Patent Publication Number: US-2022235757-A1

Title: Diaphragm pump

Description:
TECHNICAL FIELD 
     The present disclosure generally relates to diaphragm pumps, and more particularly, but not exclusively, to diaphragm constructions useful with a diaphragm pump. 
     BACKGROUND 
     Providing diaphragms with suitable and long lasting diaphragms remains an area of interest. Some existing systems have various shortcomings relative to certain applications. Accordingly, there remains a need for further contributions in this area of technology. 
     SUMMARY 
     One embodiment of the present disclosure is a unique diaphragm construction used within a diaphragm pump. Other embodiments include apparatuses, systems, devices, hardware, methods, and combinations for constructing diaphragms of diaphragm pumps. 
     For example, in one example embodiment, a diaphragm structured for use in a diaphragm pump useful to pump a working fluid is presented herein. The diaphragm, which is also referred to herein as a split-layer diaphragm, includes a first non-planar layer and a second non-planar layer. The second non-planar layer is independent from the first non-planar layer, but engaged to the first non-planar layer so that the first non-planar layer and the second non-planar layer form a closed space therebetween and travel together while flexing in an intake direction or a discharge direction within a pumping assembly of a diaphragm pump. 
     At least because the diaphragm is formed from multiple layers that form closed spaces therebetween (referred to herein as inter-layer closed spaces or volumes), the diaphragm may be a high strength, long lasting diaphragm. Specifically, the multiple layers may avoid parasitic sheer while collectively forming a high-strength membrane that may, for example, endure high pressure differentials created by mechanical actuations of the diaphragm. Moreover, since the diaphragm is formed from non-planar diaphragm layers, the diaphragm may be suitable for longer-stroke diaphragm pumps that typically operate at lower pressures (e.g., under 500 pounds per square inch (psi)), as opposed to shorter-stroke diaphragm pumps that typically operate at higher pressures (e.g., upwards of 1,000 psi). In fact, in some embodiments, the diaphragm is non-planar because it includes an inwardly cupping, annular convolute that renders the diaphragm suitable for mechanical actuations. 
     In some embodiments, the first layer and second layer of the diaphragm engage via at least one sealing feature to ensure the layers form a closed space therebetween and travel together. As an example, the diaphragm may include a first mating element disposed on a radially exterior section of at least one face of opposing faces of the first non-planar layer and the second non-planar layer. Additionally or alternatively, the diaphragm may include a second mating element disposed on a radially interior section of at least one face of the opposing faces of the first non-planar layer and the second non-planar layer. Sealing features on the exterior section and interior section may ensure the layers remain engaged adjacent both a central interface and an outer rim. In some instances, the first and second mating elements comprise beads provided on one layer that compress into the other layer. 
     Moreover, in some embodiments, the first non-planar layer and the second non-planar layer comprise two non-planar layers of equal thickness formed from a thermoplastic elastomer material. For example, the two non-planar layers may be formed from a thermoplastic vulcanizate, such as Santoprene, which is available from Exxon Mobil Corporation. Alternatively, at least one of the two non-planar layers may be a composite construction including a reinforcement and a matrix material. The reinforcement may be a fabric, a pseudo-fabric, or both. 
     In at least some embodiments with two non-planar layers of equal thickness, the diaphragm also includes a third non-planar layer disposed exteriorly of the first non-planar layer and the second non-planar layer. The third non-planar layer may be structured to be in contact with a working fluid being pumped through the diaphragm pump. That is, the third non-planar layer may be a fluid compatibility layer configured to protect the first and second layers from a working fluid, for example, if the working fluid is acidic, basic, and/or includes contaminates. For example, the third non-planar layer may be formed from polytetrafluoroethylene, thermoplastic, a thermoplastic vulcanizate, or a thermoplastic polyester elastomer, depending on a composition of the working fluid. 
     Still further, in some embodiments, the first non-planar layer is structured to be in contact with the working fluid in the pumping chamber during operation of the diaphragm pump and the second non-planar layer is structured to carry a load associated with a differential pressure formed across the split-layer diaphragm during operation of the diaphragm pump that is higher than a load carried by the first non-planar layer. For example, the second non-planar layer may have a higher stiffness than the first layer that allows the second non-planar layer to carry a higher load. In at least some of these embodiments, the first non-planar layer is formed from a polytetrafluoroethylene, thermoplastic, a thermoplastic vulcanizate, or a thermoplastic polyester elastomer, depending on the composition of the working fluid. 
     According to another example embodiment, a diaphragm pump is presented herein. The diaphragm pump includes an inlet structured to receive a fluid, an outlet structured to convey a fluid discharged by the diaphragm pump, a pumping assembly disposed between the inlet and the outlet, and a split-layer diaphragm disposed within the pumping assembly. The split-layer diaphragm is comprised of two or more unbonded, non-planar diaphragm layers that travel together, with adjacent layers of the two or more unbonded, non-planar diaphragm layers forming a closed space therebetween. The split-layer diaphragm is configured to flex in an intake direction to draw a working fluid into a pumping chamber defined by the split-layer diaphragm within the pumping assembly, and to flex in a discharge direction to expel the working fluid from the pumping chamber. 
     In various embodiments, the split-layer diaphragm may include any features, components, or structures described in connection with the diaphragm discussed above and, thus, may realize the same advantages. Additionally or alternatively, the diaphragm pump may include a mechanical actuator configured to extend through a central interface of the split-layer diaphragm and to flex the split-layer diaphragm in both the intake direction and the discharge direction. Thus, the diaphragm pump may realize the advantages of the split-layer diaphragm in a mechanically actuated diaphragm pump, which may generate harsher operating conditions than comparable air or hydraulically actuated diaphragm pumps. 
     Moreover, in some embodiments, the diaphragm pump may include a fluid washer and a back washer, and a washer pad. In such embodiments, the split-layer diaphragm is sandwiched between the washers and the washer pad is disposed between the split-layer diaphragm and the back washer. The washer pad is structured to resist wear caused by relative movement of a back layer of the split-layer diaphragm and an actuator acting on the split-layer diaphragm. For example, the washer pad may be softer (e.g., have a lower durometer rating) than the back layer of the split-layer diaphragm so that wear is pushed from the split-layer diaphragm to the back washer. This may extend the lifespan of the split-layer diaphragm. In at least some of these embodiments, the washer pad is formed from a thermoplastic vulcanizate, an ultra-high molecular weight polyethylene, or a combination thereof. 
     Still further, in some embodiments, the split-layer diaphragm is a first split-layer diaphragm, the pumping assembly is a first pumping assembly and the diaphragm pump also includes a second split-layer diaphragm disposed with a second pumping assembly and a third split-layer diaphragm disposed with a third pumping assembly. Three pumping assemblies may lower the pressure experienced by each split-layer diaphragm, thereby reducing the stress experienced by each split-layer diaphragm and allowing an overall size (e.g., diameter) of the split-layer diaphragms to be reduced. Additionally, decreasing the pressure experienced by each split-layer diaphragm may reduce or eliminate pressure ripples downstream of the diaphragm pump. 
     Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       To complete the description and in order to provide for a better understanding of the present invention, a set of drawings is provided. The drawings form an integral part of the description and illustrate an embodiment of the present invention, which should not be interpreted as restricting the scope of the invention, but just as an example of how the invention can be carried out. The drawings comprise the following figures: 
         FIG. 1  depicts a perspective view of a diaphragm pump in which the diaphragm construction presented herein may be included, according to a first example embodiment. 
         FIG. 2  depicts a perspective view of a pumping assembly included in the diaphragm pump of  FIG. 1 , according to an example embodiment. 
         FIG. 3  depicts an exploded view of the pumping assembly of  FIG. 2 . 
         FIG. 4  depicts a side sectional view of the pumping assembly of  FIG. 2 . 
         FIGS. 5-7  depict enlarged views of portions of the sectional view of  FIG. 4 . 
         FIGS. 8 and 9  depict side views of a diaphragm included in the pumping assembly of  FIG. 2 , with layers of the diaphragm shown engaged in  FIG. 7  and exploded in  FIG. 8 . 
         FIG. 10  depicts a side sectional view of another example embodiment of a pumping assembly that may be included in the diaphragm pump of  FIG. 1 . 
         FIGS. 11 and 12  depict enlarged views of portions of the sectional view of  FIG. 10 . 
         FIG. 13  depicts an exploded view of the pumping assembly of  FIG. 10 . 
         FIGS. 14 and 15  depict side views of a diaphragm included in the pumping assembly of  FIG. 10 , with layers of the diaphragm shown engaged in  FIG. 14  and exploded in  FIG. 15 . 
         FIG. 16  depicts a perspective view of a first example embodiment of a reinforced composite layer that can be used as a layer of the split-layer diaphragm presented herein. 
         FIG. 17  depicts a perspective view of an example embodiment of a fabric that can be used in the reinforced composite layer of  FIG. 16 . 
         FIG. 18  depicts a perspective view of a second example embodiment of a reinforced composite layer that can be used as a layer of the split-layer diaphragm presented herein. 
     
    
    
     DETAILED DESCRIPTION 
     For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. 
     Generally, a split-layer diaphragm and a diaphragm pump including the same are presented herein. The split-layer diaphragm includes two or more non-planar, unbonded diaphragm layers. That is, the split-layer diaphragm includes two or more undulating, independent layers. Since the diaphragm layers are unbonded, the diaphragm layers define separate sliding boundaries, which reduce stress on the diaphragm layers. Put another way, since the diaphragm layers are unbonded, the split-layer diaphragm may eliminate parasitic sheer between layers. However, at the same time, the diaphragm layers do not separate and travel together. 
     In some embodiments, the diaphragm layers travel together because closed spaces are formed between adjacent layers (also referred to as inter-layer closed spaces or volumes). Additionally or alternatively, the diaphragm layers may include sealing features, such as pressure ridges and/or interlocking beads that allow the diaphragm layers to mate and travel together. In fact, in at least some embodiments, the sealing features allow each layer to engage adjacent layers in a manner that creates inter-layer closed spaces. The sealing features may also engage portions of a pump assembly, such as washers and glands, to secure and seal the split-layer diaphragm within a pumping cavity of the pumping assembly. 
     In at least some embodiments, the diaphragm construction presented herein (i.e., a split-layer diaphragm) may be particularly advantageous for mechanically actuated pumps, which often require a high-strength diaphragm to withstand the pressure differentials created across the diaphragm. Typically, the pressure differentials created by a mechanically actuated diaphragm pump are much higher than pressure differentials created by air or hydraulically actuated diaphragm pumps. This is because air or hydraulically actuated diaphragm pumps maintain pressure in a non-worked fluid chamber, which balances the pressure differential across the diaphragm. By comparison, mechanically actuated diaphragms often do not generate a balancing pressure, leading to sinusoidal peaks of high pressure differentials. For example, when pumping working fluid at similar flow rates, a mechanically actuated diaphragm pump may generate a maximum pressure of 200 pounds per square inch (psi) peaks while an air or hydraulically actuated diaphragm pump may generate a maximum pressure of 120 psi. 
     Thus, although mechanically actuated diaphragm pumps often provide a simpler, more desirable pumping solution (e.g., due to cost of manufacturing and/or maintenance), mechanically actuated diaphragm pumps may require stronger diaphragms. The diaphragm construction presented herein may provide increased strength as compared to conventional diaphragms at least because the unbonded layers allow the diaphragm to have an increased overall thickness, at least as compared to a single layer or bonded layer construction that would fail with a similar overall thicknesses. Moreover, the diaphragm construction presented herein may provide this increased strength without experiencing delamination issues that are often encountered by diaphragms that are reinforced with a fabric, which is added in an attempt to increase the strength of the diaphragm. 
     In embodiments that are particularly advantageous for mechanically actuated pumps, the split-layer diaphragm can include an annular, inwardly cupping convolute (which may render the split-layer diaphragm non-planar). That is, in embodiments that are particularly advantageous for mechanically actuated pumps, the split-layer diaphragm includes an annular convolute that curves away from a pumping chamber for working fluid, which may have a higher pressure than an actuating or non-worked fluid chamber housing a mechanical actuator. By comparison, diaphragms for air or hydraulically diaphragm pumps may include convolutes that cup outwards, away from an actuating chamber that can be pressurized to cause a diaphragm to flex in a discharge direction. 
     Now turning to  FIG. 1 , this Figure illustrates a perspective view of a diaphragm pump  50  in which the diaphragm construction presented herein may be installed, according to an example embodiment. Diaphragm pump  50  is a mechanically actuated, triple diaphragm pump. However, diaphragm pump  50  is merely an example embodiment and, in other embodiments, a single diaphragm pump, double diaphragm pump, or a diaphragm pump including any number of diaphragms may employ the diaphragm construction presented herein. Additionally or alternatively, the diaphragm construction presented herein may be air operated, electrically operated, or driven in any other manner now known or developed hereafter. That is, a skilled artisan, upon reading the present disclosure, will appreciate that the mechanically actuated, triple diaphragm pump shown in  FIG. 1  is depicted for illustrative purposes. 
     That said, the diaphragm pump  50  depicted in  FIG. 1  includes an inlet manifold  52  configured to deliver a working fluid to a first pump assembly  54 , a second pump assembly  55 , and a third pump assembly  56 . Pumping assemblies  54 ,  55 , and  56  each house a split-layer diaphragm  100  (see, e.g.,  FIG. 2B ) that is operatively coupled to a drive mechanism  58  via a main body  59  of the diaphragm pump  50 . For example, the drive mechanism  58  may include an electric motor and the main body  59  may house one or more slider-crank mechanisms that convert rotational motion of the motor into linear motion that can drive movement (e.g., cause inward and outward flexing) of the split-layer diaphragms  100  within pumping assemblies  54 ,  55 , and  56 . Movement of the split-layer diaphragms  100  moves (i.e., pumps) working fluid from inlet manifold  52  to an outlet manifold  60 . 
     Although the triple diaphragm pump  50  is merely an example, such an arrangement may also distribute pressure among three pumping assemblies  54 ,  55 , and  56 , which may allow the pumping assemblies  54 ,  55 , and  56  to utilize split-layer diaphragms  100  with smaller diameters. That is, distributing pressure among three pumping assemblies  54 ,  55 , and  56  may reduce the stress and/or duty cycle applied to each split-layer diaphragm  100 , which may allow the diaphragm pump  50  to utilize smaller split-layer diaphragms  100  than, for example, dual or single diaphragm pumps structured to operate at similar operating parameters and/or under similar operating conditions. Distributing the pressure to three pumping assemblies  54 ,  55 , and  56  may also reduce downstream pressure ripples (e.g., downstream of outlet manifold  60 ). 
       FIGS. 2-4  depict a perspective view, an exploded view, and a sectional view of the third pumping assembly  56 , respectively, but these views are also representative of the first pump assembly  54  and the second pump assembly  55 . As can be seen, the third pump assembly  56  includes a pumping cavity inlet  61  and a pumping cavity outlet  63  that guide a working fluid into and out of the third pump assembly  56 , respectively (from inlet manifold  52  and towards outlet manifold  60 , respectively). In the depicted embodiment, the pumping cavity inlet  61  and the pumping cavity outlet  63  are defined by a pump head  64 . Meanwhile, a base  62  and the pump head  64  define a pumping cavity  66  between the pumping cavity inlet  61  and the pumping cavity outlet  63 . 
     As can be seen in  FIG. 4 , the split-layer diaphragm  100  divides (e.g., splits) the pumping cavity  66  into a pumped fluid-side portion  68  (also referred to as a pumping chamber  68  or working fluid chamber  68 ) and non-pumped fluid-side portion  70  (also referred to as non-worked fluid chamber  70 ). The split-layer diaphragm  100  is described in further detail below, but, generally, the split-layer diaphragm  100  includes at least a first layer  110  and a second layer  140 . When the split-layer diaphragm  100  flexes inwards, in intake direction D 1  (e.g., towards base  62 ), the split-layer diaphragm  100  draws a working fluid into the pumping chamber  68  from pumping cavity inlet  61  (via inlet manifold  52 ). Alternatively, when the split-layer diaphragm  100  flexes outwards, in discharge direction D 2  (e.g., towards pump head  64 ), the split-layer diaphragm  100  expels a working from the pumping chamber  68  via pumping cavity outlet  63  (towards outlet manifold  60 ). 
     In the depicted embodiment, the split-layer diaphragm  100  is secured within the pumping cavity  66  by a fluid washer  76  and a backside washer  78  that are configured to flex the split-layer diaphragm  100  in the intake direction D 1  or the discharge direction D 2 . More specifically, in the depicted embodiment, fluid washer  76  and backside washer  78  sandwich the split-layer diaphragm  100 . Then, a bolt  80  extends through the fluid washer  76 , the backside washer  78 , and the split-layer diaphragm  100  to couple washers  76 ,  78  and the split-layer diaphragm  100  to an actuation device, such as a rod, piston, slider-crank, or the like, (e.g., within main body  59 ) that is driven by drive mechanism  58  (e.g., an electric motor). 
     For example, in the depicted embodiment, the bolt  80  may be secured to a piston (not shown) and tightly couple washers  76  and  78  against the piston. To achieve this, an enlarged head of the bolt  80  engages an outer surface of the fluid washer  76  and the backside washer  78  is secured on the bolt  80 , between the fluid washer  76  and the piston. Thus, the fluid washer  76 , the backside washer  78 , and the bolt  80  may all be secured, either directly or indirectly, to a piston and will move in response to movements of the piston. 
     Additionally, a bellows  82  extends from the backside washer  78  to the base  62  to encapsulate and protect the bolt  80  and piston (or other actuator). However, in the depicted embodiment, the bellows  82  is not reliant on only its own resiliency to maintain engagement with the backside washer  78 . Instead, coupler  90  is structured to ensure that the bellows  82  remains sealed to the backside washer  78 . Additionally, coupler  90  may be structured to distribute stress from the backside washer  78  to a piston, thereby protecting the backside washer  78  from exposure to high contact stress. 
     For example, as is shown in the enlarged view of  FIG. 5 , the coupler  90  may include an undercut portion  92  configured to receive a protrusion  83  included on a distal end of the bellows  82 . The protrusion  83  extends outwards (e.g., in the discharge direction D 2 ), towards the backside washer  78  and, thus, can seal against the backside washer  78 . In fact, at least because the coupler  90  can be directly coupled to a piston disposed within the bellows  82 , outward movement of the piston may act to maintain a seal between the bellows  82  and the backside washer  78 . Consequently, even if the backside washer  78  experiences stress that causes bending, which often occurs during operation of a diaphragm pump, contact stresses through the protrusion  83  may be sufficient to maintain a seal against the backside washer  78  and protect an actuator disposed within the bellows  82 . 
     Additionally, since the undercut portion  92  of the coupler  90  allows a portion of the coupler to contact with the backside washer  78 , the coupler  90  may distribute stress from the backside washer  78  to a piston while sealing the bellows  82  against the backside washer  78 . In the depicted embodiment, roll pins  84  also extend through the coupler  90  into the backside washer  78 . Roll pins  84  ensure that the coupler  90  and bellows  82  do not twist when the bolt  80  is torqued, which could lead to early failure. 
     However, washer  76 , washer  78 , and bolt  80 , as well as other components associated therewith, are merely an example actuation arrangement and other embodiments might utilize variations thereof or entirely different actuation arrangements. For example, in some embodiments, bolt  80  might extend through only a portion (e.g., one or more layers) of the split-layer diaphragm  100 . Alternatively, a fastener might extend through one or more layers of the split-layer diaphragm  100  and attach to a rod disposed adjacent base  62 . As another example, in some embodiments, motive fluid, such as air or hydraulic fluid, may be disposed in the non-worked fluid chamber  70  to move or assist in moving the split-layer diaphragm  100  to draw in and push out (i.e., expel) a working fluid from pumping chamber  68 . Still further, in some embodiments, bolt  80  may be coupled to the drive mechanism  58  (e.g., an electric motor) via a linkage and/or may be coupled to another diaphragm (e.g., in a dual diaphragm pump). 
     Now referring to  6 - 9 , in the depicted embodiment, the split-layer diaphragm  100  is an annular component that extends around a central opening  101  (also referred to as interface  101 ). As can be seen in at least  FIG. 8 , the split-layer diaphragm  100  extends from an inner section  104  to an exterior section  106 . The inner section  104  is proximate to and/or defines the central opening  101  and the exterior section  106  is proximate to and/or forms an outer rim  107  of the split-layer diaphragm  100 . 
     As mentioned above, in the depicted embodiment, the split-layer diaphragm  100  is formed from a first layer  110  and a second layer  140 . However, these two layers are merely one example construction and, in other embodiments, the split-layer diaphragm  100  may be formed from two or more layers. Generally, the two or more layers of the split-layer diaphragm  100  have substantially the same cross-sectional dimensions (e.g., the same diameter and a central opening  101  of the same size) and are structured so that adjacent layers form a closed space therebetween. Thus, the layers travel together when the split-layer diaphragm  100  is secured within a pumping cavity  66 , such as by washers  76  and  78  sandwiching the split-layer diaphragm  100  and/or by pressure acting on one or more external layers of the split-layer diaphragm  100 . 
     That is, if the split-layer diaphragm  100  includes n layers, the split-layer diaphragm  100  may form n−1 closed spaces between the n layers, with one closed space formed between each pair of adjacent layers. Thus, as mentioned, the closed spaces(s) may be referred to herein as inter-layer closed space(s). The inter-layer closed space(s) may ensure that the layers of the split-layer diaphragm  100  travel together when the split-layer diaphragm  100  flexes in a intake direction D 1  or a discharge direction D 2  (e.g., during an outward and inward stroke of a piston). 
     This is because the inter-layer closed spaces define a fixed volume between the layers that minimizes pressure between the layers. In some embodiments, the amount of fluid enclosed in this fixed volume may be minimized to ensure the pressure between the layers is minimizes. In fact, in some instances, fluid can be removed from the closed area to form a vacuum in an inter-layer closed space. Additionally or alternatively, the volume of each enclosed space may be maximized. 
     In at least some embodiments, the inter-layer closed spaces are unlubricated closed spaces. That is, the inter-layer closed spaces may not be formed around a quantity of lubricant. However, in other embodiments, a quantity of lubricant may be included in the closed space. 
     Moreover, the split-layer diaphragm  100  presented herein is a non-planar diaphragm. That is, the split-layer diaphragm  100  has undulations or curvature and is not a flat disk. In the depicted embodiment, the split-layer diaphragm  100  is non-planar at least because first layer  110  and second layer  140  include annular convolutes  120  and  150 , respectively (see  FIG. 9 ), that mesh or mate to form an annular convolute  102  for the split-layer diaphragm  100 . The convolute  102  is an annular, inwardly cupping convolute  102  and, thus, curves or bends into the non-worked fluid chamber  70 , towards the base  62  (and towards an actuator included in non-worked fluid chamber  70 ). As mentioned above, an inwardly cupping convolute  102  may render the split-layer diaphragm  100  particular suitable for mechanical actuations, since the convolute  102  will cup away from the pumping chamber  68  and the higher pressures than may be generated therein. 
     Still referring to  FIG. 6-9 , but now with a focus on  FIGS. 6 and 7 , the diaphragm construction presented herein may, in at least some embodiments, include one or more sealing features that assist with forming the inter-layer closed space(s) between adjacent layers of the split-layer diaphragm  100 . That is, the one or more sealing features of the split-layer diaphragm  100  may ensure that inter-layer closed space(s) are maintained throughout operation of a diaphragm pump in which the split-layer diaphragm  100  is included. Put still another way, the sealing features of the split-layer diaphragm  100  (e.g., beads) may provide pressure and flow containment for each inter-layer closed space. Additionally, the one or more sealing features may seal the working fluid chamber  68  with respect to the non-worked fluid chamber  70 . 
     In the depicted embodiment, sealing features are included on an inner section  104  and an exterior section  106  of the split-layer diaphragm  100 . That is, in the depicted embodiment, the inner section  104  of the split-layer diaphragm  100  includes one or more sealing elements disposed proximate the central opening  101  while the exterior section  106  of the split-layer diaphragm  100  includes one or more sealing elements disposed at or proximate the outer rim  107 . The sealing features seal the first layer  110  against the second layer  140  and may also seal the split-layer diaphragm  100  against components of the pumping assembly  56 , such as the fluid washer  76 , the backside washer  78 , the base  62 , and/or the pump head  64 . In particular, the sealing features may be configured to seal the split-layer diaphragm  100  and the working fluid chamber  68  while allowing metal-to-metal joints to be formed between the base  62  and the pump head  64  and between the actuator (e.g., a piston) and the bolt  80 . 
     More specifically, the sealing features on the exterior section  106  may seal the first layer  110  to the second layer  140  and may also seal the exterior section  106  against the base  62  and the pump head  64 , but without preventing a metal-to-metal joint between the base  62  and the pump head  64 . Meanwhile, the sealing features on the inner section  104  may seal the first layer  110  to the second layer  140  and may also seal the inner section  104  against the fluid washer  76  and the backside washer  78 , but without preventing a metal-to-metal joint (i.e., bolted joint) between washer  76 , washer  78 , and bolt  80 . Thus, collectively, the sealing features on the inner section  104  and the exterior section  106  may form a closed space (of maximum volume) between the central opening  101  and the outer rim  107  while also forming seals between the working fluid chamber  68  and the non-worked fluid chamber  70 . The sealing features included on the exterior section  106  and the sealing features included on the inner section  104  are each described in further detail below in connection with  FIGS. 6 and 7 . 
     First, as can be seen in  FIG. 6 , in the depicted embodiment, the exterior section  106  includes sealing features in the form of an exterior cap  122  formed on the first layer  110 , an exterior cap  152  formed on the second layer  140 , and a mating element  154  formed on the second layer  140 . The exterior caps  122 ,  152  define the overall shape of the exterior section  106  and are configured to sit within and seal against an exterior gland  640 . The exterior gland  640  is formed by a front gland geometry  642  defined by the pump head  64  and a back gland geometry  622  defined by the base  62 . The exterior cap  122  of the first layer  110  may mate with and/or engage the front gland geometry  642  while the exterior cap  152  of the second layer  140  may mate with and/or engage the back gland geometry  622 . 
     More specifically, in the depicted embodiment, the working fluid chamber  68  is sealed off from the non-worked fluid chamber  70  because: (1) the exterior cap  122  of the first layer  110  engages the front gland geometry  642 ; and/or (2) the exterior cap  152  of the second layer  140  engages the back gland geometry  622 . For example, in the depicted embodiment, the exterior cap  122  has a rounded front end that can press against an into a V-shaped front gland geometry  642  to form a seal therebetween. On the other end, the back end of the exterior cap  152  may be rounded while the back gland geometry  622  has a square shape. Thus, engaging exterior cap  152  with back gland geometry  622  may create two acute points of contact between the exterior cap  152  and the back gland geometry  622  that seal the exterior gland  640  from the non-worked fluid chamber  70 . 
     Notably, in the depicted embodiment, the front gland geometry  642  is coupled to the back gland geometry  622  via a metal-to-metal joint. That is, the exterior section  106  of the split-layer diaphragm  100  is secured within the exterior gland  640 , but does not extend out of the exterior gland  640 , for example, to be secured between the pump head  64  and the base  62 . This avoids stressing the exterior section  106  of the split-layer diaphragm  100  while also eliminating leakage issues that may be encountered when a diaphragm material secured between the pump head  64  and base  62  creeps. 
     Still referring to  FIG. 6 , in the depicted embodiment, the second layer  140  includes a mating element  154  configured to engage the first layer  110 . In at least some embodiments, mating element  154  comprises a bead that will press into a soft or pliable material used to form the first layer  110  (examples of which are described in detail below) when the first layer  110  is compressed against the second layer  140  (e.g., by washers  76  and  78 ). Additionally, since the exterior cap  122  has a rounded front end that can press against an into a V-shaped front gland geometry  642 , the exterior cap  122  may prevent rotation of the first layer  110  on the mating element  154 . Meanwhile, the shapes of the exterior cap  152  of the second layer  140  and the back gland geometry  622  may allow room for the mating element  154  to compress into the first layer  110 . 
     That said, in other embodiments, a mating element  154  included at the exterior section  106  of the split-layer diaphragm  100  need not be included on the second layer  140  and could be included on a rear face of the first layer  110 . Alternatively, the mating element  154  may comprise mating elements on both opposing faces of the first layer  110  and the second layer  140 . For example, first layer  110  might include a bead and second layer  140  might include a corresponding groove. Additionally or alternatively, in some embodiments, the mating element  154  may be included outside of, but proximate to the exterior gland  640 . For example, if the split-layer diaphragm  100  includes three or more layers, a first pair of opposing faces might be engaged via a mating element  154  disposed in the exterior gland  640  while a second pair of opposing faces are engaged via a mating element  154  disposed outside (e.g., interiorly of) the exterior gland  640 . As another example, one set of opposing faces of layers in the split-layer diaphragm  100  might be engaged by two or more mating elements  154  positioned within and/or outside of the exterior gland  640 . 
     Second, and now turning to  FIG. 7 , the inner section  104  includes sealing features in the form of an interior cap  112  formed on the first layer  110 , an interior cap  142  formed on the second layer  140 , and a mating element  146  formed on the second layer  140 . The interior caps  112 ,  142  define the overall shape of the inner section  104  and are configured to sit within and seal against an interior gland  760 . The interior gland  760  is formed by a front gland geometry  762  defined by the fluid washer  76  and a back gland geometry  782  defined by the backside washer  78 . The interior cap  112  of the first layer  110  may mate with and/or engage the front gland geometry  762  while the interior cap  142  of the second layer  140  may mate with and/or engage the back gland geometry  782 . 
     More specifically, in the depicted embodiment, the working fluid chamber  68  is sealed off from the non-worked fluid chamber  70  because: (1) the interior cap  112  of the first layer  110  engages the front gland geometry  762 ; and/or (2) the interior cap  142  of the second layer  140  engages the back gland geometry  782 . For example, in the depicted embodiment, the interior cap  112  has a rounded front end that can press against an into a V-shaped front gland geometry  762  to form a seal therebetween. On the other end, the back end of the interior cap  142  may include a step configured to seat on a shoulder defined by the back gland geometry  782  defined by the backside washer  78 . 
     Notably, in the depicted embodiment, the front gland geometry  762  is coupled to the back gland geometry  782  via a metal-to-metal joint. That is, the inner section  104  of the split-layer diaphragm  100  is secured within the interior gland  760 , but does not extend out of the interior gland  760 , for example, to be secured between the fluid washer  76  and the backside washer  78 . This avoids stressing the inner section  104  of the split-layer diaphragm  100  while also eliminating leakage issues that might be encountered if a diaphragm material secured between the backside washer  78  and fluid washer  76  creeps. 
     Still referring to  FIG. 7 , in the depicted embodiment, the second layer  140  includes a mating element  146  configured to engage the first layer  110 . In at least some embodiments, mating element  146  comprises a bead that will press into a soft or pliable material used to form the first layer  110  (examples of which are described in detail below) when the first layer  110  is compressed against the second layer  140  (e.g., by washers  76  and  78 ). Additionally, since the interior cap  112  has a rounded front end that can press against an into a V-shaped front gland geometry  762 , the interior cap  112  may prevent rotation of the first layer  110  on the mating element  146 . Meanwhile, the shapes of the interior cap  142  and the back gland geometry  782  may allow room for the mating element  146  to compress into the first layer  110 . 
     That said, in other embodiments, a mating element  146  included at the inner section  104  of the split-layer diaphragm  100  need not be included on the second layer  140  and could be included on a rear face of the first layer  110 . Alternatively, the mating element  146  may comprise mating elements on both opposing faces of the first layer  110  and the second layer  140 . For example, first layer  110  might include a bead and second layer  140  might include a corresponding groove. Additionally or alternatively, in some embodiments, the mating element  146  may be included outside of, but proximate to the interior gland  760 . For example, if the split-layer diaphragm  100  includes three or more layers, a first pair of opposing faces might be engaged via a mating element  146  disposed in the interior gland  760  while a second pair of opposing faces are engaged via a mating element  146  disposed outside (e.g., exteriorly of) the interior gland  760 . As another example, one set of opposing faces of layers in the split-layer diaphragm  100  might be engaged by two or more mating elements  146  positioned within and/or outside of the interior gland  760 . 
     Moreover, in some embodiments, the fluid washer  76  and/or the backside washer  78  also include sealing features that may engage the split-layer diaphragm  100 , at or proximate to the inner section  104 , to further secure the split-layer diaphragm  100  to the fluid washer  76  and the backside washer  78 . For example, in the depicted embodiment, the fluid washer  76  includes mating elements  764  that act as sealing features and the backside washer  78  includes or is coupled to a washer pad  190  that is or includes sealing features. 
     In at least some embodiments, the mating elements  764  comprise pressure ridges and/or beads that will press into a soft or pliable material used to form the first layer  110  (examples of which are described in detail below). However, in other embodiments, mating elements  764  could be included on the first layer  110  and/or comprise a set of elements on the fluid washer  76  and the first layer  110  (e.g., a bead and corresponding groove). 
     The washer pad  190  comprises a layer of material that is softer (e.g., has a lower durometer rating) than a back layer of the split-layer diaphragm  100 . For example, in the depicted embodiment, the washer pad  190  is softer than the second layer  140 . Thus, the split-layer diaphragm  100  can push wear to the washer pad  190 . Put another way, the washer pad  190  may be an abrasion layer configured to absorb abrasion created by movement of the split-layer diaphragm  100  so that the abrasion does not wear layers of the split-layer diaphragm  100 . In fact, in at least embodiments, the washer pad  190  may be a sacrificial layer that is intended to wear while protecting the split-layer diaphragm  100 . 
     As a specific example, if the split-layer diaphragm  100  is formed from two or more layers of a thermoplastic elastomer (TPE) in the form of a thermoplastic vulcanizate (TPV), such as Santoprene available from Exxon Mobil Corporation, the washer pad  190  may be formed from a TPV, such as Santorpene, with a lower durometer rating than the TPV used to form the layers of the split-layer diaphragm  100 . Alternatively, the washer pad  190  may be formed from an ultra-high molecular weight polyethylene (UHMWPE), a TPE, or some combination of these materials, with or without TPV. To be clear, as used herein, the term “thermoplastic” can refer to a class of plastic that is melt processable such that it can be melted and reformed. 
     Additionally, in at least some embodiments, the washer pad  190  may include a protrusion  192  at its distal end. The protrusion  192  may be configured to compress and seal against the second layer  140 . Thus, in the depicted embodiment, four sealing points may be formed at or adjacent to the inner section  104  of the split-layer diaphragm  100 , between the split-layer diaphragm  100  and washers  76  and  78 . Specifically, two of the sealing points are formed by mating elements  76 , at least one sealing point is formed by interior caps  112  and  142 , and another sealing point formed by protrusion  192 . However, other embodiments may provide sufficient sealing with fewer sealing points. For example, other embodiment might provide sufficient sealing without washer pad  190  and could, for example, include a backside washer  78  with overall dimensions equal to the overall dimensions of the combination of the depicted backside washer  78  and washer pad  190 . 
     Now turning to  FIGS. 8 and 9 , in the depicted embodiment, first layer  110  and second layer  140  have substantially similar, if not identical geometries, and, thus are layers of equal thickness. For example, first layer  110  and second layer  140  may each have a thickness in the range of approximately 0.07 inches to approximately 0.10 inches, in the range of approximately 0.085 inches to approximately 0.095 inches, or even in the range of approximately 0.06 inches to approximately 0.11 inches, such as a thickness of approximately 0.090 inches. However, in other embodiments, first layer  110  and second layer  140  may have different thicknesses. 
     Moreover, in the depicted embodiment, the first layer  110  and the second layer  140  may be formed from the same material. Forming the first layer  110  and the second layer  140  from the same material may create a split-layer diaphragm  100  that has characteristics of a single layer of that material, but with improved flexibility, pliability, and/or stress management. For example, if first layer  110  and second layer  140  are both formed from a TPV, such as Santoprene, with a specific thickness (e.g., of 0.090 inches) and a specific durometer rating (e.g., 40D), the split-layer diaphragm  100  may have an overall membrane strength that is nearly equivalent to a single layer of Santoprene with a thickness that is double the thickness of each individual layer (e.g., 0.180 inches), but may experience less stress than this thicker layer of Santoprene. In fact, testing has found that forming the split-layer diaphragm  100  from two layers of Santoprene with a 40D durometer may extend the lifespan of a diaphragm to a lifespan that is five to twenty times longer that known diaphragms (i.e., a 500%-2000% increase in lifespan). 
     However, other materials, including other TPEs, such as Pebax available from Arkema S.A., may also provide an extended lifespan. In fact, the particular arrangement of the split-layer diaphragm  100  may allow the constituent layers to be formed from a variety of TPEs, including TPEs with durometer ratings that are not typically usable in mechanically actuated diaphragm pumps (e.g., since the harder durometer would not provide a combination of strength and flex to accommodate the stresses induced by differential pressure over a sufficient life span). As another example, in some instances, the layers of split-layer diaphragm  100  could be formed from a thermoplastic polyester elastomer such as Hytrel available from E.I. Du Pont De Nemours &amp; Co. 
     Still further, in some embodiments, each layer may be a composite construction including a matrix material and a reinforcement material, such as a fabric, a pseudo-fabric, or both. That is, in some embodiments, the layers of split-layer diaphragm  100  (e.g., first layer  110  and second layer  140 ) are single material layers, but in other embodiments, multiple materials can form each constituent layer of the split-layer diaphragm  100 . Example composite constructions are discussed in further detail below; however, generally, in at least some embodiments, multiple layers of material can be considered as a “layer” of the overall diaphragm construction (e.g., as first layer  110  or second layer  140 ). Thus, the term “layer” is not intended to limited to a single layer and/or a single monolithic layer; instead, the term “layer” is used herein for ease of convenience and is not intended to be limited to a single layer and/or single monolithic layer unless expressly stated to the contrary. 
     Moreover, the first layer  110  and the second layer  140  (as well as any other layers in the split-layer diaphragm  100 ) do not need to be formed from the same material. In fact, in some embodiments, the first layer  110  is formed from a first material and the second layer  140  is formed from a second material that is different from the first material. For example, the first layer  110  may be formed from a material suitable for handling fluid compatibility issues and the second layer  140  may be structured to support a higher load than the first layer  110  (with the load stemming from pressure differential across the split-layer diaphragm  100 ). 
     As a specific example, the first layer  110  may be formed from polytetrafluoroethylene (PTFE), a TPE, a TPV, such as Santoprene, or a thermoplastic polyester elastomer such as Hytrel, to provide a range of compatibility suitable for various working fluids, including highly acidic fluids, highly basic fluids, and fluids with particulate contamination (e.g., ceramic particulate). Any of these materials could be provided with a variety of thicknesses, such as a thickness in the range of approximately 0.02 inches to approximately 0.10 inches. 
     Meanwhile, the second layer  140  can be constructed with a strength and/or stiffness as well as flex life to accommodate more of the stresses induced by differential pressure across the split-layer diaphragm  100  than the first layer  110 . In such instances, the second layer  140  can be made from a TPE, like Pebax, a TPV, like Santoprene, or a reinforced material, provided the composition allows the second layer  140  to accommodate stresses generated by high differential pressures across the diaphragm. In these embodiments, the second layer  140  may have a variety of thicknesses such as a thickness in the range of approximately 0.04 inches to approximately 0.10 inches. 
     Now turning to  FIGS. 10-15 , these Figures illustrate another example embodiment of a pumping assembly  56 ′ that may be included in the diaphragm pump  50  of  FIG. 1 . In this example embodiment, the pumping assembly  56 ′ is substantially similar to the third pumping assembly  56  described above, but now includes another example embodiment of a split-layer diaphragm  200 . For example, the pumping assembly  56 ′ includes the same base  62  and pump head  64  as pumping assembly  56 . Thus, for brevity, the description of  FIGS. 10-15  focuses on portions of pumping assembly  56 ′ that differ from pumping assembly  56 , such as split-layer diaphragm  200  and fluid washer  276 . Otherwise, parts of pumping assembly  56 ′ that are similar to (or identical to) parts of pumping assembly  56  are labeled with like numerals and any description of like numerals included herein should be understood to apply to like components or features of  FIGS. 10-15 . 
     That said, the most notable components of pumping assembly  56 ′ that differ from pumping assembly  56  are split-layer diaphragm  200  and fluid washer  276  (each of which can be seen clearly in the exploded view of  FIG. 13 ). First, as can be seen in  FIG. 10 , the fluid washer  276  is similar to fluid washer  76  insofar as it works with backside washer  78  to sandwich and secure a split-layer diaphragm. However, now, the fluid washer  276  is encapsulated within a washer covering  278  that prevents the fluid washer  276  from being directly exposed to working fluid in the working fluid chamber  68 . The fluid washer  276  still forms a metal-to-metal contact with the backside washer  78 ; however, the washer covering  278  also contacts backside washer  78  and extends entirely around the fluid washer  276  between its contact points with backside washer  78 . In at least some embodiments, the washer covering  278  is formed from materials that can be used to form the third layer  210  of the split-layer diaphragm  200 , which are described in detail below. 
     Second, the split-layer diaphragm  200  is similar to the split-layer diaphragm  100  in that it is an annular component that extends around a central opening  201 , from an inner section  204  to an exterior section  206 . However, now, the split-layer diaphragm  200  includes a third layer  210  disposed on a front side of the first layer  110 , so that the first layer  110  is sandwiched between the third layer  210  and the second layer  140 . Additionally, the split-layer diaphragm  200  is still non-planar; however, now the split-layer diaphragm  200  includes an inwardly cupping convolute  202  formed by the annular convolute  120  of the first layer  110 , the annular convolute  150  of the second layer  140  and an annular convolute  220  of the third layer  210  (see  FIG. 15 ). 
     In some embodiments, the third layer  210  is formed from a material suitable for handling fluid compatibility issues. For example, the third layer  210  may be formed from PTFE, a TPE, a TPV, such as Santoprene, or a thermoplastic polyester elastomer such as Hytrel to provide a range of compatibility suitable for various working fluids, including highly acidic fluids, highly basic fluids, and fluids with particulate contamination (e.g., ceramic particulate). 
     Then, the first layer  110  and the second layer  140  (or any number of layers disposed interiorly of the third layer  210 ) can provide strength for the split-layer diaphragm  200 , such as via the constructions described above in connection with split-layer diaphragm  100  (e.g., by forming layers  110  and  140  from a 40D Santorpene). However, in the depicted embodiment, the first layer  110  and second layer  140  of the split-layer diaphragm  200  might have reduced thicknesses as compared to the constructions of split-layer diaphragm  100  (so that split-layer diaphragm  100  and split-layer diaphragm  200  can both fit within pumping assemblies  56  and  56 ′ of identical dimensions). That said, in other embodiments, the thicknesses of first layer  110  and second layer  140  may vary based on the pump in which they are included, the number of layers included in split-layer diaphragm  200 , or any other number of factors. 
     As can be seen in  FIGS. 11 and 12 , the split-layer diaphragm  200  is secured within glands  640  and  760  in a similar manner to split-layer diaphragm  100 ; however, now, the third layer  210  engages the front geometries of these glands. Specifically, as can be seen in  FIG. 11 , the third layer  210  includes an exterior cap  222  configured to extend over the exterior cap  122  of the split-layer diaphragm  100  in an arcuate manner. Thus, a rounded portion of the exterior cap  222  can be compressed into and seal against a V-shape defined by the front gland geometry  642  of the pump head  64 . Additionally, the exterior cap  222  wraps around the exterior cap  122  and extends back over the tops of both the exterior cap  122  of the split-layer diaphragm  100  and the exterior cap  152  of the second layer  140 . This may ensure that the third layer  210  covers any fluid incompatible layers of split-layer diaphragm  200  (e.g., layers  110  and  140 ) and protects these layers, as well as fluid washer  276 , from damage (e.g., corrosion) that might be caused by a working fluid, such as a basic, acidic, or particulate carrying working fluid. 
     Meanwhile, as can be seen in  FIG. 12 , the third layer  210  includes an interior cap  212  configured to extend over the interior cap  112 ′ of the split-layer diaphragm  100 . In the depicted embodiment, the interior cap  112 ′ is sharper than the interior cap  112  included in the embodiment of  FIGS. 2-9  and, thus, may secure the first layer  110  to the third layer  210 . Additionally, the interior cap  112 ′ may compress the interior cap  212  of the third layer  210  into a V-shape defined by the front gland geometry  762  of the fluid washer  76 . Thus, the interior cap  212  may seal interior gland  760  and protect the interior sections of first layer  110  and the third layer  210  from a potentially damaging fluid. In fact, in the depicted embodiment, the specific geometries of the interior cap  112 ′ and the interior cap  212  may generate a high sealing pressure without requiring an excessive closing force, which may minimize the pre-load applied to the bolt  80  during assembly of the pumping assembly  56 ′. 
     Notably, in the depicted embodiment, both the interior gland  760  and the exterior gland  640  are each closed around the split-layer diaphragm  200  via metal-to-metal joints. That is, the interior and exterior sections  204 ,  206  of the split-layer diaphragm  200  are secured within their respective glands  640 ,  760  and do not extend out of their respective glands  640 ,  760  to be secured between the pump head  64  and base  62  or between washers  276  and  78 . This avoids stressing the split-layer diaphragm  200  while also eliminating leakage issues that are encountered when a diaphragm material secured between metal components. 
     Now turning to  FIGS. 16-18 , as mentioned, in some embodiments, at least one layers of the split-layer diaphragms presented herein (e.g., layers  110  and  140 ) may be formed from multiple parts. For example, one or more layers of a split-layer diaphragm may be composite constructions formed from a reinforcement encapsulated within a matrix. The reinforcement can be a fabric or pseudo-fabric material and, in some forms, can be formed from two fabric or pseudo-fabric materials with offset weave patterns. An offset may provide improved stiffness in every direction as compared to a non-offset construction. 
     Generally, with the composite constructions presented herein, a reinforcement can be encapsulated within a matrix (e.g., a TPE/TPV material) via an injection molding process or compression molding process. Additionally or alternatively, the reinforcement can made of fabric, pseudo-fabric reinforcements, and/or a TPE material such as TPV and can be installed into a more elastic, lower modulus TPE/TPV&#39;s matrix. This may improve the resiliency of the matrix so that the composite construction can withstand larger pressure differentials, but without degrading the ability of the matrix material to respond to actuations of a pressure stroke. 
     Furthermore, in at least some embodiments, a fabric or pseudo-fabric reinforcement can be made of a material that is similar or bondable to the material used to form the matrix (e.g., overmolded TPE/TPV), which may be selected based on the specific application for which the split-layer diaphragm including the composite construction is intended. When the materials have a similar polymer chemistry, the materials can form a thermomechanical bond during a molding process (e.g., during an overmolding process). For example, a polypropylene (PP) fabric or pseudo-fabric reinforcement can be overmolded and encapsulated by a PP based TPV (e.g. Santoprene). The PP can be stiffer than the TPV thus acting like a net/support for the composite construction. 
       FIG. 16  illustrates a first example of a composite construction  300 . In composite construction  300 , a reinforcement  302  is arranged in a unique pattern within a matrix  304 . Specifically, the reinforcement (e.g., a pseudo-fabric) is arranged in a spider web shape, radiating from a center. This strengthens the composite construction in a radial direction, which provides improved stiffness across the entire composite construction  300 , instead of only stiffening specific areas of the construction (which may occur, for example, when a rectangular pattern applied to a circular layer). However, composite construction  300  is merely an example and, in various embodiments, the reinforcement  302  can be defined in any unique and/or uncommon patterns that are conducive for managing the stress profile experienced by a diaphragm. 
     Regardless of the specific pattern, a variety of materials can be used to ensure reinforcement  302  acts to reinforce the strength of the matrix  304  and these materials can be arranged in manner similar to how fabrics are woven. For example, when the reinforcement  302  is a fabric, the reinforcement can have any variety of woven characteristics such as a 2-D or 3-D woven fabrics, knitted fabrics, stitched fabrics, braids, nonwovens, and multiaxial fabrics. However, to achieve the strength reinforcement, the reinforcement  302  can be molded in this woven arrangement. Moreover, some embodiments may include one or more layers of reinforcement  302  (e.g., fabric and/or pseudo fabric). For example, in one non-limiting form two layers of fabric, with an offset of 45 degrees between the weave patter, can be stacked atop one another prior to a molding process. 
     Additionally or alternatively, the reinforcement  302  can be located at any variety of depths within the thickness of the matrix  304 . For example, in some forms the reinforcement  302  extends through the matrix  304  in a position where a portion of the reinforcement  302  is located on one side of the composite construction  300  and another portion of the reinforcement  302  is located on the opposing side of the composite construction  300 . 
     One example of a thermoplastic fabric is illustrated in  FIG. 17 . As can be seen, the thermoplastic fabric  306  may include a weave pattern  308  that resembles a weave pattern that may include in conventional fabrics and, thus, may have increased strength, at least as compared to a TPE. However, thermoplastic fabric  306  is merely one example material that may be used as reinforcement  302  and, regardless of the exact form of the reinforcement  302 , the reinforcement  302  (e.g., fabric) can provide additional strength to the matrix  304  (e.g., TPE). Some specific examples of the composite strength layer include polypropylene (PP) and UHMWPE based fabrics bond with TPE and polyethylene terephthalate/polybutylene terephthalate (PET/PBT) based fabrics with copolyester elastomer (COPE) TPEs. Partially fluorinated fabrics bond with flexible polyvinylidene fluoride (PVDF) or Solmyra (Fluorinated TPE) available from Solvay of Bruxelles, Belgium, are also suitable materials. 
     Regardless of the exact composition, the composite construction  300  may, in some embodiments, be formed via an injection molding process. For example, the reinforcement  302  can be held in place via retracting core pins during a molding process to achieve a precise orientation within the matrix  304 . Thus, processing the reinforcement  302  (e.g., fabric or pseudo-fabric) can include forming the reinforcement  302 , placing the reinforcement  302  into a mold, capturing the reinforcement  302  within the mold with core pins, injecting the mold with the matrix  304  material, and curing the composite construction  300  prior to removal of the core pins. Alternatively, the core pins may be retained within the overmolded composite construction  300 . 
     As another example, the composite construction  300  may, in some embodiments, be formed via a compression molding process. In such a process, the matrix  304  (e.g., TPE/TPV) can be extracted and clamped within a mold which also includes the reinforcement  302 . Then, compressive pressure may be applied prior to removing the newly formed composite construction  300  from the mold. 
     Now turning to  FIG. 18 , another example composite layer  400  is formed by overmolding a first material  402  (i.e., matrix  402 ) over and around a layer of material  404  (i.e., reinforcement  404 ). Materials suitable for the construction illustrated in  FIG. 18  can, in addition to those mentioned above, include polypropylene, polyethylene, polyamide, polycarbonate (PC,) acrylonitrile butadiene styrene (ABS), an ionomer resin such as Surlyn available from E.I. Du Pont De Nemours of Midland, Mich., and UHMWPE based laminates bond with TP. In addition, PET, PBT, PC+PBT alloy based laminates bond with COPE TPEs. Further, fluorinated polymers such as PVDF, tetrahydrocannabivarin (THV), ethylene chlorotrifluoroethylene (ECTFE), ethylene tetrafluoroethylene (ETFE), polychlorotrifluoroethylene (PCTFE), fluorinated ethylene propylene (FEP), or perfluoroalkoxy alkanes (PFA) laminates bond with flexible PVDF or Solmyra (Fluorinated TPE). Still yet further, thermoplastic polyurethanes, PVDF, THV, ECTFE, ETFE, PCTFE laminates bond with Capien (Fluorinated thermoplastic polyurethane (TPU)). 
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. 
     Additionally, in reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary. Furthermore, unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.