Patent Description:
For large scale industrial systems, the bed volume is so great compared to void volumes of liquid between columns that even elaborate valve systems involving extensive conduits do not interfere with the process. There has been a recent trend, however, in scaling SMB smaller to pilot and sub-pilot volumes, as the need for more sophisticated applications has arisen in the fine chemicals and pharmaceutical fields requiring gram to kilogram quantities of product.

<CIT>, <CIT>, <CIT>, <CIT> and <CIT> disclose background art. In particular, <CIT> discloses a valve block according to the preamble of claim <NUM>.

In an illustrative embodiment, an example valve block is disclosed. The valve block includes a fluid-transfer plate, a pressure plate, and a diaphragm disposed between the fluid-transfer plate and the pressure plate. Inlet channels are formed through the fluid-transfer plate and selectively opened or closed via the diaphragm by pressure applied to recesses on the pressure plate. The inlet and outlet bores of each fluid channel connect in a common inlet channel and outlet channel respectively. The sizing and number of inlet and outlet bores are selected to avoid deleterious deformation of the diaphragm and to control the pressure required to force fluid through the valve (back pressure). Accordingly, in one embodiment, an inlet channel may include four or more inlet bores, with each inlet bore being <NUM> (<NUM> inches) or less in diameter.

In another illustrative embodiment, an example valve block is disclosed. A valve block includes an inlet channel formed on a first surface of a fluid-transfer plate and an outlet channel formed on the first surface of the fluid-transfer plate. The valve block can also include a plurality of inlet bores each extending from the inlet channel to a second surface of the fluid-transferplate and a plurality of outlet bores each extending from the outlet channel to the second surface of the fluid-transfer plate. The valve block can further comprise a recess fillable with a pressurized material formed on a first surface of a pressure plate and a diaphragm disposed between the second surface of the fluid-transfer plate and the first surface of the pressure plate. The diaphragm is configured to prevent flow of a fluid from the plurality of inlet bores to the plurality of outlet bores if the recess is filled with the pressurized material. The diaphragm is further configured to allow flow of the fluid from the plurality of inlet bores to the plurality of outlet bores if the recess is filled with a material having a pressure less than a pressure of the fluid.

An illustrative valve block includes a pressure plate, a fluid transfer block, and a diaphragm. The pressure plate includes a pressure channel configured to receive a pressurized first fluid and a recess in a surface of the pressure plate. The pressure channel and the recess are fluidly connected. The fluid transfer block includes an inlet connection configured to receive a second fluid and an outlet connection. The fluid transfer block also includes a plurality of valve inlet bores each fluidly connected to the inlet connection. The plurality of valve inlet bores are distributed along at least part of a first circular shape. The fluid transfer block further includes a plurality of valve outlet bores each fluidly connected to the outlet connection. The plurality of valve outlet bores are distributed along at least part of a second circular shape. The first circular shape is within the second circular shape. The diaphragm is between the pressure plate and the fluid transfer block. The plurality of valve inlet bores and the plurality of valve outlet bores are adjacent to the recess.

An illustrative valve block includes a pressure plate, a fluid transfer block, and a diaphragm. The pressure plate includes a pressure channel configured to receive a pressurized first fluid and a recess in a surface of the pressure plate. The pressure channel and the recess are fluidly connected. The fluid transfer block includes an inlet connection configured to receive a second fluid and an outlet connection. The fluid transfer block includes a plurality of valve inlet bores each fluidly connected to the inlet connection and a plurality of valve outlet bores each fluidly connected to the outlet connection. The plurality of valve inlet bores are surrounded, at least in part, by the plurality of valve outlet bores. The diaphragm is between the pressure plate and the fluid transfer block. The plurality of valve inlet bores and the plurality of valve outlet bores are adjacent to the recess.

An illustrative valve block includes a pressure plate, a fluid transfer block, and a diaphragm. The pressure plate includes a plurality of pressure channels each configured to receive a pressurized first fluid and a plurality of recesses in a surface of the pressure plate. Each of the plurality of pressure channels are fluidly connected to one of the plurality of recesses. The fluid transfer block includes a plurality of inlet connections each configured to receive a second fluid and a plurality of outlet connections. The fluid transfer block further includes a plurality of valve inlet bore sets and a plurality of valve outlet bore sets. Each of the valve inlet bore sets comprises a plurality of valve inlet bores distributed along at least part of a first circular shape. Each of the valve inlet bore sets are fluidly connected to one of the plurality of inlet connections. Each of the valve outlet bore sets comprises a plurality of valve outlet bores distributed along at least part of a second circular shape. Each of the valve outlet bore sets is fluidly connected to one of the plurality of outlet connections. The diaphragm is between the pressure plate and the fluid transfer block. Each of the plurality of valve outlet bore sets corresponds to one of the plurality of valve outlet bore sets and one of the plurality of recesses. The first circular shape of one of the plurality of valve inlet bore sets is within the second circular shape of the corresponding one of the plurality of valve outlet bore sets.

Illustrative examples not being part of the claimed invention and embodiments of the invention will hereafter be described with reference to the accompanying drawings wherein like numerals denote like elements.

In designing specialized valve systems for controlling the scaled-down SMB applications, the present inventors have recognized several issues with the current valve designs. For example, typical valves that employ moving parts, such as rotary valves, encounter the problem that fluid and solute mixtures tend to have a deleterious effect on the reliability of moving parts and, therefore, on the reliability of the valves. As another example, systems that employ flexible diaphragms (or membranes) may also suffer reliability issues due to over-stretching of the diaphragm or contact between the diaphragm and edges/corners of structures on the plates. Further still, some valve systems generate unacceptably high pressure and/or fluid linear velocity at flow rates required for various applications.

Some applications for valve systems with a flexible diaphragm require flow rates and/or pressures that are higher than existing flexible diaphragm valve systems can accommodate. For example, existing diaphragm valve systems can have a maximum flow rate on the scale of milliliters per minute (e.g., up to <NUM> milliliters/minute (mL/min)) or <NUM> kPa (<NUM> pounds per square inch (psi)) fluid pressure. Various embodiments of the present disclosure can accommodate flow rates on the scale of liters per minute (e.g., <NUM> liters/minute (L/min)) and <NUM> MPa (<NUM> pounds per square inch (psi)) fluid pressure. For example, in an illustrative embodiment of the present disclosure, a valve block can be operated between ambient temperatures (e.g., <NUM>° Celsius (C)-<NUM>° C) and <NUM>° C with flow rates between <NUM>/min and <NUM>/min at fluid pressures up to <NUM> MPa (<NUM> pounds per square inch (psi)). An example fluid that flows through the valve block can have no suspended solids and can range from <NUM> centipoise (cP) to <NUM> cP viscosity. In some embodiments, the viscosity of the fluid can be greater than <NUM> cP. One specific example can be for monoclonal antibody (mAb) capture from a culture fluid on a production scale. In such an example, the valve block can be operated at flow rates between <NUM>/min and <NUM>/min with an aqueous process fluid with protein concentrations up to <NUM> milligrams/milliliter (mg/mL), with up to <NUM> molar (M) sodium chloride (NaCl), <NUM> sodium hydroxide (NaOH), and with pH values ranging from <NUM> to <NUM>.

This disclosure generally relates to systems, structures, and methods associated with fluid-transfer valves. In some embodiments, a group of valves is formed by sandwiching a pliant diaphragm between a fluid-transfer plate and a pressure plate. Each plate may be designed and machined to have specialized channels and bores to direct fluid flow. The fluid-transfer plate (which can also be referred to as the upper plate) contains at least two channels etched or otherwise formed into its flat upper surface, with each channel connecting to fluid connectors above the fluid-transfer plate. Multiple bores are machined or otherwise formed through the fluid-transfer plate, along the length of each of the channels to the flat lower surface of the fluid-transfer plate. In operation, a fluid may be introduced into one channel from one of the fluid connectors and, if a fluid valve associated with the channel is open, then the fluid may flow down through the bores to the lower surface of the fluid-transfer plate. On the lower surface of the plate, the flow is directed from the bores that connect to the first channel, through bores that connect with a second channel, and up into the fluid connector that connects to the second channel. The first channel acts as an inlet for the fluid and the second channel acts as an outlet.

The pressure plate, or lower plate (in some references the pressure plate may be referred to as the "upper pneumatic plate," "pneumatic plate," or "upper plate"), may contain recesses or dimples on its upper surface that can be positioned relative to the fluid-transfer plate such that each recess covers at least two bores on the bottom of the fluid-transfer plate. Each recess is coupled to a bore, which is operably coupled to a valve that directs the flow of pressurized material. When pressurized material is forced into a recess, the diaphragm between the plates is pushed against the bottom of the fluid-transfer plate, pressing the diaphragm over the bores covered by the recess. Such a state may be termed a valve-closed state, because the fluid flow between the covered bores is blocked or closed.

When pressure is removed from the material in the recess, the fluid in the bores may push the diaphragm down into the recess, creating a channel through which fluid may flow between the bores covered by the recess. During this valve-open state, fluid may flow from bores connected to one fluid connection to bores connected to another connector. Therefore, by controlling the pressure applied to the material in the recesses, a system may control the flow of fluid between different connections.

Such a valve block may be used in any fluid transfer or control application in which a fluid valve is required. An example of a system in which such a valve could be applied is described in more detail in <CIT>. For this and other references, features of any of the embodiments disclosed in the reference may be used in the described embodiments. Similar structures in each reference may be substituted with structures in another reference. In cases where the references disagree, the embodiments or language of the present disclosure will be controlling. Example Valve Control System.

With reference to <FIG>, a block diagram of a control system <NUM> is shown in accordance with an illustrative example. Control system <NUM> controls the operation of a valve system to direct the flow of fluid in a manner that simulates a moving bed. In some embodiments, control system <NUM> can be configured to control the operation of the valve system in accordance with any other fluid system comprising valves. Control system <NUM> implements a desired process by controlling the states (open or closed) of one or more valves of a valve block assembly and may also control the pumps that direct the flow of fluid into and out of the valve system. The components of control system <NUM> may be mounted to or otherwise connect to an electronics board in the valve system. Control system <NUM> may include an input interface <NUM>, an output interface <NUM>, a computer-readable medium <NUM>, a processor <NUM>, and a controller application <NUM>.

Different and/or additional components may be incorporated into control system <NUM>. For example, control system <NUM> may further include a communication interface. Components of control system <NUM> may be mounted to the valve system or mounted in a separate device or set of devices. As a result, the communication interface can provide an interface for receiving and transmitting data between the valve system and one or more additional devices hosting components of control system <NUM> using various protocols, transmission technologies, and media. The communication interface may support communication using various transmission media that may be wired or wireless. Thus, the components of control system <NUM> may be connected as appropriate using wires or other coupling methods or wirelessly and may be positioned locally or remotely with respect to the valve system.

Input interface <NUM> provides an interface for receiving user-input and/or machine instructions for entry into control system <NUM> as known to those skilled in the art. Input interface <NUM> may use various input technologies including, but not limited to, a keyboard, a pen and touch screen, a mouse, a track ball, a touch screen, a keypad, voice recognition, motion recognition, disk drives, remote controllers, input ports, one or more buttons, etc. to allow an external source, such as a user, to enter information into control system <NUM>. The valve system may have one or more input interfaces that use the same or a different interface technology.

Output interface <NUM> provides an interface for presenting information from control system <NUM> to external systems, users, or memory as known to those skilled in the art. For example, output interface <NUM> may include an interface to a display, a printer, a speaker, etc. The output interface <NUM> may also include alarm/indicator lights, a network interface, a disk drive, a computer memory device, etc. The valve system may have one or more output interfaces that use the same or a different interface technology.

Computer-readable medium <NUM> is an electronic holding place or storage for information so that the information can be accessed by processor <NUM> as known to those skilled in the art. Computer-readable medium <NUM> can include, but is not limited to, any type of random access memory (RAM), any type of read only memory (ROM), any type of flash memory, etc. such as magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips,. ), optical disks (e.g., compact disk (CD), digital video disk (DVD),. ), smart cards, flash memory devices, etc. The valve system may have one or more computer-readable media that use the same or a different memory media technology. The valve system may have one or more drives that support the loading of a memory medium such as a CD, a DVD, a flash memory card, etc..

Processor <NUM> executes instructions as known to those skilled in the art. The instructions may be carried out by a special purpose computer, logic circuits, or hardware circuits. Thus, processor <NUM> may be implemented in hardware, firmware, software, or any combination of these methods. The term "execution" is the process of running an application or the carrying out of the operation called for by an instruction. The instructions may be written using one or more programming language, scripting language, assembly language, etc. Processor <NUM> executes an instruction, meaning that it performs the operations called for by that instruction. Processor <NUM> operably couples with input interface <NUM>, output interface <NUM>, computer-readable medium <NUM>, controller application <NUM>, etc. to receive, to send, and to process information and to control the operations of the valve system. Processor <NUM> may retrieve a set of instructions from a permanent memory device such as a ROM device and copy the instructions in an executable form to a temporary memory device that is generally some form of RAM. The valve system may include a plurality of processors that use the same or a different processing technology. In an illustrative embodiment, the instructions may be stored in computer-readable medium <NUM>.

Controller application <NUM> includes operations that control the valve system and may provide a graphical user interface with selectable and controllable functionality to define the processes executed by the valve system. The operations may be implemented using hardware, firmware, software, or any combination of these methods. With reference to the illustrative embodiment of <FIG>, controller application <NUM> is implemented in software stored in computer-readable medium <NUM> and accessible by processor <NUM> for execution of the computer-readable instructions that embody the operations of controller application <NUM>. The computer-readable instructions of controller application <NUM> may be written using one or more programming languages, assembly languages, scripting languages, etc. The functionality provided by controller application <NUM> may be distributed among one or more modules and across one or more device. For example, controller application <NUM> may include a module that controls the opening and closing of one or more valves that is separate or integrated with a module that controls pump flow rates. Controller application <NUM> provides control signals to the plurality of electrical connectors, which connect to the valves as well as to the pumps associated with a plurality of pump connectors that apply pressure to fluid either entering the valve block at inlets <NUM> or <NUM> or exiting the valve block through outlets <NUM> or <NUM>. Although numbered fluid paths <NUM>-<NUM> are referred to as "inlets" and "outlets," the illustrated structure and orientation of the inlets relative to the outlets should not be seen as limiting the ways that inlets and/or outlets are implemented. In some cases, fluid paths may be equivalent or identical in structure, such that users may change which fluid path is used as inlet and which is used as outlet to the valve. In some embodiments, the changing from inlet to outlet may be automated.

To produce the controlling pressure in each fluid valve, a gas valve is connected to a reservoir of pressurized gas and to a vent. For example, with reference to <FIG>, a first gas valve 118a is shown connected to a first pressure reservoir 114a and a first vent 116a, and a second gas valve 118b is shown connected to a second pressure reservoir 114b and a second vent 116b. First pressure reservoir 114a and second pressure reservoir 114b may be the same or different. First vent 116a and second vent 116b may be the same or different. The one or more gas valves may be designed as normally open or may be designed as normally closed. Controller application <NUM> can be designed to support either method of valve operation. In an illustrative embodiment, the gas valves are normally closed and are switched at <NUM> volts. To reduce heat, the voltage applied to the gas valves may be stepped down to <NUM> volts or lower after switching while maintaining the state.

With further reference to <FIG>, a simplified cross sectional view of a portion of a valve block is shown connected to first gas valve 118a and to second gas valve 118b to illustrate the operation of the valve states. Pressure plate <NUM> includes a first recess 122a and a second recess 122b coupled to a first gas channel 124a and a second gas channel 124b, respectively. First gas channel 124a and second gas channel 124b operably couple to first gas valve 118a and to second gas valve 118b, respectively. Fluid-transfer plate <NUM> and top plate <NUM> include a first fluid channel (comprised of inlet <NUM> and outlet <NUM>) and a second fluid channel (comprised of inlet <NUM> and outlet <NUM>). As shown with reference to <FIG>, pneumatic pressure from second gas valve 118b applied to second recess 122b causes diaphragm <NUM> to stop the flow of fluid through the second fluid channel (i.e., from inlet <NUM> to outlet <NUM>). Pneumatic pressure released by first gas valve 118a through first gas channel 124a allows fluid pressure through the first fluid channel from inlet <NUM> to deflect diaphragm <NUM> into first recess 122a thereby allowing the flow of fluid through the first fluid channel from inlet <NUM> to outlet <NUM>.

Diaphragm <NUM> can be formed of a polymer that is sufficiently pliant to permit deflection when pneumatic pressure is relieved in a pressure channel, such as first gas channel 124a. Diaphragm <NUM> can be of a material chosen to be pliable, resistant to tearing and penetration, gas impermeable, and chemically resistant. For example, such deflection may be caused by fluid pressure from inlet <NUM>. In that case, the pressure in first gas channel 124a could be an ambient air pressure, for instance, so that only the fluid pressure in the first gas channel 124a causes the deflection, rather than suction in first gas channel 124a. In an illustrative embodiment, diaphragm <NUM> may be naturally formed in a substantially flat shape, such that the first recess 122a is closed in the absence of a pressure differential. In other cases, diaphragm <NUM> may be preformed and/or may be naturally biased in an open (recessed) position in first recess 122a. In an illustrative embodiment, diaphragm <NUM> may be formed of perfluoroalkoxy (PFA) copolymer resin having a thickness of <NUM> (<NUM> inches). Alternatively, other materials and/or thicknesses may be used. In another illustrative embodiment, diaphragm <NUM> can be made of fluorinated ethylene propylene (FEP) copolymer resin.

Although some aspects of controlling a valve system are shown in <FIG>, other aspects of an illustrative valve control system may be found in <CIT>. Example Valve Block #<NUM>.

<FIG> shows an exploded view of a valve block <NUM> according to an illustrative example. As shown, valve block <NUM> includes top plate <NUM>, fluid-transfer plate <NUM>, and pressure plate <NUM> with various passages, grooves, channels, and bores disposed in the plates. A diaphragm that is functionally similar to diaphragm <NUM> in <FIG> (discussed in greater detail below) is omitted in <FIG> for clarity. As will be shown with reference to <FIG>, top plate <NUM>, fluid-transfer plate <NUM>, pressure plate <NUM>, and a diaphragm, may be joined to form a functional valve block.

Top plate <NUM> of valve block <NUM> has bores formed therethrough, which align with features of fluid-transfer plate <NUM> and/or pressure plate <NUM>. For example, bore <NUM> may align with corresponding bores through top plate <NUM> and pressure plate <NUM> to provide a cavity through which structural supports may be placed. As another example, bore <NUM> and bore <NUM> may provide fluid passages for receiving and expelling fluids to/from valve block <NUM>. In particular, bore <NUM> and bore <NUM> may be aligned with channel <NUM> and channel <NUM>, respectively, which are cut or otherwise formed in fluid-transfer plate <NUM>. In use, then, fluid may enter the valve block through one of bore <NUM> or bore <NUM> and be input into channel <NUM> or channel <NUM>.

Top plate <NUM>, fluid-transfer plate <NUM>, and/or pressure plate <NUM> can be made of any material that is inert and structurally rigid enough for the valve block <NUM> to form the necessary seals between the various plates. Bore <NUM> can be used to create a compressive force between top plate <NUM>, fluid-transfer plate <NUM>, and pressure plate <NUM>. Bore <NUM> can also be used to align the various plates and prevent one or more of the plates from creeping out of place after initial alignment. For example, top plate <NUM> can be made of stainless steel. In some embodiments, top plate <NUM>, fluid transfer plate <NUM>, and/or pressure plate <NUM> can be made of material that is less structurally rigid and alternative methods can be used to create a compressive force between the various plates to form the necessary seals and prevent creeping. For example, a clamp can be used. In another example, a valve body housing can be used. In such embodiments, top plate <NUM>, fluid transfer plate <NUM>, and/or pressure plate <NUM> can be made of aluminum or plastic. If plastic is used, the plastic can be Class VI plastic that can be used in pharmaceutical processes and/or can be biocompatible. Examples of such plastics include polyetherimide (PEI), polycarbonate (PC), acetal copolymer, polypropylene (PP), polyether ether ketone (PEEK), perfluoroalkoxy (PFA), polysulfone (PSU), polyphenylsulfone (PPSU), cyclic olefin copolymer (COC), polytetrafluoroethylene (PTFE), etc. In some embodiments, top plate <NUM>, fluid transfer plate <NUM>, and pressure plate <NUM> can all be made of the same or similar material. In other embodiments, the various plates can have materials of construction that vary from one another.

Additionally, the surfaces of top plate <NUM>, fluid-transfer plate <NUM>, and pressure plate <NUM> can be machined (or otherwise finished) to have a smooth finish. In some embodiments, the surface finish can have a roughness average (Ra) of <NUM> micrometers (<NUM> microinches). The smooth finish can be provided to create a seal where two plates touch. In some embodiments, instead of a smooth finish, a chemically compatible and/or biocompatible gasket can be used.

Fluid-transfer plate <NUM>, as will be shown in more detail in <FIG>, may include features for facilitating and controlling fluid flow through valve block <NUM>. As shown, fluid-transfer plate <NUM> may include channel <NUM> and channel <NUM> that may function as common inlet or outlet channels for fluid from bore <NUM> and/or bore <NUM>. Though not shown in <FIG>, channel <NUM> and channel <NUM> may each connect to multiple bores that extend through fluid-transfer plate <NUM>. The combination of bore <NUM> and bore <NUM> with channel <NUM> and channel <NUM> (including the bores that extend from channel <NUM> and channel <NUM> through fluid-transfer plate <NUM>) may be considered functional implementations of inlet <NUM> and outlet <NUM> as shown in <FIG>.

Similarly, recess <NUM> and recesses <NUM>, formed in/on pressure plate <NUM>, may be considered implementations of the combination of first recess 122a and second recess 122b with first gas channel 124a and second gas channel 124b. As shown by recess <NUM>, some embodiments may include a single recess for controlling fluid transfer through all fluid paths from a set of inlet and outlet channels (e.g., <NUM> and <NUM>). As shown by recesses <NUM>, some embodiments may include a separate recess for controlling fluid transfer through each fluid path from a set of inlet and outlet channels (e.g., <NUM> and <NUM>). In either case, each of recess <NUM> or recesses <NUM> may be surrounded by a sealing structure <NUM> or sealing structures <NUM>. Although sealing structure <NUM> and sealing structures <NUM> are shown as grooves or channels around recess <NUM> and recesses <NUM>, other sealing structures may be used. The features of pressure plate <NUM> will be explained in more detail with respect to <FIG>.

<FIG> shows features of the top side of a fluid-transfer plate <NUM>. As shown, in addition to features for providing structural support (bores around the exterior of the plate), fluid-transfer plate <NUM> may include, for example, channel <NUM> and channel <NUM>. Also as shown, channel <NUM> and channel <NUM> may each include a widened area (<NUM> and <NUM>) for receiving fluid into the channel. Although widened area <NUM> and widened area <NUM> are shown at opposite ends of channel <NUM> and channel <NUM>, fluid receiving structures may be placed anywhere along the fluid channels, and need not be limited to a slight rounding and widening of the channel. In some cases, no alteration is necessary for receiving fluid into a channel. Although fluid-transfer plate <NUM> shows two sets of inlet and outlet channels, and fluid-transfer plate <NUM> shows three sets of inlet and outlet channels, any number of channels may be used in an illustrative embodiment. Additionally, sets of inlet and outlet channels may be shaped, oriented, and connected in ways other than those shown in the figures. As one alternative example, the inlet and outlet channels may be circular or semicircular shape and oriented in an annular arrangement with respect to one another. Many other alternatives are possible.

Along the length of channel <NUM> and channel <NUM>, bore <NUM> and bore <NUM> are formed to provide fluid flow paths through fluid-transfer plate <NUM>. As shown, bore <NUM> and bore <NUM> may be offset from the center of channel <NUM> and channel <NUM>, respectively. Such an offset may be useful in designing valves to transfer fluid at high rates, because the closer the inlet bores are to their respective outlet bore, the shorter the distance the fluid must travel. Additionally, if the pressure recesses for controlling the valves are similar in shape to first recess 122a and second recess 122b of <FIG>, then the offset bores would be more centrally located with respect to the pressure recess(es). In particular, when a pressure recess has a rounded and/or sloping shape, bores offset towards the center of the pressure recess would be located under a deeper portion of the recess than a bore in the middle of channel <NUM> or channel <NUM>. When open, a bore beneath a deeper recess may accommodate a faster flow rate because of the larger maximum open volume above the bore. However, in other embodiments, bore <NUM> and/or bore <NUM> may, alternatively, be formed in the center of channel <NUM> and channel <NUM>, respectively, or even formed offset to the outside of channel <NUM> and channel <NUM>.

The sizing of bores <NUM> and bores <NUM> is an important feature of present embodiments to optimize fluid flow and pressure drop. In typical fluid transfer systems, single larger bores are used to maintain a high flow rate by reducing the flow velocity and pressure drop across the valve. Insufficient flow area can result in unacceptable pressure drop and/or flow velocities high enough to cause turbulent flow and/or spontaneous vaporization ("flashing") of a fluid as fluid passes through the valve. However, the present inventors have recognized that such large-bore implementations may have inherent limitations in flexible-diaphragm based valve systems. If the bore diameter becomes too large, for example, physical damage and/or permanent deformation of the diaphragm can occur during operation. Physical damage may result in a breach or perforation of the diaphragm. Permanent deformation may result in a compromised (e.g., perforated) seal in a closed state or inability of fluid pressure to produce sufficient deflection of the diaphragm into the recess in the open state.

Because excessive permanent deformation of diaphragm <NUM> results in decreased performance of the valve block <NUM>, the bores <NUM> and bores <NUM> should be sized large enough such that sufficient flow is permitted, but sized small enough to prevent an unacceptable amount of permanent deformation of diaphragm <NUM>. Decreased performance of the valve can include a reduced flow rate, blocked flow, and/or unacceptably high pressure drop through the valve in an open state. Permanent deformation of diaphragm can be caused by a combination of pressure and temperature. For example, gas pressure in gas channel 124a (or gas channel 124b) can put stress on the elasticity of diaphragm <NUM> causing permanent deformation. That is, diaphragm <NUM> can be permanently deformed if the diaphragm <NUM> does not return to its original (or substantially original) shape under non-pressurized conditions. The extent of permanent deformation can be sufficient to prevent the diaphragm from fully deflecting into the recess under fluid pressure, therefore impinging upon and restricting fluid flow from inlet <NUM> to outlet <NUM>, resulting in increased flow velocity and pressure drop. In another example, if the temperature of the fluid contacting diaphragm is too high, diaphragm <NUM> can become permanently deformed by wearing down the elasticity of the diaphragm <NUM>. In particular, a combination of high fluid temperature and high gas pressure can cause an unacceptable amount of permanent deformation. As such, as the fluid temperature rises, the minimum gas pressure required to cause permanent deformation of diaphragm <NUM> falls.

The diameter size of the bores <NUM> and bores <NUM> can be a factor in determining pressure drop across the diaphragm <NUM> for a given flow rate. For example, if the diameter size of fluid inlet bores (e.g. <NUM>) is small, the fluid velocity can increase the pressure drop across the diaphragm <NUM>. In another example, if the outlet bores (e.g., <NUM>) are small, the outlet bores can restrict flow through the valve, creating higher fluid velocity and therefore a higher differential pressure across the valve at the diaphragm <NUM>. In yet another example, if the bores <NUM> or bores <NUM> are large, then the recesses <NUM> must accordingly be large. If the recesses <NUM> are too large, then the diaphragm <NUM> can experience deformation that exceeds the elasticity of the material. That is, the diaphragm <NUM> can be deformed in a manner such that the diaphragm <NUM> does not return to its original (or substantially original) shape under non-pressurized conditions.

<FIG> is a table that shows the results of an experiment regarding deformation of a diaphragm of a valve in accordance with an illustrative example. In the experiment, a test valve in accordance with the present disclosure was constructed having four identical rows, each with six different bore diameters. The six different bore diameters were <NUM> inches, <NUM> inches, <NUM> inches, <NUM> inches, <NUM> inches, and <NUM> inches (<NUM>, <NUM>, <NUM>, <NUM> <NUM>, <NUM>). Four identical diaphragms of <NUM> inch (<NUM>) thick PFA were used, each under different test conditions for twenty-four hours. The first test condition was at a temperature of <NUM>° C at <NUM> psi (<NUM> MPa). The second test condition was at a temperature of <NUM>° C at <NUM> psi. The third test condition was at a temperature of <NUM>° C at <NUM> psi. The fourth test condition was at a temperature of <NUM>° C at <NUM> psi (<NUM> MPa). After each test condition, the diaphragm was removed from the valve body and the deformation of the diaphragm corresponding to the various bores was measured using an analog height indicator. The average deformation of the diaphragm in inches corresponding to each bore diameter under each pressure and temperature condition shown in the table of <FIG>. Also shown in the table of <FIG> is the corresponding pressure increase due to the deformation calculated using an assumed flow rate of <NUM>/min of water at <NUM>° C through a valve having the corresponding bore diameter and with a recess depth of <NUM> inches (<NUM>).

As mentioned above, <FIG> shows the results under four different test conditions. For example, at a temperature of <NUM>° C and at a pressure of <NUM> psi, the diaphragm corresponding to the bore diameter of <NUM> inches (<NUM>) had an average deformation of <NUM> inches (<NUM>) and a <NUM> percent (%) increase in pressure. At the same temperature and pressure, the diaphragm corresponding to the bore diameter of <NUM> inches (<NUM>) had an average deformation of <NUM> inches (<NUM>) and a <NUM>% increase in pressure.

The present inventors have determined that pressure increases greater than <NUM>% are unacceptable and correspond to excessive permanent deformation of the diaphragm. The corresponding deformation ranges from <NUM> inches to <NUM> inches (<NUM> to <NUM>). An "unacceptable" amount of deformation is determined if the valve has either (A) an increase of pressure drop across the valve of greater than <NUM> MPa (10psi) at <NUM>/min of water at 20ºC or (B) permanent deformation of the diaphragm greater than <NUM>% of the original thickness of the diaphragm.

Because a slight amount of permanent deformation of the diaphragm <NUM> can be tolerated, large bore diameters can be used with less severe process conditions. For example, bore diameters of <NUM> (<NUM> inches) or more can be used with fluid pressures of <NUM> MPa (<NUM> psi) and with fluid temperatures of <NUM>° C for at least <NUM> hours without significant permanent deformation to the diaphragm <NUM>. However, if the fluid pressure is raised to <NUM> MPa (<NUM> psi), enough permanent deformation to the diaphragm <NUM> can occur to degrade the performance of the valve.

Another factor that can affect the permanent deformation of diaphragm <NUM> is the shape and depth of recesses <NUM>. In one embodiment, recesses <NUM> can be an oval shape. In other embodiments, recesses <NUM> can be circular. Depth of recesses <NUM> can also affect the permanent deformation of diaphragm <NUM> because if the depth is too deep, then deformation of the diaphragm <NUM> during operation of the valve can exceed an elasticity of the diaphragm <NUM>. In some embodiments, a depth of recesses <NUM> can be <NUM> (<NUM> inches (<NUM> mil)). In another embodiment, a depth of recesses <NUM> can be <NUM> (<NUM> inches (<NUM> mil)). In other embodiments, a depth of recesses <NUM> can be between <NUM> and <NUM> (<NUM> inches and <NUM> inches). In yet other embodiments, a depth of recesses <NUM> can be less than <NUM> (<NUM> inches) or greater than <NUM> (<NUM> inches).

In some embodiments, the shape of bores <NUM> and bores <NUM> can be circular. In other embodiments, the shape of bores <NUM> and bores <NUM> can be oval shaped. In yet other embodiments, the shape of bores <NUM> and bores <NUM> can be slot shaped. In some embodiments, the bores <NUM> and bores <NUM> can be chamfered. The shape of bores <NUM> and bores <NUM> can be any shape designed to minimize permanent deformation of the diaphragm at operating pressures and temperatures. The shape of bores <NUM> and bores <NUM> can further be designed such that there is a desired pressure drop and fluid velocity across the valve at the desired flow rate.

In the present disclosure, multiple smaller bores may be used rather than a single large bore, in combination with the other disclosed features and systems, in order to accommodate high flow rates without the limitations of large diameter bores. In an illustrative embodiment, each bore may have a diameter of less than <NUM> (<NUM> inches) and, in some embodiments, a diameter of <NUM> (<NUM> inches) or less. The valve block may employ multiple bores from a single fluid source and/or multiple bores leading to a single outlet. The example of <FIG> shows channel <NUM> and channel <NUM> having seven bores each. In some embodiments, a greater number of bores may be included in each channel in order to accommodate a faster flow rate and/or reduce pressure drop. In some embodiments, a greater number of bores may be provided that have a smaller diameter such that the valve can have a similar pressure drop and fluid velocity at a given flow rate to a valve with a fewer number of bores with a larger diameter. The embodiment of <FIG>, however, may be sufficiently optimized by utilizing seven bores of about <NUM> (<NUM> inches) in diameter, spaced about <NUM> (<NUM> inches apart) (from center of bore to center of bore) along the inlet or outlet channel (<NUM> or <NUM>) and a distance of about <NUM> (<NUM> inches) between one inlet bore and one outlet bore on the upper side of the fluid transfer plate. Channel <NUM> and channel <NUM> may be separated by about <NUM> (<NUM> inches) from the center of the channel <NUM> to the center of the channel <NUM> on the lower side of the fluid-transfer plate <NUM>.

<FIG> shows features of the bottom side of fluid-transfer plate <NUM> in accordance with an illustrative embodiment. As with the top side of fluid-transfer plate <NUM>, shown in <FIG>, the bottom side of fluid transfer plate <NUM> contains bores therethrough for structural support or fluid transfer. In particular, bores <NUM> and bores <NUM> correspond with bores <NUM> and <NUM> of the top side of plate <NUM>. Between bores <NUM> and bores <NUM>, there is a raised portion <NUM> of fluid-transfer plate <NUM> that may act as a barrier between the inlet and outlet bores. In particular, as shown in the simplified valve structure of <FIG>, when the diaphragm is pushed up onto the bottom side of the fluid-transfer plate <NUM>, the contact between the diaphragm and raised portion <NUM> constitutes a fluid barrier, preventing flow from bores <NUM> to bores <NUM>. When in an open valve state, fluid flows up over raised portion <NUM> from the inlet bores (e.g., <NUM>) to the outlet bores (e.g., <NUM>) and through fluid-transfer plate <NUM> from the inlet channel (e.g., <NUM>) to the outlet channel (e.g., <NUM>). In an illustrative embodiment, bores <NUM> may be sufficiently equivalent to bores <NUM>, such that users may choose to flow fluid in either direction. The illustrated sizing and spacing of the bores on the bottom side of fluid-transfer plate <NUM> are merely for illustrative purposes, and are not intended to be limiting the scope of the disclosure.

As will be shown in greater detail in <FIG>, fluid-transfer plate <NUM> may be brought into connection with a pressure plate, such as pressure plate <NUM>, in order to control the opening and closing of the fluid channels, as previously discussed. <FIG> shows a perspective drawing of an example pressure plate <NUM> that can be used in combination with a fluid-transfer plate to produce a valve system. As discussed above, a flexible diaphragm is placed between the fluid-transfer plate <NUM> and the pressure plate <NUM>. In order to provide space for structural supports, bores are bored or otherwise formed at least partially through pressure plate <NUM>, as shown by the peripheral bores shown in <FIG>. Additionally as shown, pressure plate <NUM> includes recesses, such as recess <NUM> and recesses <NUM>, which may be aligned with bores and raised portions on the bottom of a fluid-transfer plate <NUM>.

As discussed above, a valve diaphragm composed of a pliant pressure responsive material (e.g., diaphragm <NUM>) is disposed between the upper surface of the pressure plate <NUM> and the lower surface of the fluid-transfer plate <NUM>. The diaphragm <NUM> lacks bores except where used for screws or other fasteners for holding the assembly together. For use in SMB chromatography, there is a barrier plate or gasket forming a sealing interface at the upper surface of the fluid-transfer plate <NUM>, forming an upper barrier wall to the fluid egress and ingress channels (e.g., channel <NUM> and channel <NUM>). The plate or gasket also has column access bores to communicate with chromatographic columns and the ingress and egress channels. Finally above the barrier plate or gasket there is an anchor plate having an upper and a lower surface containing column communicating bores in alignment with the chromatographic columns and the ingress and egress channels.

Recess <NUM> and recesses <NUM> may each include a recessed portion <NUM> and recessed portion 502B, some form of fluid seal (e.g., sealing structure <NUM> and sealing structures <NUM>), and bore <NUM>, bores <NUM>, bore 506B and bore 508B. Bore <NUM> may be considered the functional implementation of first gas channel 124a and second gas channel 124b shown in <FIG>. In some embodiments, bore <NUM> and bore 506B may be a pressure inlet and a venting outlet, used respectively for increasing the pressure in recessed portion <NUM> and recessed portion 502B in order to produce a valve closed state, and for venting said pressure to establish a valve open state. Bores <NUM> and bore 508B may be pressure inlet ports to sealing structure <NUM> and sealing structures <NUM> (which can be o-ring channels). Sealing structure <NUM> and sealing structures <NUM> may be a circumferential groove or channel encompassing the perimeter of recessed portion <NUM> and recessed portion 502B and containing any type of fluid sealing mechanism that may maintain pressure in recessed portion <NUM> and recessed portion 502B. For example, a fluid sealing mechanism installed within sealing structure <NUM> may be an o-ring, flexible gasket, blade gasket, labyrinth seal, U-cup, a pressure cup, or a combination of these or other sealing architectures. Similarly, sealing structures <NUM> are located around the perimeters of recesses <NUM> and may contain a fluid sealing mechanism as described above with reference to sealing structure <NUM>. Pressure may be applied to sealing structure <NUM> and sealing structures <NUM> through bores <NUM> and bore 508B to increase the seal force applied by the fluid sealing mechanism. In an example embodiment, fluid pressure through bores <NUM> and bore 508B may be independent of the pressure/flow of pressurized material through bore <NUM> and bore 506B. More, fewer, or different bores, seals, and structures than those shown in the figures may be utilized in an example recess. Although elements <NUM>, 502B, 506B, and 508B are only labeled with respect to one of recesses <NUM>, <FIG> shows that each of recesses <NUM> may include similar structures.

As shown, in addition to a single pressure valve (e.g., recess <NUM>) controlling all channels of a valve inlet/outlet, multiple recesses (e.g., recesses <NUM>) may individually control fluid flow between each set of bores. Although the example of <FIG> and <FIG> show four recesses, any number of recesses may be utilized in order to ensure as flexible a structure as needed for a particular application. In practice, since each set of bores may connect to the same inlet or outlet channel, the individual control of the sets of bores may be used primarily in controlling the particular flow rate of fluid. For example, if a certain application requires a fluid to maintain a particular flow regime (e.g., laminar or turbulent), establish a specific linear flow velocity, or maintain or establish a certain pressure differential, then the number of fluid pathways utilized may be adjusted to cause fluid to conform to the desired flow regime. As another example, if a system detects that a valve around a particular set of bores has become damaged, the system may responsively cut off fluid flow through the damaged valve by maintaining a continuous closed state for that valve. Other example applications of the independent control of different fluid channels may also be used. Additionally, the valves between one inlet and outlet need not be limited to either all a single collective valve or independent control. For example, a combination of multiple-bore valves and single-bore valves may be produced.

Any controllable material may be used as a source of pressure in pressure plate <NUM>. In order to maintain independent control of the different valves, a system may have multiple inlets <NUM> for pressurized material. In particular, the number of pressurized material inlets may be equal to the number of controllable recesses in the plate. The pressure of each of these inlets <NUM> may be controlled at the valve block or in a separate the control system connected to inlets <NUM>. In an example embodiment, the pressurized material in pressure plate <NUM> is different than the fluid being transferred in fluid-transfer plate <NUM>. Accordingly, the material and manufacture of the diaphragm may be selected to prevent mixing between the pressurized material and the transferred fluid.

<FIG> shows a cross-section of valve block <NUM> as assembled, taken at line A - B (shown in <FIG>). As shown, bore <NUM> (which can be used for structural support) extends into each of top plate <NUM>, fluid-transfer plate <NUM>, diaphragm <NUM>, and pressure plate <NUM>. Additionally, bore <NUM> is positioned such that it connects with the widened area of channel <NUM> (which can be an inlet channel), providing essential fluid flow down to recess <NUM>. At recess <NUM>, pressurized material from inlet <NUM> may provide sufficient pressure to diaphragm <NUM> in order to close recess <NUM> and prevent flow of the fluid from channel <NUM> to channel <NUM>.

<FIG> show various views of an assembled valve block comprising multiple valves in accordance with an illustrative embodiment. As shown in <FIG>, a valve block with multiple valves can have varying configurations of inlet connection bore <NUM> and outlet connection bore <NUM> (and corresponding inlet channels and outlet channels). In the embodiment shown in <FIG>, the valve block can have inlet connection bores <NUM> that can provide a fluid inlet to multiple valves <NUM>. <FIG> is a front view of the valve block and <FIG> is a rear view of the valve block. Additionally, the valve block can have multiple outlet connection bores <NUM> that provide a fluid outlet for multiple valves. In some embodiments, the inlet connection bore <NUM> can act as an outlet and the outlet connection bore <NUM> can act as an inlet. <FIG> show a perspective view of the valve block with multiple valves and the various bores and channels corresponding to each valve in accordance with an illustrative embodiment. <FIG> shows a cut-away side perspective of a valve block with multiple valves in accordance with an illustrative embodiment.

<FIG> show various views of an assembled valve block comprising multiple valves in accordance with an illustrative embodiment. <FIG> shows a side perspective of the valve block. As shown in <FIG>, the valve block can have multiple valves <NUM> within the same valve block. <FIG> shows an embodiment of the bottom side of a fluid-transfer plate <NUM> that comprises five inlet bores <NUM> and five outlet bores <NUM> in accordance with an illustrative embodiment. As shown in <FIG>, the inlet bores <NUM> and the outlet bores <NUM> can be configured in an annular shape. <FIG> shows a view of pressure plate in accordance with an illustrative embodiment. As shown in <FIG>, recesses <NUM> can have a shape corresponding to the shape of the inlet bores <NUM> and the outlet bores <NUM>. In the embodiment shown in <FIG>, recesses <NUM> have a circular shape. <FIG> show perspective views of the outside surface of an assembled valve block comprising multiple valves in accordance with an illustrative embodiment.

In some instances, wetted surfaces of a process system (e.g., the inside of tubing, valves, instruments, etc.) should be as clean and contaminant free as possible. For example, using the same equipment for processes such as manufacturing of food, pharmaceuticals, chemicals, etc. requires that the equipment is thoroughly cleaned between uses to prevent contamination of the new batch from the previous batch. For complex equipment, such as the various valve blocks described herein, sufficient cleaning of the equipment can be difficult, overly expensive, and/or practically impossible.

In some embodiments, the various valve blocks described herein can be manufactured and/or used such that they are disposable or single-use. For example, all of the plates in the valve block assembly can be replaceable or treated as single-use components. In another example, only the plates that touch the process material are replaced between batches. In such an example, a pressure plate that provides pressure to the diaphragm, but does not touch the process material, may be re-used without the need for cleaning between batches.

In an illustrative embodiment, one or more of the plates can be made of biocompatible and/or medical-grade materials. For example, the plates can be made of a USP Class VI polymer that is in compliance with FDA regulations for use in pharmaceutical processes. Examples of such polymers available in appropriate grades include polyetherimide (PEI), polycarbonate (PC), acetal copolymer, polypropylene (PP), polyether ether ketone (PEEK), perfluoroalkoxy (PFA), polysulfone (PSU), polyphenylsulfone (PPSU), cyclic olefin copolymer (COC), polytetrafluoroethylene (PTFE), etc. In alternative embodiments, any suitable material can be used.

<FIG> show various views of an assembled valve block comprising multiple valves in accordance with an illustrative embodiment. <FIG> show isometric views of opposite sides of a valve block <NUM>. <FIG> show views of opposite sides of the valve block <NUM>. An illustrative valve block <NUM> includes a top plate <NUM>, a fluid transfer block <NUM>, a diaphragm <NUM> (e.g., a membrane), a frame <NUM>, and a pressure plate <NUM>. The fluid transfer block <NUM> includes a bore plate <NUM>, a channel plate <NUM>, and a transfer plate <NUM>. In alternative embodiments, additional, fewer, and/or different elements may be used. The diaphragm <NUM> can be any suitable diaphragm, such as diaphragm <NUM>, diaphragm <NUM>, diaphragm <NUM>, etc. In alternative embodiments, additional, fewer, and/or different elements may be used.

In an illustrative embodiment, the valve block <NUM> includes multiple through-bolt holes <NUM>. The through-bolt holes <NUM> can be used to compress the various plates together. The various plates can be compressed to form a fluid-tight seal between the plates. In the embodiment illustrated in <FIG>, the valve block <NUM> has twelve through-bolt holes <NUM>. In alternative embodiments, the valve block <NUM> can include additional or fewer through-bolt holes <NUM>. The through-bolt holes <NUM> can be used to allow a rod (e.g., a bolt) to pass through the through-bolt holes <NUM>. Either and/or both ends of the through-bolt holes <NUM> can include counter bores to allow bolt heads, nuts, etc. to be flush with or below the outer surface of the valve block <NUM>. Any suitable securing mechanism can be used to compress the layers of the valve block <NUM> via the through-bolt holes <NUM>, such as bolts, nuts, threaded rods, clamps, rivets, etc. In alternative embodiments, any suitable method of compressing the layers of the valve block <NUM> can be used. For example, clamps may be used. In such an example, the valve block <NUM> may not have or use the through-bolt holes <NUM>. In other alternate embodiments, two or more layers may be mechanically, chemically, or thermally bonded or fused together. For example, diffusion bonding may be used to bond two or more layers together.

In an illustrative embodiment, the top plate <NUM> includes one or more inlet bores <NUM> and/or outlet bores <NUM>. For ease of discussion and clarity, various elements of the valve block <NUM> are described as "inlet" or "outlet. " However, in alternative embodiments, the flow through the valve block <NUM> can be reversed and an "outlet" can be an inlet and an "inlet" can be an outlet. Further, the particular embodiment illustrated in <FIG> (and <FIG>) is illustrative only. The particular location of bores, holes, channels, etc. can be changed or modified in any suitable manner. The inlet bores <NUM> and outlet bores <NUM> can be configured to be connected to a process such that fluid is received through the inlet bores <NUM> and extracted through the outlet bores <NUM>. Any suitable connection can be used, such as a threaded connection, a quick disconnect connection, a pressure fitting, a flange, etc..

In an illustrative embodiment, the pressure plate <NUM> includes one or more pressure inlets <NUM>. As explained in greater detail below, the pressure inlets <NUM> can be used to provide pressure to the surface of the diaphragm <NUM> to permit or restrict flow through the valve. When the pressure supplied to the pressure inlets <NUM> is above a certain threshold, the valve is closed and fluid does not flow through the valve. When the pressure is below the threshold, the pressure from the fluid opposite the pressure inlets <NUM> deflects the diaphragm and the fluid flows through the valve. In an illustrative embodiment, each valve of the valve block <NUM> is associated with one of the pressure inlets <NUM>. In alternative embodiments, one of the pressure inlets <NUM> can be used to operate multiple valves of the valve block <NUM>. <FIG> and <FIG> illustrate the pressure plate <NUM> with six pressure inlets <NUM> (corresponding to six valves). However, in alternative embodiments, any suitable number of pressure inlets <NUM> can be used.

In the embodiment illustrated in <FIG> and <FIG>, the valve block <NUM> includes a frame <NUM> that is separate from the pressure plate <NUM>. In an illustrative embodiment, the frame <NUM> contains a central cutout such that the pressure plate <NUM> directly contacts the diaphragm <NUM>. In some embodiments, the frame <NUM> and the pressure plate <NUM> are a single piece. In an alternative embodiment, the frame <NUM> may not be used. The frame <NUM> can include screw holes <NUM> that are used to hold the frame to the valve block <NUM>. In the embodiment illustrated in <FIG> and <FIG>, the screw holes <NUM> are smaller than the through-bolt holes <NUM> and are configured to accept a smaller securing mechanism (e.g., screw). As shown in <FIG> and <FIG>, the screw holes <NUM> do not extend through the entire valve block <NUM>. In an illustrative embodiment, the screw holes <NUM> are configured to receive a screw that threads into receiving threads in one of the plates of the fluid transfer block <NUM> (e.g., the bore plate <NUM>). In alternative embodiments, the screw holes <NUM> do extend through the valve block <NUM> and can operate similar to the through-bolt holes <NUM>. In some embodiments, the screw holes <NUM> are used with rods for alignment of the layers of the valve block <NUM> during assembly, maintenance, etc. In the embodiment illustrated in <FIG> and <FIG>, the frame <NUM> has eight screw holes <NUM>. In alternative embodiments, the frame <NUM> can have additional or fewer screw holes <NUM>.

<FIG> and <FIG> show cross-sectional views of an assembled valve block in accordance with an illustrative embodiment. <FIG> is a cross-sectional view of the valve block <NUM> at line A-A of <FIG>. <FIG> is a cross-sectional view of the valve block <NUM> at line B-B of <FIG>.

As illustrated in <FIG>, the frame <NUM> can include a sealing groove <NUM> that can be used to seal the diaphragm <NUM> against the transfer plate <NUM>. The sealing groove <NUM> can include a sealing mechanism, such as an o-ring. In an illustrative embodiment, the pressure plate <NUM> has sealing grooves <NUM> that receive the sealing members <NUM>. The sealing members <NUM> can be any suitable sealing mechanism. For example, the sealing members <NUM> can be an o-ring. The cross-sectional shape of the o-ring can be circular, square (e.g., with a static seal face), octagonal, etc. In an illustrative embodiment, the sealing grooves <NUM> are not pressurized. In alternative embodiments, the sealing grooves <NUM> are pressurized, for example to create a pressurized o-ring seal. In alternative embodiments, any suitable method of sealing around the recess <NUM> can be used. In some embodiments, the sealing grooves <NUM> are not used. For example, the pressure plate <NUM> can include a ridge around the recess <NUM> that applies a greater force against the diaphragm <NUM> than the flat surface of the pressure plate <NUM>.

The sealing members <NUM> create a seal around the recess <NUM>. As described above, gas pressure from the pressure channel <NUM> can press the portion of the diaphragm <NUM> within the recess <NUM> against the transfer plate <NUM>, thereby preventing flow through the valve associated with the recess recess <NUM>. Gas pressure from the pressure channel <NUM> can be relieved, thereby permitting the flow of the liquid within the valve block <NUM> to deflect the diaphragm <NUM> into the recess <NUM>, thereby permitting flow through the valve.

<FIG> and <FIG> show exploded views of a valve block in accordance with an illustrative embodiment. <FIG> and <FIG> show opposite sides of the exploded view of the valve block <NUM>. <FIG> shows a close-up view of a portion of a pressure plate of a valve block in accordance with an illustrative embodiment. The view of <FIG> is a close-up view of the circle "G" of <FIG>.

As shown in <FIG>, the various sealing members <NUM> fit into respective sealing grooves <NUM> of each valve. The embodiment illustrated in <FIG> has six valves. In alternative embodiments, any suitable number of valves can be used.

As shown in <FIG>, the pressure channel <NUM> may not be concentric with the recess <NUM>. In alternative embodiments, the pressure channel <NUM> is concentric with the recess <NUM>. The pressure channel <NUM> can be located at any suitable location for any suitable reason. For example, in the embodiment illustrated in <FIG>, the pressure channel <NUM> of each of the recesses <NUM> of the pressure plate <NUM> is offset away from the centerline of the pressure plate <NUM>. Such an arrangement can allow gas valves (e.g., solenoids) to be mounted directly to the pressure plate <NUM> without interference from one another.

<FIG> show various views of a pressure plate of a valve block in accordance with an illustrative embodiment. <FIG> shows a side of the pressure plate <NUM> that is opposite of the view of <FIG> is a cross-sectional view of the pressure plate <NUM> along line C-C of <FIG>. As shown by the center lines in <FIG>, the various through-bolt holes <NUM>, pressure channel <NUM>, recess <NUM>, etc. can be arranged in line with one another (e.g., as a grid). In alternative embodiments, the various elements can be arranged in any suitable pattern, arrangement, etc..

<FIG> show various views of a fluid transfer block of a valve block in accordance with an illustrative embodiment. <FIG> shows the face of the fluid transfer block <NUM> opposite of the face shown in <FIG> is a side view of the fluid transfer block <NUM>. <FIG> is a close-up view of the circle "H" of <FIG> shows one set of valve outlet bores <NUM> and one set of valve inlet bores <NUM>, which are associated with one valve of the valve block <NUM>.

As shown in <FIG>, the bore plate <NUM> includes inlet bores <NUM> and outlet bores <NUM>. In an illustrative embodiment, the inlet bores <NUM> and the outlet bores <NUM> extend through the bore plate <NUM>. As seen in <FIG>, the transfer plate <NUM> includes valve outlet bores <NUM> and valve inlet bores <NUM>. Both sets of the valve outlet bores <NUM> at the top of the transfer plate <NUM> illustrated in <FIG> are fluidly connected to the outlet bore <NUM> at the top of the bore plate <NUM> illustrated in <FIG> when all valves of the valve block <NUM> are closed. Similarly, both sets of the valve inlet bores <NUM> at the bottom of the transfer plate <NUM> illustrated in <FIG> are fluidly connected to the inlet bore <NUM> at the bottom of the bore plate <NUM> illustrated in <FIG> when all valves of the valve block <NUM> are closed.

The top right set of the valve outlet bores <NUM> illustrated in <FIG> is fluidly connected to the outlet bore <NUM> at the top left of the bore plate <NUM> in <FIG> (it is noted that <FIG> illustrate opposite sides of the fluid transfer block <NUM>) when all valves of the valve block <NUM> are closed. Similarly, the top left set of the valve outlet bores <NUM> illustrated in <FIG> is fluidly connected to the outlet bore <NUM> at the top right of the bore plate <NUM> in <FIG> when all valves of the valve block <NUM> are closed. The same is true for the bottom outlet bores <NUM> and valve outlet bores <NUM> of <FIG>.

An illustrative transfer plate <NUM> includes outside shut-off valve bores <NUM> and inside shut-off valve bores <NUM>. The left set of the outside shut-off valve bores <NUM> and the inside shut-off valve bores <NUM> of the transfer plate <NUM> illustrated in <FIG> operate to selectively connect the valve outlet bores <NUM> at the top left and bottom left of the transfer plate <NUM> illustrated in <FIG> when the diaphragm (membrane) above the outside shut-off valve bores <NUM> and the inside shut-off valve bores <NUM> allows flow between the outside shut-off valve bores <NUM> and the inside shut-off valve bores <NUM>. That is, referring to <FIG>, the left set of the inside shut-off valve bores <NUM> is fluidly connected to a corresponding set of the valve outlet bores <NUM> when all valves are closed, and the left set of the outside shut-off valve bores <NUM> are fluidly connected to a corresponding set of the valve outlet bores <NUM> when all valves are closed. The same is true for the valve outlet bores <NUM>, the outside shut-off valve bores <NUM>, and the inside shut-off valve bores <NUM> on the right half of the embodiment illustrated in <FIG>.

<FIG> show various views of a fluid transfer block of a valve block in accordance with an illustrative embodiment. <FIG> is a cross-sectional view of the fluid transfer block <NUM> along line N-N in <FIG>. <FIG> is a cross-sectional view of the fluid transfer block <NUM> along line K-K in <FIG>. <FIG> is a close-up view of the circle "M" of <FIG> show cross-sectional views of a fluid transfer block of a valve block in accordance with an illustrative embodiment. <FIG> is a cross-sectional view of the fluid transfer block <NUM> along line F-F of <FIG>. <FIG> is a close-up view of the circle "J" of <FIG>.

<FIG> shows the opposite side of the bore plate <NUM> as is shown in <FIG>. The inlet bores <NUM> and the outlet bores <NUM> extend through the entire bore plate <NUM>. The inlet grooves <NUM> are formed (e.g., machined) into the surface of the bore plate <NUM>, but do not extend through the bore plate <NUM>. Fluid transferred into the inlet bores inlet bores <NUM> fills and/or travels through the inlet grooves <NUM>. In an illustrative embodiment, the surface of the channel plate <NUM> that abuts the surface of the bore plate <NUM> shown in <FIG> includes complementary grooves to the inlet grooves <NUM> (e.g., as shown in <FIG>).

As illustrated in <FIG>, the channel plate <NUM> includes inlet channels <NUM>. The inlet channels <NUM> extend through the channel plate <NUM>. As illustrated in <FIG>, the inlet channels <NUM> line up with the inlet grooves <NUM> such that fluid can flow between the inlet grooves <NUM> and the inlet channels <NUM>. In the embodiment illustrated in <FIG>, the inlet distribution grooves <NUM> are circular in shape. In alternative embodiments, the inlet distribution grooves <NUM> can be any suitable shape, such as square, rectangular, octagonal, etc. In some embodiments, the surface area of the transfer plate <NUM> that abuts the face of the channel plate <NUM> illustrated in <FIG> has complementary grooves (e.g., as shown in <FIG>).

The surface area of the inlet distribution grooves <NUM> can align with the valve inlet bores <NUM>. That is, the circumference of a circle that intersects the valve inlet bores <NUM> (as arranged, for example, in <FIG>) aligns with the inlet distribution grooves <NUM> such that the inlet distribution grooves <NUM> and the valve inlet bores <NUM> are fluidly connected. The inlet bores <NUM> extend through the transfer plate <NUM>. Thus, the inlet bores <NUM>, the inlet grooves <NUM>, the inlet channels <NUM>, and the inlet distribution grooves <NUM> are fluidly connected when the valves are closed (e.g., the diaphragm <NUM> is pressed against the transfer plate <NUM>).

When the valves are opened (e.g., the diaphragm <NUM> is not pressed against the transfer plate <NUM>), fluid flowing from the valve inlet bores <NUM> passes between the diaphragm <NUM> and the surface of the transfer plate <NUM> (e.g., by deflecting the diaphragm <NUM> into the recess <NUM>) and through the valve outlet bores <NUM>. The valve outlet bores <NUM> extend through the transfer plate <NUM>. Similar to the configuration of the valve inlet bores <NUM> and the inlet distribution grooves <NUM>, the valve outlet bores <NUM> are fluidly connected to the outlet collection grooves <NUM>. Outlet collection grooves <NUM> are separated from inlet distribution grooves <NUM> by a land of material <NUM>. In the embodiment illustrated in <FIG>, the outlet collection grooves <NUM> are circular in shape. In alternative embodiments, the outlet collection grooves <NUM> can be any suitable shape, such as square, rectangular, octagonal, etc. In some embodiments, the surface area of the transfer plate <NUM> that abuts the face of the channel plate <NUM> illustrated in <FIG> has complementary grooves (e.g., as shown in <FIG>).

The outlet collection grooves <NUM> are fluidly connected to the outlet bores <NUM>, which extend through the bore plate <NUM> and the channel plate <NUM>. The outlet collection grooves <NUM> are fluidly connected to the outlet bores <NUM> via the outlet grooves <NUM>. In an illustrative embodiment, the surface area of the transfer plate <NUM> that abuts the face of the channel plate <NUM> illustrated in <FIG> has complementary grooves to the outlet grooves <NUM>. Thus, when the valves are closed, the valve outlet bores <NUM> are connected to the respective outlet bores <NUM> via the outlet collection grooves <NUM> and the outlet grooves <NUM>.

As shown in <FIG>, in some embodiments, the outlet collection grooves <NUM> can be fluidly connected to shut-off transfer grooves <NUM>. The valves associated with the outside shut-off valve bores <NUM>, the inside shut-off valve bores <NUM>, the inner shut-off grooves <NUM>, and the outer shut-off grooves <NUM> together can be referred to as shut-off valves. The shut-off valves control flow between the top outlet bores <NUM> of <FIG> and the bottom outlet bores <NUM>. The shut-off valves can work similarly as the valves described above.

The inner shut-off grooves <NUM> perform a function similar to the inlet distribution grooves <NUM>. However, in the embodiment illustrated in <FIG>, the inner shut-off grooves <NUM> do not have valve inlet bores. That is, fluid enters a shut-off groove <NUM> via the shut-off transfer groove <NUM>, not through an inlet bore. The inside shut-off valve bores <NUM> can be fluidly connected to the inner shut-off grooves <NUM> when the shut-off valves are closed. Similarly, the outside shut-off valve bores <NUM> are fluidly connected to the outer shut-off grooves <NUM> when the shut-off valves are closed. The inner shut-off grooves <NUM> are separated from the outer shut-off grooves <NUM> by a land of material <NUM>.

For example, in the embodiment illustrated in <FIG>, fluid from the bottom left shut-off transfer groove <NUM> flows into the left outer shut-off groove <NUM> and the left set of outside shut-off valve bores <NUM> of <FIG>. When the left shut-off valve is closed, fluid does not flow between the outside shut-off valve bores <NUM> and the inside shut-off valve bores <NUM>. When the left shut-off valve is open, fluid is permitted to flow, for example, from the outside shut-off valve bores <NUM>, between the diaphragm <NUM> and the surface of the transfer plate <NUM>, and into the inside shut-off valve bores <NUM>. The fluid can flow from the inside shut-off valve bores <NUM> to the left inner shut-off groove <NUM>, through the top left shut-off transfer groove <NUM>, and into the upper-left outlet bore <NUM>. In alternative examples, the flow can be reversed. By using the shut-off valves and the bi-directional flow characteristics of the other valves, fluid can be controlled to flow between any of the inlet bores <NUM> or any of the outlet bores <NUM> to any of the other inlet bores <NUM> or the other outlet bores <NUM>.

As shown in <FIG>, the valve outlet bores <NUM> and the valve inlet bores <NUM> are each arranged in a circular shape. The valve inlet bores <NUM> are within the circular shape of the valve outlet bores <NUM>. In an illustrative embodiment, the circular shapes of the valve outlet bores <NUM> and the valve inlet bores <NUM> have the same center point. In some embodiments, the valve outlet bores <NUM>, the valve inlet bores <NUM>, and the recess <NUM> of a valve have the same center point. In the embodiment illustrated in <FIG>, the valve inlet bores <NUM> form a full circle, and the valve outlet bores <NUM> form two parts of an incomplete circle. In alternative embodiments, the valve outlet bores <NUM> can be spread evenly throughout the circular shape. In some embodiments, there are additional valve outlet bores <NUM> to complete the circular shape. Any suitable arrangement or number of valve outlet bores <NUM> (or valve inlet bores <NUM>) may be used. For example, the valve inlet bores <NUM> may not form a complete circle.

In an illustrative embodiment, fluid flows from the valve inlet bores <NUM> to the valve outlet bores <NUM>. The fluid flowing from the valve inlet bores <NUM> flows in an efficient manner to the valve outlet bores <NUM>, thereby permitting a relatively high flow. For example, conceptually, the fluid flows in a half-torroidial pattern. Thus, the fluid travels a relatively short distance from one of the valve inlet bores <NUM> to one of the valve outlet bores <NUM>. In some instances, turbulent flow can result in alternative flow patterns. Additionally, the greater the number of bores, the less resistance the fluid encounters (e.g., less pressure drop across the valve). Any number of bores can be used. In some embodiments, the number of valve inlet bores <NUM> for a valve can be different than the number of valve outlet bores <NUM>.

As the fluid flows from the valve inlet bores <NUM> to the valve outlet bores <NUM>, the fluid applies pressure to the diaphragm <NUM>, thereby deflecting the diaphragm <NUM>. The diameter and geometry of the valve outlet bores <NUM>, the valve inlet bores <NUM>, the recess <NUM>, and the sizes and positions of such elements in relation to one another can be chosen to optimize the flow characteristics of the valve (e.g., pressure drop). In some instances, such sizes can be chosen, at least in part, to reduce the overall footprint of the valve. In an illustrative embodiment, a desirable depth and diameter of the recess <NUM> may be those minimum dimensions which produce a required pressure drop for a given set of design flow conditions (e.g., flow rate, temperature, fluid properties, etc.). Pressure drop for a given set of design flow conditions across a proposed valve may first be predicted to a sufficient approximation by means of calculations, applying engineering principles of fluid mechanics. The result of the calculated pressure drop can predict if the desired diameter and depth of the recess <NUM> should be altered. In some instances, pressure drop calculations may be repeated in an iterative manner for various changes in dimensions until optimum sizes and pressure drops are discovered. A test valve may be constructed with a recess <NUM> fabricated to the optimum depth and diameter discovered by the predictive calculations. The test valve may be operated under the design flow conditions, and the actual pressure drop across the valve may be measured, thereby validating the predicted pressure drop derived from calculations. In some embodiments, the recess <NUM> may be <NUM> inches in diameter and <NUM> inches deep. In other embodiments the recess <NUM> may be <NUM> inches in diameter and <NUM> inches deep. In still other embodiments, the recess <NUM> may be larger or smaller in diameter and shallower or deeper in depth. Examples of diameters of valve outlet bores <NUM> and valve inlet bores <NUM> may be found in <FIG>. Other embodiments may utilize bores larger or smaller in diameter than those illustrated in <FIG>. Still other embodiments may utilize differing combinations and pluralities of valve outlet bores <NUM> and valve inlet bores <NUM> in greater or fewer numbers than shown in <FIG>.

In some instances, the diameters of the circles formed by the valve outlet bores <NUM> and the valve inlet bores <NUM> are chosen to be as close as possible. That is, the distance between the valve outlet bores <NUM> and the valve inlet bores <NUM> of a valve can be designed to be as small as practically possible, yet large enough to allow for adequate sealing when the valve is closed. By decreasing the distance between the valve outlet bores <NUM> and the valve inlet bores <NUM>, the valve has a lower pressure drop and, therefore, greater throughput for a given inlet pressure. Further, by reducing the distance between the valve outlet bores <NUM> and the valve inlet bores <NUM>, the deadspace is decreased. As each valve decreases in size, the overall size of the valve block <NUM> can be decreased, resulting in less material required for the valve block <NUM>, shorter internal flow paths, and a lower cost of manufacture. In some instances, a desirable feature of embodiments of the valve block of the present disclosure is to minimize the deadspace (e.g., dead volume), which includes the volume occupied by fluid within the valve block (e.g., bores, grooves, and channels). As an illustrative example, in liquid chromatography, excess dead volume can interfere with separation performance by causing peak broadening, anomalous peaks, dilution, and/or cross contamination of sample components. When embodiments of the valve block of the present disclosure is used in liquid chromatography, a number of valves can be located upstream and/or downstream from each of one or more chromatography columns. Therefore the dead volume contributed by the valve block can significantly affect separation performance.

In an illustrative embodiment, the diameter of the recess <NUM> is chosen such that the majority of flow from the valve inlet bores <NUM> to the valve outlet bores <NUM> occurs within the deepest portion of the recess <NUM> (e.g., not near the edges). As the size of the recess <NUM> increases, the pressure drop across the valve decreases. At a certain point, however, increasing the diameter of the recess <NUM> does not result in lower pressure drops across the valve because all or most of the flow is within the deepest portion of the recess <NUM>.

The depth of the recess <NUM> can be chosen to allow the greatest amount of deflection while maintaining the integrity and the shape of the diaphragm <NUM>. In some instances, the depth of the recess <NUM> can be chosen based on the fluid and/or flow properties. For example, for use with fluid with cooler temperatures, the recess <NUM> can be deeper than for use with fluid with higher temperatures.

The shape of the valves in the embodiment illustrated in <FIG> allows for relatively high flows with relatively low pressure drop across the valves. <FIG> is a table that shows the results of an experiment regarding flow rates of a valve block in accordance with an illustrative embodiment. The experiment was performed using a valve block in accordance with the valve block <NUM> illustrated in <FIG>. The test fluid was water at ambient temperature. The upper inlet bore <NUM> was the water inlet to the valve block <NUM> and the lower inlet bore <NUM> was used to allow water to exit the valve block. The four outlet bores <NUM> were connected in pairs with two tubing shunts, or jumpers, consisting of polymer tubing with a <NUM> millimeter internal diameter. The valve block <NUM> so configured provided a flow path with a single system inlet and single system outlet allowing flow through either of two inlet valves, either of two outlet valves, and/or either of two shut-off valves in any possible or desirable combination. A differential pressure gauge was installed between the inlet bores <NUM> and configured to measure the differential pressure of the water inlet and the water exit to the valve block <NUM>, thereby measuring total pressure drop of the water flowing through the valve block <NUM>. The pressure drop was measured with water flow rates from <NUM> liter per minute (L/min) to <NUM>/min with the valves under test in the open position. The results are shown in <FIG>. For a given flow rate (L/min), the average pressure drop per valve in pounds per square inch (psi) is shown.

The construction and arrangement of the elements of the systems and methods as shown in the illustrative embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. Additional information regarding the present valve block designs are also discussed in <CIT>.

Additionally, in the subject description, the words "illustrative" or "exemplary" are used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as "illustrative" is not necessarily to be construed as preferred or advantageous over other embodiments or designs. Rather, use of the word illustrative is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other illustrative embodiments without departing from the scope of the appended claims.

Claim 1:
A valve block (<NUM>) comprising:
a pressure plate (<NUM>) comprising:
a channel (<NUM>) configured to receive a first fluid; and
a recess (<NUM>) in a surface of the pressure plate (<NUM>), wherein the channel (<NUM>) and the recess are fluidly connected;
a fluid transfer block (<NUM>) comprising:
an inlet connection (<NUM>) configured to receive a second fluid;
an outlet connection (<NUM>);
a fluid transfer plate (<NUM>) comprising a plurality of valve inlet bores (<NUM>) each fluidly connected to the inlet connection (<NUM>), a plurality of valve outlet bores (<NUM>) each fluidly connected to the outlet connection (<NUM>),
wherein the plurality of valve inlet bores are surrounded, at least in part, by the plurality of valve outlet bores;
wherein the valve block (<NUM>) further comprises a diaphragm (<NUM>) between the pressure plate (<NUM>) and the fluid transfer block (<NUM>), wherein the plurality of valve inlet bores (<NUM>) and the plurality of valve outlet bores (<NUM>) are adjacent to the recess (<NUM>),
the valve block (<NUM>) being characterized in that the fluid transfer block (<NUM>) further comprises
a channel plate comprising:
an inlet distribution groove (<NUM>) and an inlet channel (<NUM>), wherein the plurality of valve inlet bores (<NUM>), the inlet connection (<NUM>), the inlet distribution groove (<NUM>) and the inlet channel (<NUM>) are fluidly connected; and
an outlet groove (<NUM>) and an outlet collection groove (<NUM>), wherein the plurality of valve outlet bores (<NUM>) are fluidly connected to the outlet connection (<NUM>) via the outlet collection groove (<NUM>) and the outlet groove (<NUM>).