Patent Publication Number: US-2021190062-A1

Title: Liquid pump and related systems and methods

Description:
RELATED APPLICATIONS 
     This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/951,513, filed Dec. 20, 2019, and entitled “Liquid Pump and Related Systems and Methods,” which is incorporated herein by reference in its entirety for all purposes. 
    
    
     GOVERNMENT SPONSORSHIP 
     This invention was made with Government support under Contract No. Army W31P4Q-18-1-0001 awarded by DARPA. The Government has certain rights in the invention. 
    
    
     TECHNICAL FIELD 
     Liquid pumps and related systems and methods are generally described. 
     SUMMARY 
     The present disclosure is generally directed to liquid pumps and related systems and methods. Certain of the pumps described herein comprise a plurality of leaves that define a cavity into which a liquid-containing, deformable reservoir has been placed. In some embodiments, at least one intraleaf space is expanded using a working fluid such that liquid is expelled from the deformable reservoir. In some embodiments, the portion(s) of the liquid pump wetted by the liquid being dispensed is disposable. 
     The subject matter of the present invention involves, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of one or more systems and/or articles. 
     Certain aspects are related to devices. In some embodiments, the device comprises a first leaf comprising a rigid surface, a deformable surface, and a space between the rigid surface and the deformable surface; and a second leaf connected to the first leaf; wherein the first leaf and the second leaf define a cavity into which a deformable, liquid-containing reservoir can be positioned. 
     Some aspects are related to methods of expelling liquid from a deformable reservoir positioned between a first leaf and a second leaf. In some embodiments, the method comprises transporting a working fluid into a space between a rigid surface of the first leaf and a deformable surface of the first leaf such that the volume of the space is expanded and liquid is expelled from the deformable reservoir. 
     Other advantages and novel features of the present invention will become apparent from the following detailed description of various non-limiting embodiments of the invention when considered in conjunction with the accompanying figures. In cases where the present specification and a document incorporated by reference include conflicting and/or inconsistent disclosure, the present specification shall control. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying figures, which are schematic and are not intended to be drawn to scale. In the figures, each identical or nearly identical component illustrated is typically represented by a single numeral. For purposes of clarity, not every component is labeled in every figure, nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention. 
         FIG. 1  is, according to certain embodiments, a cross-sectional schematic illustration of a system that can be used to pump fluid. 
         FIG. 2  is, according to some embodiments, a perspective view of an open pump with a single deformable surface in one of the leaves. 
         FIG. 3  is, according to some embodiments, a cross sectional view of a pump with a single deformable surface in one of the leaves. 
         FIG. 4  is, according to some embodiments, a perspective view of an open pump with a two deformable surfaces, one on each leaf. 
         FIG. 5  is, according to some embodiments, a cross sectional view of a pump with two deformable surfaces. 
         FIG. 6  is, according to some embodiments, a perspective view of a closed pump. 
         FIG. 7  is, according to some embodiments, a perspective view of a deformable reservoir. 
         FIG. 8  is, according to some embodiments, a perspective view of a deformable reservoir that includes a valve. 
         FIGS. 9A-9C  are, according to some embodiments, pictures of a deformable reservoir, a deformable reservoir containing colored liquid, and a deformable reservoir containing liquid and placed over a pump leaf. 
         FIG. 10  is, according to some embodiments, a picture of three open pumps with respective filled deformable reservoirs. 
         FIG. 11  is, according to some embodiments, a cross sectional view of a pump that includes items for operation of a valve embedded in the deformable reservoir. 
         FIG. 12  is, according to some embodiments, a schematic of a reaction scheme. 
         FIG. 13  is, according to some embodiments, a schematic of a reaction scheme. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure relates to a method and a device to pump fluids. In some embodiments, the pump comprises a deformable reservoir that contains the fluid to be dispensed. In certain embodiments, the reservoir is located within a cavity defined by at least two leaves connected together. As would be understood by those of ordinary skill in the art, in the context of the present disclosure, “leaf” (plural, “leaves”) refers to a solid body that is capable of being positioned such that it faces another solid body (e.g., another leaf). In some embodiments, at least one of the leaves comprises a rigid surface and a deformable surface. The deformable surface of the leaf (or of the leaves) can face the exterior of the deformable reservoir. In certain embodiments, the pump further comprises a fluidic connection from outside the pump to a space between the rigid surface of the leaf and the deformable surface of the leaf. The space between the rigid surface of the leaf and the outer surface of the leaf is also described herein as the “intraleaf space.” In some embodiments, fluid can be pumped out of the deformable reservoir by pumping a working fluid into the intraleaf space. Pumping the working fluid into the intraleaf space can cause the intraleaf space to expand, which in turn applies pressure to the deformable reservoir causing fluid to be expelled from the deformable reservoir. 
       FIG. 1  is a cross-sectional schematic illustration of a system that can be used to pump fluids, in accordance with certain embodiments. In  FIG. 1 , the system comprises a deformable reservoir  100  containing fluid  105  to be dispensed. Reservoir  100  is inserted into a pump comprising first leaf  102 A and second leaf  102 B. The first and second leaves can be connected to each other. For example, as illustrated in  FIG. 2  and  FIG. 4 , first leaf  102 A is connected to second leaf  102 B via hinge  200 . The first and second leaves can form a clam shell form factor, according to some such embodiments. 
     In some embodiments, at least one of the two leaves comprises a rigid surface and a deformable surface. For example, in  FIG. 1 , leaf  102 A comprises rigid surface  103 A and deformable surface  101 A. Optionally, leaf  102 B may also comprise a rigid surface and a deformable surface. For example, in  FIG. 1 , leaf  102 B comprises deformable surface  101 B and rigid surface  103 B. The rigid surface and the deformable surface within a leaf define the intraleaf space. For example, in  FIG. 1 , leaf  102 A comprises intraleaf space  108 A and leaf  102 B comprises intraleaf space  108 B. 
     In accordance with certain embodiments, to dispense fluid from the pump, a working fluid is pumped (e.g., using external means, such as a pump) into the intraleaf space. The pressure of this working fluid can be transferred through the deformable surface to the deformable reservoir, squeezing the deformable reservoir, and thus dispensing fluid. For example, referring to  FIG. 1 , in some embodiments, a working fluid is pumped into intraleaf space  108 A, resulting in the application of pressure to deformable reservoir  100  and the movement of fluid  105  from within deformable reservoir  100  out of deformable reservoir  100  via exit  240 . 
     In one embodiment, the second leaf has a concave contour to house the deformable bag. In some such embodiments, the second leaf also contains a second deformable surface to better brace the dispensing bag during pump operation. 
       FIG. 3  is, according to some embodiments, a cross sectional view of a pump with a single deformable surface  101 A in one of the leaves ( 102 A). In this embodiment, second leaf  102 B does not include a deformable surface, but rather, has only a rigid surface ( 103 B). The embodiment in  FIG. 3  also show retaining features  210 , which can be used to fasten deformable surface  101 A. 
       FIG. 4  is, according to some embodiments, a perspective view of an open pump with two deformable surfaces  101 A and  101 B, one on each of the leaves  102 A and  102 B. In the embodiment shown in  FIG. 4 , deformable surface  101 A is connected using a retaining ring  210 . Deformable surface  101 B can be glued to leaf  102 B, in some embodiments. The embodiment shown in  FIG. 4  also includes additional features  220  embedded in leaf  102 A to provide valve action. 
       FIG. 5  is, according to some embodiments, a cross sectional view of the embodiment shown in  FIG. 4 .  FIG. 5  also shows port  230 A used to access the intraleaf space  108 A between leaf  102 A and the deformable surface  101 A. 
       FIG. 7  is, according to some embodiments, a perspective view of a deformable reservoir. In  FIG. 7 , the deformable reservoir comprises inlet/outlet tubing  240 . 
       FIG. 8  is, according to some embodiments, a perspective view of a deformable reservoir that includes an area  250  that, when compressed, provides valve action by stopping the flow of liquid. 
       FIG. 11  is, according to some embodiments, a cross sectional view of a pump that include items  220  for operation of a valve embedded in the deformable reservoir by external actuator  280 .  FIG. 6  is a perspective view schematic illustration of a pump in which the pump is fastened using external actuator  280 . 
     Prototypes of the pumps have been used to achieve pumping pressures of 1 MPa. Generally, it is believed that the maximum pressure than can be achieved will depend on the specifics of the design (e.g., material thicknesses, properties, etc.) and will not depend on the general concepts disclosed herein. In some embodiments, the pump can be configured to achieve a pumping pressure of at least, 2 MPa, at least 10 MPa, or at least 50 MPa (and/or, in some embodiments, a pumping pressure of up to 1 MPa, up to 100 MPa, or more). 
     Any of a variety of materials can be used to make the leaves. In some embodiments, all or a portion of the leaves are made of metal, plastic, or combinations of these. Generally, the material from which the leaves are made are selected to be able to withstand the desired pressure of operation. In some embodiments, all or a portion of the leaves are made of aluminum. 
     The leaves may be made using any of a variety of manufacturing techniques, including but not limited to milling, molding, 3D printing, and combinations of these. 
     Generally, the leaves are fastened to each other in a manner that allows the pump to withstand the desired applied pressure. In some embodiments, the leaves are fastened using a latch  280  with a pin (e.g., to form a hinge). This type of fastening arrangement can allow for quick access to the interior of the pump while allowing the pump to withstand a relatively large pressure. Depending on various factors (such as pressurization level), other fastening methods could also be used. For example, in some cases, the leaves can be bolted together, which can be useful, for example, for more durable operation. Other fastening methods include, but are not limited to, adhesive fastening (e.g., using epoxy), thermal bonding, magnetic coupling, mechanical latching or fastening, and the like. 
     In some embodiments, pressurization of the deformable reservoir ( 100 ) occurs when a working fluid is introduced into the intraleaf space. The working fluid can be any of a variety of different fluids. In some embodiments, the working fluid is an inert fluid. The use of an inert fluid can provide increased safety of operation. Non-limiting examples of working fluid include gases (e.g., air, nitrogen, argon, and the like) and liquids (e.g., water, oil, and the like). 
     In some embodiments, removal/depressurization of the working fluid allows for stopping of the pumping action and/or replacement/reloading of the deformable reservoir. 
     In some embodiments the working fluid can be quickly pressurized and depressurized or its pressure can be modulated according to a specific pattern. This can be done to achieve benefits in addition to the dispensing of fluid, non-limiting examples of which include mixing of the fluid present in the deformable reservoir and/or oscillatory flow pumping. In some embodiments in which mixing is performed, the deformable reservoir contains two or more different fluids (e.g., which may be loaded into and/or removed from the deformable reservoir by utilizing one port or multiple ports). 
     Inflow and outflow of the working fluid (into and out of the intraleaf space, respectively) can be achieved using one or more ports. The specifics of the fluidic scheme for the working fluid do not alter the generality of the concepts disclosed herein. 
     In some embodiments, the maximum operating pressure of the working fluid is close to the maximum dispensing pressure of the pump. In some embodiments, the working fluid pressure within the intraleaf space can be set to a negative value (with respect to atmospheric reference pressure). Operating the pump in this way can allow for refilling of the deformable reservoir. 
     Different fluidic schemes, with or without valves, and with one or more pressure sources, may be deployed to achieve specific pumping operation. For instance, a scheme may involve only dispensing once from a deformable reservoir, and hence a single source is used. In some embodiments, valves may be added to relieve the pressure of the working fluid prior to opening the pump to replace the deformable reservoir. As another non-limiting example, a scheme may require dispensing the fluid in the deformable reservoir and then refilling it. In some such embodiments, the working fluid is first pressurized inside the pump, and then its pressure is relieved and then taken to a negative pressure value for a refilling operation. 
     In accordance with some embodiments, the deformable reservoir contains (e.g., is filled with) liquid to be dispensed by the pump. The deformable reservoir can have any of a variety of different shapes. In some embodiments, when empty, the deformable reservoir can appear as circular, rectangular, oval, square, or any other shape. In some embodiments, the deformable reservoir has a single port that is used as both an inlet and an outlet. In other embodiments, the deformable reservoir has more than one port (e.g., a first port used as an outlet and a second port used as an inlet). In one embodiment, the pump has only a single inlet, which is used as both an inlet and an outlet. 
     In some embodiments, the deformable reservoir is filled with the liquid through the inlet of the pump. In some such embodiments, when the pump is later pressurized, the liquid flows out the same path in which it entered. Other embodiments may have a deformable reservoir with two, or three, or more input/output ports (as may be required by a specific application). 
     The deformable reservoir may include, in some embodiments, other features such as valves, check valves, specific areas for sensor installation, and the like. Any of these additions may provide additional features to complement and enhance the final product. 
     In some embodiments, valves (e.g., embedded in the deformable reservoir or not embedded in the deformable reservoir (i.e., external valves)) may be used to operate more than one pump at the same time to achieve specific operating scenarios. In some embodiments, multiple pumps can be operated to achieve continuous flow. For example, in some such embodiments, one pump can be refilled with the second pump is dispensing, and vice versa. 
     The deformable reservoir may be made of any of a variety of different materials. Generally, the deformable reservoir is made of a material that ensures that the reservoir can be squeezed or otherwise deformably compressed. Examples include but are not limited to polymers, metals, and the like. In some embodiments, the deformable reservoir is made of polymeric material. The polymeric material can be, in some embodiments, in the form of a polymer film. Polymers can be of a variety of different types. Examples include, but are not limited to, perfluorinated polymers (e.g., Polytetrafluoroethylene (PTFE), Ethilene Tetrafluoroethylene (ETFE), Fluorinated ethylene propylene (FEP), Polychlorotrifluoroethylene (PCTFE), chlorotrifluoroethylene (CTFE), Polyvinylidene fluoride (PVDF), etc), polypropylene, polyethylene, and the like. The reservoirs can also be made with thin metal films, for instance aluminum foil or other foils adequately thin to be able to be deformed. Bonding between layers of polymer can be achieved using a variety of methods. For example, in some embodiments, bonding between layers of polymer can be achieved using heat based adhesion and/or with the addition of chemicals (e.g., an adhesive such as a glue, or solvent). 
     For chemical applications, in some embodiments, the utilization of thermoplastic perfluoro-polymers can yield a very chemically stable substrate that can be deployed with a large variety of aggressive media. 
     The deformable surface can be made, for example, with elastomers, polymers, metals, or combinations of these materials. In some embodiments, the use of materials with good elastic behavior can be advantageous, for example, because of the large deformation they can withstand. Non-limiting examples of such materials include Neoprene, natural rubber, Viton, Buna, Aflas, Silicon rubber, Santoprene, and the like. In accordance with some embodiments, the deformable surface can be fastened onto the leaf in any of a variety of ways. Non limiting examples include mechanical fastening (with or without a retaining structure, such as a ring), adhesion (e.g., using glue or another adhesive), mounting the deformable surface on a support structure that is fully constrained when the pump is closed, among others. The thickness on the deformable surface will generally depend on the specific material selected and its mechanical properties, together with the specification stemming out from the intended use of the pump. In some embodiments, thicknesses can be as little as 1 micron and as much as 5 millimeters. Other thicknesses could also potentially be used. 
     Certain of the embodiments disclosed herein can provide one or more advantages. The dispensable liquid is, in accordance with certain embodiments, fully encapsulated in the deformable reservoir, thus preventing gasses from dissolving into the liquid during operation. The deformable reservoir concept also allows for disposability, in some embodiments. For example, in some embodiments, the wetted parts (i.e., those parts that contact the pumped liquid(s)), are entirely interchangeable without any alteration to the rest of the pump. 
     In accordance with certain embodiments, the pump is able to produce a stable flow with minimal or no oscillations of flow rate. 
     Some applications may require a metering function, which can be achieved in a variety of ways using certain of the embodiments described herein. Examples of ways to control flow rate include: use of a mass flow meter, a proportional valve with an inline flow sensor, or calculation of the pressure drop downstream of the pump (which would dictate the flow rate for the assigned pressure of the fluid used to pressurize the pump), adjustment of the pressure of the working fluid. In accordance with certain of the embodiments disclosed herein, the pump is not a metering pump itself, and hence, flow rate can be adjusted for each application with other known means. 
     In accordance with certain embodiments, during operation, the deformable reservoir is mechanically braced by a second deformable surface associated with the second leaf. This bracing action can, in certain cases, allow the deformable reservoir to be used at elevated pressures, even when the deformable reservoir is made of a thin material (which might only allow a low pressure rating of the deformable reservoir when it is outside of the pump cavity). In some such embodiments, the deformable reservoir does not need to be designed to withstand, when outside of the pumping system, the pressure of operation deployed when inside the pumping system. 
     In accordance with certain embodiments, the material from which the deformable reservoir is made and the material from which the deformable wall of the leaf (or leaves) is made act as two degrees of separation between the process liquid to be dispensed and the working fluid used for dispensing. This isolation can, in certain cases, render certain of the embodiments described herein suitable for use with liquids that need containment. Non-limiting examples of liquids one might wish to dispense but that may require well-controlled containment are: aggressive or toxic liquids and liquids that need to be isolated (e.g., to avoid external contamination). Because the liquids never directly contact the enclosure, in accordance with certain embodiments, a wider variety of materials can be used. Over the long term, this can allow for a higher production rate and lower cost. 
     Another advantage, in accordance with certain embodiments, is that the pump can be commercialized as a low cost pump. For example, the leaves can, in accordance with certain embodiments, be made with low cost injection molded materials. The deformable reservoirs can also be configured to be disposable and/or low cost, in accordance with certain embodiments. These features, together with the ability to resist to harsh chemicals, can make certain of the pumps described herein suitable for chemical laboratories both for research and development and for teaching laboratories. It is believed that applications in the field of flow chemistry would benefit from the availability of this type of tool, as current pump products are expensive. 
     Generally, the pumps described herein can run individually or can work in series together. Linking together the outlet lines of multiple pumps can allow for complete customization of pumping. In some embodiments in which multiple pumps are used, different pressures can be used for different pumps. In certain embodiments in which multiple pumps are used, each pump could contain the same fluid, or different pumps could each have their own type of fluid. The use of multiple pumps, in accordance with certain embodiments, can allow for large changes in delivered flow rates (e.g. large increases and/or large decreases, potentially over very short periods of time). In addition, in some embodiments, the addition of each additional pump adds another layer of combinations for a given application. 
       FIGS. 9A-9C  show examples of deformable reservoirs, in accordance with certain embodiments. The reservoirs shown in  FIGS. 9A-9C  are in the form of a cartridge.  FIG. 9A  shows an empty deformable reservoir.  FIG. 9B  shows a deformable reservoir filled with red fluid.  FIG. 9C  shows a deformable reservoir inside an open pump. 
       FIG. 10  shows examples of 3 different pumps, each containing deformable reservoirs each with a different colored liquid. 
     U.S. Provisional Application No. 62/951,513, filed Dec. 20, 2019, and entitled “Liquid Pump and Related Systems and Methods” is incorporated herein by reference in its entirety for all purposes. 
     The following example is intended to illustrate certain embodiments of the present invention, but does not exemplify the full scope of the invention. 
     Example 
     This example describes the use of liquid pumps, in accordance with certain embodiments, in the context of a larger project aimed at designing a simple, robust, and low cost system capable of producing on-demand reagents using a combination of liquid and solid pods or cartridges. The systems included pumps, tubular reactors, valves, fittings, and chemical containers. 
     Pumps, in accordance with certain embodiments, have been used as pumps for this project. To demonstrate an application, on demand synthesis of Grignard reagents (Turbo Grignard) and (i-PrMgCl.LiCl) and Knochel-Hauser base derived from HMDS (HMDSMgCl.LiCl) were reiterated on the ODR prototype. Similar i-PrMgCl.LiCl yield (86%) was obtained with the scheme shown in  FIG. 12 , using optimized conditions established on commercial flow system. The synthesis utilizes both liquid reagents—pumped on demand with the described invention—and solid reagents immobilized on a cartridge. The cartridge included three solution bags (THF, activating solution and i-PrCl solution) and two tubular reactors (Mg chips/powder and LiCl) connected in-series. 
     In the case of HMDSMgCl.LiCl, the same cartridge configuration was used, using the scheme shown in  FIG. 13 , and slightly lower yield (83%) was obtained compared with the reaction performed on the Vapourtec flow system. This variation was attribute to unsteady flow rate produced by propane released during the reaction, thus affecting fluid dynamics and back pressure control. 
     Product purities, i-PrCl quantitative conversion, and yields were confirmed by NMR demonstrating the ability to safely produce high quality organomagnesium reagents on demand with the use of such a pumping system. 
     While several embodiments of the present invention have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the functions and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the present invention. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, the invention may be practiced otherwise than as specifically described and claimed. The present invention is directed to each individual feature, system, article, material, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, and/or methods, if such features, systems, articles, materials, and/or methods are not mutually inconsistent, is included within the scope of the present invention. 
     The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” 
     The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Other elements may optionally be present other than the elements specifically identified by the “and/or” clause, whether related or unrelated to those elements specifically identified unless clearly indicated to the contrary. Thus, as a non-limiting example, a reference to “A and/or B,” when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A without B (optionally including elements other than B); in another embodiment, to B without A (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc. 
     As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or” as defined above. For example, when separating items in a list, “or” or “and/or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of” or “exactly one of,” or, when used in the claims, “consisting of,” will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the claims, shall have its ordinary meaning as used in the field of patent law. 
     As used herein in the specification and in the claims, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc. 
     In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of” and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.