropolymers including perfluoroalkoxy alkane (PFA), ethylene tetrafluoroethylene (ETFE), and fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), and perfluoroalkoxy alkane (PFA). This occurs, for example, when system100is configured for use in ultra-pure fluid handling applications, where the tubing segments116and operational components118are typically constructed from polymeric materials to satisfy purity and corrosion resistance standards.

To mitigate static charge buildup, the tubing segments116may be electrically connected to ground140at various points in the fluid circuit112via some of the conductive straps136. The conductive straps136disperse charge from the conductive strips running the length of the tubing116to ground140. Additionally, sections of the tubing segments116may be electrically tied together via conductive straps136that bridge the electrical pathway across each of the non-conductive operative components118. The conductive straps136are tied to the exterior of one or more of the tubing segments116and form an electrical connection with the conductive strips that run the length of each segment.

However, it would be desirable to improve static charge mitigation in ultra-pure fluid handling systems for improved component performance and reduction in potentially damaging ESD events.

SUMMARY

One or more embodiments of the disclosure are related to a fluid circuit in a fluid handling system. In one or more embodiments, the fluid circuit includes a plurality of operative components. In certain embodiments, each of the operative components includes a body portion with a fluid flow passageway therethrough and a pair of tubing connector fittings. In one or more embodiments, the body portion includes a unitary conductor portion extending between the connector fittings and displaced from the fluid flow passageway. In various embodiments, to provide a fluid passageway through the fluid circuit, the operative components are connectable together via one or more tubing segments that connect to the components at their respective tubing connector fittings. In one or more embodiments, the fluid passageway defines a portion of a flow path in the fluid handling system from a fluid supply toward a process stage.

Referring back to prior artFIG. 1, the non-conductive fittings120,122, valve124, filters126and sensor128electrically isolate segments of the fluid circuit112by causing breaks in conductivity between tubing segments116. Consequently, while tubing segments116are grounded, static charge still builds within each of the non-conductive operative components118. For example, in an ultra-pure fluid handling system, a differential measured from the exterior of a PTFE fitting can reach nearly 30,000 volts. Similarly, in the filters126, fluid friction from fluid passing through a filter membrane can cause a measurable voltage differential of nearly 30,000 volts. Any ESD events from this built up charge can result in damage to the fittings120,122, valve124, filters126, sensor128and other components in the fluid circuit112. Such damage can lead to leaks or spills of fluid, reduced performance in filters126, sensors128or other equipment, and/or ignition of flammable materials or chemicals in the plumbing or in the exterior environment.

Furthermore, the conductive straps136and electrical connections for bridging the operative components118and for grounding the fluid circuit112are required to be manually added. Depending on the number of fittings, valves, filters, sensors, and other non-conductive operative components in the system, the conductive straps135and bridging connections can require extensive time and labor to set up. For example, a fluid handling system configured for a wet etch and cleaning process can require nearly two hundred conductive straps to configure the system for ESD mitigation. Additionally, these connections need to be consistently checked and maintained. If one or more of the conductive straps136or electrical connections fail, the result is static charge buildup and ESD events which could damage the system100.

Accordingly, one or more embodiments of the disclosure are directed to a fluid circuit with integrated ESD mitigation. In one or more embodiments, the fluid circuit includes a plurality of operative components each including a body portion with a fluid flow passageway therethrough and a pair of tubing connector fittings. In various embodiments, the operative components are connectable together via one or more tubing segments that connect to the components at their respective tubing connector fittings.

In certain embodiments, each body portion comprises a non-conductive fluoropolymer portion that defines the fluid flow passageway through the body portion and extends to ends of each of the pair of tubing connector fittings. In various embodiments, each body portion further includes an outer conductive pathway that extends between the tubing connector fittings and that is unitary with the non-conductive fluoropolymer portion.

In certain embodiments, the plurality of tubing segments each include a non-conductive fluoropolymer tubing portion and a strip of conductive polymer extending axially on and unitary with the non-conductive fluoropolymer tubing portion. The strip of conductive polymer of the tubing segment conductively connected to the conductive pathway of the body portion at the tubing connector fittings.

In one or more embodiments, each of the tubing connector fittings include a bridging component for conductively connecting the outer conductive pathway of the body portion to the strip of conductive polymer of the tubing portion connected to the respective tubing connector fitting. The bridging component formed of a conductive polymer and may be, for example, a nut, a sleeve, an O-ring or other shaped ring, and flexible thin wrap, such as tape.

A feature and advantage of the various embodiments is that each operative component has a conductive path that is integral and unitary with the nonconductive portions such that there is a gapless juncture between the conductive path and the nonconductive portions of the operative component. The gapless juncture minimizes accumulation of contaminants in cracks and provides a robust body portion of the operative component. In addition, such a gapless juncture provides a proximity to the fluid flow path that is closer than a comparable on the surface of the component conductive portion. A further feature and advantage is that the conductive portions of the operative components are not exposed at any wetted surfaces of the fluid flow circuit minimizing the possibility of contaminating the fluid flow stream with additives that provide the conductivity.

DETAILED DESCRIPTION

FIG. 2depicts a fluid handling system150according to one or more embodiments of the disclosure. The system150provides a flow path for fluid to flow from a fluid supply152to one or more process stages156positioned downstream. System150includes a fluid circuit160which includes a portion of the flow path of the fluid handling system150. The fluid circuit160includes tubing segments164and a plurality of operative components168that are interconnected via the tubing segments164. Depicted inFIG. 2, the operative components168include an elbow shaped fitting170, T-shaped fitting172, a valve174, filters176and flow sensor178. However, in various embodiments the fluid circuit160can include additional or fewer operative components168in number and in type. For example, the fluid circuit160could substitute or additionally include pumps, mixers, dispense heads, sprayer nozzles, pressure regulators, flow controllers, or other types of operational components. In assembly, the operative components168are connected together by the plurality of tubing segments164connecting to the components168at their respective tubing connector fittings186. Connected together, the plurality of tubing segments164and operative components168provide a fluid passageway through the fluid circuit160from the fluid supply152and toward the process stages156.

In certain embodiments, the operational components168each include a body portion182that defines fluid flow passageway therethrough and one or more tubing connector fittings186. In some embodiments, at least one of the tubing connector fittings186is an inlet portion for receiving fluid into the body portion182and at least another one of the tubing connector fittings186is an outlet portion for outputting fluid received via the inlet portion. For example, T-shaped fitting172includes one tubing connector fitting186that is an inlet portion that receives fluid from the fluid supply152and two tubing connector fittings186which are outlet portions outputting fluid toward the process stages156. In certain embodiments, the inlet portion and the outlet portion are each connected or connectable to a tubing segment164. However, in some embodiments, for example where the operative components168in the fluid circuit160includes a spray nozzle, only the inlet portion is required to be connectable to a tubing segment164. In some embodiments one or more of the operative components168includes a single tubing connector fitting186.

In various embodiments the body portion182is constructed using a non-conductive polymeric material. For example, the body portion182can be constructed from fluoropolymers including, but not limited to, perfluoroalkoxy alkane (PFA), ethylene tetrafluoroethylene (ETFE), fluorinated ethylene propylene (FEP), ethylene chlorotrifluoroethylene (ECTFE), and polytetrafluoroethylene (PTFE).

As shown inFIG. 2, each body portion182is additionally constructed using a conductive material to form an outer conductor portion that extends between and provides an electrical path between each of the tubing connector fittings186. In various embodiments, the outer conductive pathway is unitary with the body portion182and is constructed from a conductive polymeric material. For example, in some embodiments the outer conductor portion is constructed from PFA loaded with conductive material (e.g. loaded PFA). This loaded PFA includes, but is not limited to, PFA loaded with carbon fiber, nickel coated graphite, carbon fiber, carbon powder, carbon nanotubes, metal particles, and steel fiber. In various embodiments, conductive materials have a resistivity level less than about 1×1012Ohms Per Square while non-conductive materials have a resistivity level greater than about 1×1012Ohms Per Square. In certain embodiments, conductive materials have a resistivity level less than about 1×109Ohms Per Square while non-conductive materials have a resistivity level greater than about 1×109Ohms Per Square.

As depicted inFIGS. 3 and 4, tubing segments164are partially conductive, having a main portion or tubing portion187constructed from non-conductive or low conductive material and having a secondary portion or conductive portion188constructed from a conductive material that extends axially along the length of the tubing portion187. For example, in some embodiments, tubing segments164each include a tubing portion187of a non-conductive fluoropolymer and conductive portion188formed as a strip of conductive polymer extending axially on and unitary with the non-conductive fluoropolymer main portion187. In certain embodiments, tubing portion is constructed from PFA with the one or more conductive strips of the secondary portion constructed from carbon loaded PFA that is extruded along the length of each of the tubing segments164at or near its exterior surface. In some embodiments, the tubing segments164in the fluid circuit160are FLUOROLINE® tubing.

Referring again toFIG. 2, each of the operative components168includes a bridging component for conductively connecting the respective outer conductive pathway of the body portion182to the conductive portion188of the tubing segments164(shown inFIGS. 3 and 4) that are connected to the operative components168. As such, in certain embodiments the connected operative components168and tubing segments164form an electrical pathway along the entirety of the fluid circuit160, eliminating breaks in conductivity between the tubing segments160. A circuit diagram190is superimposed over the fluid circuit160to illustrate the electrical pathway.

In certain embodiments, to mitigate static charge buildup, one or more of the tubing segments164and/or the operative components168are electrically connected to ground194via one or more conductive straps198. The conductive straps198continuously disperse static charges as they build up in the fluid circuit160by providing a pathway to ground194from the electrical pathway.

FIGS. 3 and 4depict example operative components210according to one or more embodiments of the disclosure.FIG. 3depicts an operative component210that is a fitting214, and, more specifically, is a three way connector having a “T” shape (e.g. a T-shaped fitting).FIG. 4depicts a valve218.

The fitting214includes a body portion222and three connector fittings226extending outwardly from the body portion222. The valve218includes a body portion230and two connector fittings227extending outwardly from the body portion230. In various embodiments, connector fittings226and227are substantially the same design. As described above, in various embodiments the body portion222,230is constructed using a non-conductive polymeric material. For example, the body portion222,230can be constructed from fluoropolymers including, but not limited to, PFA, ETFE, FEP, and PTFE.

In certain embodiments, body portion222,230ofFIGS. 3 and 4, each include an outer conductor portion234,238that extends across the body portion222,230between each of the connector fittings226,227and is exposed at the outer surface of the body portions222,230. Surfaces that are included as a part of the outer conductor portion234,238are indicated by reference numeral242.

In some embodiments, the outer conductor portion234,238is an outer layer of conductive polymer material, such as carbon loaded PFA, or other suitable conductive polymer, that is inlaid, via an overmolding process, into the non-conductive polymeric material of the body portion222,230to form a continuous path of conductor material that is unitary with the body portion222,230and that extends between each of the connector fittings226,227.

In certain embodiments, the outer conductor portion234,238is formed as a strip of material running across the body portion222,230that forms approximately 5%-10% of the exterior surface of the body portion222,230. In other embodiments the outer conductor portion234,238of material running across the body portion222,230forms approximately 11%-90% of the exterior surface of the body portion222,230. In still some other embodiments, the outer conductor portion234,238is larger, forming approximately 40%-90% of the exterior surface or, in some embodiments, the entire exterior surface of the body portion222,230. In certain embodiments, the outer conductor portion234,238may be formed of a thin conductive film at the surface of the body portion222,230or incorporated on the thin film. In various embodiment, the thin film is wrapped around a portion of the body portion222,234and extends between each of the connector fittings226,227.

Depicted inFIG. 4, each connector fitting227includes a shoulder region246that abuts the body portion230and extends outwardly to form a neck region250, a threaded region254, and a nipple portion258. In various embodiments, the nipple portion258is suitable for accepting a tubing segment164, which is shown inFIGS. 3 and 4connected to each of the connector fittings226,227. In one or more embodiments, the connector fittings227include a nut262for tightening to the threaded region254to secure the tubing164. In one or more embodiments, nut262has a generally cylindrical shape having an interior surface including threads266for mating with threaded region254. In addition, nut262has an outer surface including ribs270which are symmetrically disposed about the outer surface for mating with a wrench or locking device for tightening or loosening of the nut262on the threaded region254.

In one or more embodiments, the nut262is constructed entirely from a conductive polymeric material to form an outer conductor portion274that extends the length of the nut262between the tubing164and the body portion230. For example, in certain embodiments the nut262is constructed entirely from loaded PFA, polyaniline, a combination of conductive polymers, or other suitable conductive polymer.

Additionally, in one or more embodiments, the connector fittings227include a conductor portion278that forms a portion of the shoulder region246and abuts the outer conductor portion238of the body portion230. In certain embodiments, the conductor portion278extends from the shoulder region246to form a part of the threaded region254. In some embodiments, the conductor portion274is a layer of conductive polymer material, such as carbon loaded PFA, or other suitable conductive polymer, that is inlaid into non-conductive polymeric material of the connector fittings227and nut262.

As depicted inFIG. 4, when the operative component210is assembled with tubing164, the conductor portion274of the nut262contacts the conductive portion188of tubing164at a forward portion290and forms a continuous path rearwardly from the forward portion290to an O-ring294positioned between the nut and the shoulder portion246. In various embodiments, the O-ring294is constructed from conductive material, and transfers charge between the conductor portion274of the nut262and the connector fittings227. For example, in one or more embodiments, the O-ring294is constructed from loaded PFA, polyaniline, a combination of conductive polymers, or other suitable conductive polymer.

As such, the nut262acts as a bridging component that forms and electrical pathway from the tubing164and transfers charge to the fitting connector227, via the O-ring294and the shoulder region246. From there, the outer conductor portion of the body portion230receives the charge which is transferred across the body portion230and to a conductor portion of the other tubing section164via a similar path by which the charge was received.

Those of skill in the art will appreciate that, while the example embodiments illustrated inFIGS. 3 and 4have identical connector fittings226,227, in certain embodiments, the connector fittings226,227may have varying sizes, may have various designs, such as step-down or step-up fittings, or may be located on various types of operative components210.

FIGS. 5 and 6depict example embodiments of connector fittings for operative components, according to one or more embodiments of the disclosure.

FIG. 5depicts a connector fitting300that includes a shoulder region304that abuts a body portion308of an operative component and extends outwardly to form a neck region316, a threaded region320, and a nipple portion324. Tubing328is received by the nipple portion324, which, in certain embodiments, may be configured as a FLARETEK® fitting.

In one or more embodiments, the connector fitting300includes a nut332for tightening to the threaded region320to secure the tubing328. Seen inFIG. 5, the nut332includes an outer conductor portion336formed from a layer of conductive polymer formed at the surface of the nut332. The conductor portion336extends the length of the nut332between a forward portion340proximate the tubing328and a rearward portion344proximate the shoulder region304.

Additionally, in one or more embodiments, the connector fitting300includes a conductor portion348that forms a portion of the shoulder region304and abuts the outer conductor portion352of the body portion308. In certain embodiments, the conductor portion348extends from the shoulder region304to form a part of the threaded region320.

In some embodiments, the conductor portions336,348of the nut332and of the connector fitting330is a layer of conductive polymer material, such as carbon loaded PFA, or other suitable conductive polymer, that is inlaid via an overmolding process into the non-conductive polymeric material of the connector fittings330and the nut332.

When the connector fitting300is assembled with tubing328, the conductor portion336of the nut332contacts the conductive surface356of tubing328at the forward portion340and forms a continuous path rearwardly from the forward portion340to a conductive O-ring360positioned between the nut332and the shoulder portion304. In various embodiments, the conductor portion336of the nut332, has minimal or no direct contact with the conductor portion348of the connector fitting300. As such, in various embodiments, the O-ring360ensures an electrical pathway between the conductor portion336the nut332and the conductor portion348that forms an electrical pathway from the tubing328, along the nut332, to the shoulder region304and to the outer conductor portion352of the body portion308.

In various embodiments, the O-ring360is constructed from conductive material, such as loaded PFA, or other conductive polymer or elastomer, and transfers charge between the conductor portion336of the nut332and the connector fitting300.

FIG. 6depicts a connector fitting380similar to as described with reference toFIG. 5. For example, connector fitting380includes a shoulder region384that abuts a body portion308of an operative component and extends outwardly to form a neck region388, a threaded region392, and a nipple portion396. Tubing328is received by the nipple portion396, which, in certain embodiments, may be configured as a FLARETEK® fitting connector.

The connector fitting380includes a nut400for tightening to the threaded region392to secure the tubing328. The nut400is constructed entirely from a conductive polymeric material, such as carbon loaded PFA. As such the nut400includes a conductor portion404extends the entirety of the nut400between a forward portion408proximate the tubing328and a rearward portion412proximate the shoulder region384.

The connector fitting380includes a conductor portion416that forms a portion of the shoulder region384, abuts the outer conductor portion352of the body portion308. The conductor portion416of the connector fitting380extends from the shoulder region384to form a part of the threaded region392.

When the connector fitting380is assembled with tubing328, the conductor portion404of the nut400contacts the conductive surface356of tubing328at the forward portion408and forms a continuous path rearwardly from the forward portion408to the threaded region392mated with the nut400. As such an electrical pathway is formed from the tubing328, along the nut400, to the threaded region392and to the outer conductor portion of the body portion308. In one or more embodiments, as the conductor portion404of the nut400is entirely constructed from conductive polymer, no O-ring is required between the shoulder384and the nut400, as electrical contact is sufficiently established between the conductor portion404of the nut400and the conductor portion392in the threaded region416.

FIGS. 7A-7Cdepicts a connector fitting420similar to the connector fittings described with reference toFIGS. 5 and 6. For example, connector fitting420includes a shoulder region424that abuts a body portion308of an operative component and extends outwardly to form a neck region428, a threaded region432, and a nipple portion436. Tubing440is received by the nipple portion436, which, in certain embodiments, may be configured as a FLARETEK® fitting. The connector fitting420includes a nut444for tightening to the threaded region432to secure the tubing440. In certain embodiments, the nut444is constructed entirely from a non-conductive polymeric material, such as PFA, PTFE, or other non-conductive fluoropolymer or polymer.

Depicted inFIGS. 7A and 7B, in one or more embodiments, the connector fitting420includes a conductive wrap448wrapped about a portion of the connector fitting420from the tubing440to the threaded region432proximate the shoulder region424. In one or more embodiments, the conductive wrap448is a thin membrane or thin sheet of conductive polymeric material, or other suitable conductive material configured as a non-adhesive fluroropolymer conductive tape that secures to the exterior of the tubing440and threaded region432.

Accordingly, when the assembled with tubing440, the conductive wrap448forms a continuous path rearwardly from the forward portion452to the threaded region432. As such an electrical pathway is formed from the tubing440, along the conductive wrap448, to the conductor portion460and to the outer conductor portion352of the body portion308.

FIGS. 8A, 8B, and 8Cdepict an operative component500, according to one or more embodiments. Operative component500includes a body portion504and connector fittings508. In one or more embodiments, the operative component500additionally includes an operative element506in the body portion. The operative element506, in various embodiments, broadly includes suitable structure, electronics, or other materials for configuring the operative component500to perform various operations. For example, in some embodiments, the operational element506is a mixer, sensor, filter, pump, or other suitable element. As such, the operative component500is configurable to perform various different processes or tasks within a fluid circuit.

The body portion504includes a conductor portion512of conductive PFA positioned along the exterior surface516of the body portion504. The conductor portion512extends between each of the connector fittings508and forms electrical contact between a conductive portion520in each of the connector fittings508. Depicted inFIG. 8B, in one or more embodiments, the conductor portion512is a narrow strip of conductive material that is inlaid into a recess524formed in the non-conductive polymer material of the body portion504. For example, in certain embodiments, the conductor portion512is a strip having a width of less than one centimeter. In some embodiments, the conductor portion512is a strip having a width in the range between one tenth of a centimeter to one centimeter. Described further below, with reference toFIGS. 9-11, the conductor portion512can be formed via an overmolding process where the body portion504is first partially formed from non-conductive fluoropolymer in a mold that defines the recess524or cavity in the exterior surface. A conductive fluoropolymer can then be overmolded into the recess524to form the conductor portion512.

As described above, in various embodiments the operative component500is connected with tubing segments532at each of the connector fittings508. The connector fittings508form an electrical pathway from conductive portions536of the tubing532through the connector portions508and across the conductor portion512.

In various embodiments, as shown inFIG. 8B, the body portion504includes an attachment feature528. In one or more embodiments, the attachment feature528is a piece of conductive material that is conductively connected with the conductor portion512for attachment to an external electrical contact. For example, attachment feature528can be connected to an electrical contact which is grounded in order to configure the operative component500for ESD mitigation. In one or more embodiments, the attachment feature528is a connector boss which is threaded for attachment to a nut or other threaded connector. In some embodiments, the attachment feature528is a tab, a threaded hole, or other suitable feature for connecting to an electrical contact. However, in certain embodiments, the attachment feature528can be configured for interference fit, snap fit, friction fit, or other method of fitting with an electrical contact.

FIG. 9depicts a method600for forming an operative component, according to one or more embodiments. In operation604, the method600includes providing a mold for making a body portion. In various embodiments, the mold includes one or more mold inserts therein which are positioned to form the outer conductor portion of the body portion. In operation608, the method600includes injecting non-conductive fluoropolymer material into the mold to form or partially form the body portion. In operation612, once the partially formed body portion is cooled, the mold inserts are removed. In various embodiments, once the mold inserts are removed, the partially formed body portion is returned to the mold.

In operation616, the method600includes injecting additional overmolding material into the mold cavity to form the body portion. In various embodiments the additional overmolding material is conductive fluoropolymer. In one or more embodiments, the mold cavity corresponds to the specific portions which are being overmolded. For example, in certain embodiments, the mold inserts lay out the position and pathway of the outer conductor portion, as described above.

Once the body portion is initially molded and the mold inserts removed, as in operations608and612, the result is a recess in the body portion having a negative image of the outer conductor portion. The additional overmolding material is injected into this recess, thereby forming the unitary body portion. Then the completed portion which comprises the body portion and the overmolded portion is removed.

In some embodiments the body portion cavity may have a cavity for forming a connector boss. In such a case, the first molded conductor portion is molded with the connector boss which is then inserted into the respective cavity the in the body portion cavity.

FIG. 10depicts a method700for forming an operative component, according to one or more embodiments. In operation704, the method700includes providing a mold for making a body portion. In certain embodiments, it may be suitable to have the conductor portion molded first and then insert the conductor portion into the mold cavity for the body portion. As such, in operation708, the method700initially includes injecting a conductive fluoropolymer material into the mold to form the conductor portion. In operation712, the method700includes injecting a non-conductive fluoropolymer material into the mold to form the body portion about the pre-molded conductor portion. Once cooled, in operation716, the body portion with the inlaid conductor portion is then removed from the mold.

FIG. 11depicts a method800for forming an operative component, according to one or more embodiments. In operation804, the method800includes providing a first mold of a conductor portion of a body portion. In operation808, the method800includes providing a second mold of a body portion. In operation812, the method800includes molding a conductor portion using a conductive fluoropolymer in the first mold. In operation816, the method800includes removing the conductive portion from the first mold. In operation820, the method800includes removing the conductive portion from the first mold. In operation824, the method800includes injecting non-conductive fluoropolymer around the conductive portion. In operation828, the method800includes removing the body portion with conductor portion inlaid in the non-conductive portion.

FIG. 12depicts a method850for forming an operative component, according to one or more embodiments. In operation854, the method850includes providing a mold of a body portion. In operation858, the method850includes providing a conductive polymer film. In operation862, the method850includes inserting the conductive polymer film into the mold of the body portion. In operation866, the method850includes overmolding a non-conductive polymer onto the conductive polymer film. In operation870, the method850includes removing the molded body portion from the mold.

FIG. 13depicts a schematic view of a method of forming an operative component, according to one or more embodiments. First a mold904is provided for making a body portion and/or a conductor portion. In some embodiments the base portion is first molded and is then put the same mold904with a mold insert removed. Then the mold904is closed and additional overmolding material912is injected into the mold cavity which corresponds to the specific portions which are being overmolded. Once cooled, the completed portion which comprises the body portion and the overmolded conductor portion is removed. In some embodiments, additional molds can be used for different stages of the overmolding process.

In some embodiments, the conductor portion is first molded and then is put into the same mold904. Then the mold904is closed and additional overmolding material912is injected into the mold904to form the body portion908.

In certain embodiments, a thin film908of conductive fluoropolymer is first inserted into the mold904. Once inserted the body portion can be molded such that the film908forms an exterior surface of the body portion extending from connector to connector.

Additional description and illustration of overmolding is included in U.S. Pat. No. 6,428,729, and publication US20050236110 which are incorporated by reference, except for express definitions and patent claims contained therein.

The following clauses define particular aspects and embodiments of the invention.

Clause 1. A fluid circuit defining a flow path for a fluid from a fluid supply toward a process stage, the fluid circuit comprising: a plurality of operative components, each operative component comprising a body portion with a fluid flow passageway therethrough and a plurality of tubing connector fittings, the operative components connected by a plurality of tubing segments connecting to the components at their respective tubing connector fittings, the plurality of tubing segments and operative components providing the flow path through the fluid circuit; wherein each body portion comprises a non-conductive fluoropolymer portion, the non-conductive fluoropolymer portion defining the fluid passageway and extending to ends of each of the respective plurality of tubing connector fittings, each body portion further comprising an outer conductor that extends between each of the plurality of tubing connector fittings and that is unitary with the non-conductive fluoropolymer portion, the plurality of tubing segments each comprising a non-conductive fluoropolymer tubing portion and a strip of conductive polymer extending axially on and unitary with the non-conductive fluoropolymer tubing portion; wherein each of the connectors having a bridging component for conductively connecting the respective outer conductor of the body portion to the strip of conductive polymer of the tubing portion connected to the connector.
Clause 2. The fluid circuit of clause 1, wherein each of the pair of tubing connector fittings comprises a threaded nipple portion and a conductive nut attachable to the threaded nipple portion, and wherein the bridging component is the conductive nut.
Clause 3. The fluid circuit as in any one of the preceding clauses, wherein the plurality of operative components includes any one of a valve, a filter, a T-connector, an elbow connector, a pump, and a sensor.

Clause 4. The fluid circuit as in any one of the preceding clause, wherein at least one of the component body portions comprise an attachment feature that is conductively connected to the outer conductor of said respective component body portion.

Clause 5. A fluid circuit defining a flow path for a fluid from a fluid supply toward a process stage, the fluid circuit comprising: a plurality of operative components, each of the plurality of operative components comprising a body portion with a fluid flow passageway therethrough and a plurality of tubing connector fittings, the operative components interconnected by a plurality of tubing segments connecting to the components at their respective tubing connector fittings, the plurality of tubing segments and operative components providing the flow path through the fluid circuit; wherein each component body portion comprises a non-conductive fluoropolymer portion, the non-conductive fluoropolymer body portion defining the fluid flow passageway, each component body portion further comprising a conductive portion unitary with the non-conductive fluoropolymer portion and displaced outwardly from the fluid flow passageway, the conductive portion having an outwardly exposed connector to the conductive portion, each of the plurality of operative components conductively connected together.
Clause 6. The fluid circuit of clause 5, wherein each tubing segment has conductive portion comprising a fluoropolymer and each of the plurality of operative components are conductively connected together through the tubing segments.
Clause 7. The fluid circuit as in any one of clauses 5-6, wherein each of the plurality of operative components are conductively connected through conductive straps connecting to the respective conductor portions.
Clause 8. An operative fluid circuit component comprising: a body portion comprising a non-conductive fluoropolymer portion that defines a fluid flow path extending between an inlet portion and an outlet portion, the body portion further comprising a non-interior fluoropolymer conductor unitary with the non-conductive fluoropolymer portion, the non-interior fluoropolymer conductor extending between the inlet portion and outlet portion, at least the inlet portion configured for receiving a tubing end having a conductive portion and conductively connecting the non-interior fluoropolymer conductor portion to the conductive portion of the tubing end.
Clause 9. The operative fluid circuit component of clause 8, wherein the non-interior fluoropolymer conductor is configured as a strip having a width in the range of 0.1 centimeter to 1 centimeter wide.
Clause 10. The operative fluid circuit component as in any one of clauses 8-9, wherein the outlet portion comprises a spray nozzle.
Clause 11. The operative fluid circuit component as in any one of clauses 8-10, wherein the inlet portion comprises a male nipple portion and a nut, the male nipple portion having a threaded portion for engaging the nut, whereby the nut conductively engages the non-interior fluoropolymer conductor of the component body portion and the conductive portion of a tubing end in the inlet portion thereby conductively connecting said fluoropolymer conductor and conductive portion of the tubing end.
Clause 12. The operative fluid circuit component as in any one of clauses 8-11, wherein one of the non-interior fluoropolymer conductor and the non-conductive fluoropolymer portion is overmolded onto the other of the non-interior fluoropolymer conductor and the non-conductive fluoropolymer portion.
Clause 13. The operative fluid circuit component of any one of clauses 8-12, wherein the operative fluid circuit component is one of the set of a valve, a filter, a T-connector, an elbow connector, a pump, and a sensor.
Clause 14. The operative fluid circuit component of any one of clauses 8-12, wherein the body portion comprises an attachment feature for connection of a grounding strap to said component.
Clause 15. The operative fluid circuit component of clause 14 wherein the attachment feature comprises one of a threaded boss, a tab, and a threaded hole.
Clause 16. A fluid circuit defining a flow path for a fluid from a fluid supply toward a process stage, the fluid circuit comprising: a plurality of operative components, each operative component comprising a fluoropolymer body portion with a fluid flow passageway therethrough and a plurality of tubing connector fittings, the operative components connected by a plurality of tubing segments connecting to the components at their respective tubing connector fittings, the plurality of tubing segments and operative components providing the flow path through the fluid circuit;

wherein a path to ground is provided that extends through each operative component and each tubing segment.

Clause 17. The fluid circuit of clause 16 wherein the plurality of tubing segments each comprising a non-conductive fluoropolymer tubing portion and a strip of conductive polymer extending axially on and unitary with the non-conductive fluoropolymer tubing portion, and wherein each body portion comprises a conductive fluoropolymer portion extending from a pair of the plurality of tubing connector fittings.
Clause 18. The fluid circuit of as in any one of clauses 16 or 17, wherein each body portion comprises a non-conductive fluoropolymer portion defining the fluid passageway and extending to ends of each of the respective plurality of tubing connector fittings.
Clause 19. The fluid circuit as in any one of clauses 16-19, wherein each body portion comprises a non-conductive fluoropolymer portion defining the fluid passageway and extending to ends of each of the respective plurality of tubing connector fittings, the non-conductive fluoropolymer portion forming a gapless juncture with the conductive fluoropolymer portion.
Clause 20. An operative fluid circuit component comprising:
a body portion and at least two connector portions, the body portion comprising a non-conductive fluoropolymer portion that defines a fluid flow path extending between the at least two connector portions, the body portion further comprising a non-interior fluoropolymer conductor extending between the at least two connector portions, each connector portion configured for receiving a tubing end having a conductive portion and conductively connecting the non-interior fluoropolymer conductor portion to the conductive portion of the tubing end, one of the non-conductive fluoropolymer portion and the fluoropolymer conductor portion overmolded on the other of the non-conductive fluoropolymer portion and the fluoropolymer conductor portion.
Clause 21. The fluid circuit as in any one of the preceding clauses wherein the connector fitting includes a conductive wrap.
Clause 22. The fluid circuit as in any one of the preceding clauses wherein the conductive polymer of the tubing segment is conductively connected to the conductive pathway of the body portion at the tubing connector fitting.
Clause 23. The fluid circuit as in any one of the preceding clauses wherein the connector fitting includes a nut that is constructed of conductive polymeric material.
Clause 24. The fluid circuit as in any one of the preceding clauses wherein the conductive portion forms 5-10% of the exterior surface of the body portion.