Patent Description:
The inventions relate to fluid flow and delivery devices and methods, and more particularly to valves used to control fluid flow and delivery.

Valves are well known for use as flow control devices for gas and liquid fluid delivery. In the semiconductor industry as well as others, delivery of process chemicals during various processing operations is controlled using valves, for example, high purity valves. Exemplary applications for valves used in the semiconductor industry include chemical vapor deposition (CVD) and atomic layer deposition (ALD). In many applications, rapid precise control of the amount of fluid supplied is required.

In accordance with an exemplary aspect of one or more of the inventions presented in this disclosure, a valve cavity cap arrangement is provided in combination with a valve body defining a valve cavity having a recessed surface from which a central passage and at least one radially offset passage extend. The valve cavity cap arrangement includes an insert and a threaded cap. The insert is received in the valve cavity and includes an inner annular sealing surface sized to seal against a portion of the recessed surface surrounding the central passage, an outer annular sealing surface sized to seal against an outer periphery of the recessed surface, surrounding the at least one radially offset passage, and a solid web portion extending between the inner annular sealing surface and the outer annular sealing surface. The threaded cap includes an outer threaded portion threadably engaged with an internal threaded portion of the valve cavity, a central end portion configured to apply a first sealing force to the inner annular sealing surface, and an outer end portion configured to apply a second sealing force to the outer annular sealing surface.

In accordance with an exemplary aspect of one or more of the inventions presented in this disclosure, a method of sealing a valve cavity is contemplated, with the valve cavity including a recessed surface from which a central passage and at least one radially offset passage extend. In the exemplary method, an insert is installed in the valve cavity, such that an inner annular sealing surface of the insert engages a portion of the recessed surface surrounding the central passage and an outer annular sealing surface of the insert engages an outer periphery of the recessed surface, surrounding the at least one radially offset passage. A cap is assembled with the valve cavity, such that a central end portion of the cap applies a first sealing force to the inner annular sealing surface, and an outer end portion of the cap applies a second sealing force to the outer annular sealing surface.

This Detailed Description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the invention as claimed is broader than and unlimited by the exemplary embodiments, and the terms used in the claims have their full ordinary meaning.

While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions--such as alternative materials, structures, configurations, methods, circuits, devices and components, alternatives as to form, fit and function, and so on--may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions, as defined by the appended claims, even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Parameters identified as "approximate" or "about" a specified value are intended to include the specified value, values within <NUM>% of the specified value, and values within <NUM>% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present disclosure may, but need not, be to scale, and therefore may be understood as teaching various ratios and proportions evident in the drawings. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.

Diaphragm valves are used as flow control devices for gas and liquid fluids. In the semiconductor industry, for example, process system gases are controlled using diaphragm valves. A diaphragm valve may be installed into a process system in many different ways, including being mounted on manifolds or substrates that use surface mount technology. In one such exemplary surface mount configuration, as shown and described in co-owned <CIT> (the "'<NUM> Patent,") and reproduced in <FIG> and <FIG> herein, a manifold body block <NUM> includes a plurality of internally threaded valve cavities <NUM> each defining a recessed surface <NUM> from which a central passage <NUM> and at least one radially offset passage <NUM> extend. A seat carrier subassembly <NUM> is installed in each valve cavity <NUM>, and includes a seat carrier <NUM> defining a central opening <NUM> aligned with the central passage <NUM>, and outer openings <NUM> substantially aligned with (e.g., at least partially radially aligned with) the at least one offset passage <NUM>. An outer rim <NUM> of the seat carrier <NUM> supports (and may be welded to) a diaphragm <NUM> with the diaphragm and outer rim being clamped between the valve cavity recessed surface <NUM> and a bonnet nut <NUM> threaded into the valve cavity <NUM> to retain the seat carrier subassembly <NUM> and to provide for threaded assembly of an actuator assembly <NUM>. A body seal <NUM> surrounds the central opening <NUM> and seals against the recessed surface <NUM> around the central passage <NUM>, and a valve seat <NUM> (which may be integral with the body seal <NUM>) surrounds the central opening <NUM> and seals against the diaphragm <NUM> to block flow between the central and offset passages <NUM>, <NUM> when the diaphragm is in a closed (e.g., downward) position. In valve arrangements having more than one offset passage, the offset passages may be open to each other in the diaphragm's closed position, for example, to maintain flow through a fluid system, with the central passage providing for fluid sampling or injection when the diaphragm is in an open position. <CIT> discloses another example of a flow control valve.

In multi-valve, surface mounted manifold systems, it may be desirable to provide an array of manifolds with the same number of valve positions or valve cavities, such that each manifold assembly fits in the same footprint and allows the manifolds to be configured with a variable number of valves based on system needs, while allowing for economies of scale associated with manufacture of a single manifold body configuration. In manifold applications where valve actuated flow control at one or more of the valve positions is not required, a cap may be installed in place of the valve. In one exemplary arrangement, a flow-through cap may provide a means for the flow to pass continuously through the installed location, as if the valve cavity/position were provided with a valve that is always in an open position.

According to an exemplary aspect of the present application, in some applications, flow through one or more valve positions, for example, in a manifold assembly, may not be desired. According to the invention, a valve cavity cap arrangement provides a first metal-to-metal seal portion around a central passage extending to the valve cavity to block flow between the central passage and one or more outer radial passages, and an independent second seal portion around an outer periphery of the valve cavity, to prevent shell leakage of fluid in the outer radial passage(s).

In an exemplary embodiment, as shown in <FIG>, a valve cavity cap arrangement <NUM> includes a seal cartridge or insert <NUM> sized to be received in a valve cavity <NUM> of a valve body (e.g., manifold body <NUM>), and a threaded cap <NUM> having an outer threaded portion <NUM> threadably engageable with the internal threaded portion <NUM> of the valve cavity. The exemplary insert <NUM> includes a solid central portion <NUM> surrounded by an inner annular sealing bead <NUM> sized to seal against a central passage seal portion 34a of the recessed surface <NUM> surrounding the central passage <NUM>, to block fluid flow to and/or from the central passage. A solid web portion <NUM> of the insert <NUM> extends between the inner annular sealing surface <NUM> and an outer annular sealing bead <NUM> sized to seal against an outer periphery seal portion 34b of the recessed surface <NUM>, surrounding the offset passage(s) <NUM>, <NUM> to provide a seal around the offset passage(s), while maintaining fluid communication between the offset passages <NUM>, <NUM>, in embodiments having more than one offset passage. The insert <NUM> is metal (e.g., stainless steel) to provide a metal-to-metal seal between the valve cavity and the insert. As used herein, "annular" may include circular or any other suitable surrounding shape (e.g., oblong, elliptical, etc.).

The threaded cap <NUM> includes a central end portion <NUM> configured to engage a central bearing surface <NUM> of the insert <NUM> to apply a first sealing force to the inner annular sealing surface <NUM> and an outer end portion <NUM> (e.g., an annular sealing surface) configured to engage an outer bearing surface <NUM> of the insert to apply a second sealing force to the outer annular sealing surface <NUM>. While this may be accomplished with a single-piece cap configuration, in the illustrated embodiment, the cap <NUM> is a two-piece configuration having an inner cap plug <NUM> defining the central end portion <NUM> assembled with an outer cap nut <NUM> defining the outer end portion <NUM>, for example, by threaded engagement between an outer threaded portion <NUM> of the cap plug <NUM> and an inner threaded portion <NUM> of the cap nut <NUM>. In such an arrangement, the cap plug <NUM> may be threadably adjusted within the cap nut <NUM> for independent adjustment of the first and second sealing forces. Tightening adjustments of the cap plug <NUM> and the cap nut <NUM> may be made, for example, based on tightening torque or incremental turns from a snug tight condition. As shown in <FIG>, the cap plug <NUM> and the cap nut <NUM> may include outer grippable portions 121a, 123a to facilitate tightening with a tool (e.g., wrench flats 121a) or user hand grip (e.g., contoured hand grip portions 123a), and the cap nut <NUM> may be provided with one or more vent ports <NUM>, for example, to detect leakage past the insert <NUM>.

Additionally, according to another aspect of the present disclosure, the web portion <NUM> of the insert <NUM> may be thin enough to provide an increased degree of flexing between the outer and inner sealing beads so that differences in the valve cavity recessed surface can be accommodated and the load transfer from outer to inner seal is minimized. A suitable thickness may be selected as a function of the potential seal surface offset between the central passage seal portion 34a and the outer periphery seal portion 34b, and/or the amount of load-loss (resulting from web deflection) that may be tolerated. In an exemplary embodiment, a web portion <NUM> having a thickness between about <NUM> (<NUM>") and about <NUM> (<NUM>"), or about <NUM> (<NUM>") may be used to provide web deflection sufficient to accommodate a seal offset (e.g., due to dimensional tolerances in the valve cavity seal surfaces and/or the annular sealing surface surfaces) of up to about <NUM> (<NUM>"). In other embodiments, even thicker web portions may still allow for independent loading of the outer and inner annular sealing surfaces <NUM>, <NUM> by the cap nut <NUM> and cap plug <NUM>.

In the illustrated embodiment, the web portion <NUM> is substantially coplanar with the insert bearing surfaces <NUM>, <NUM>, for example, to provide an enlarged space between the valve cavity recessed surface <NUM> and the web portion <NUM> to maximize flow between the offset passages <NUM>, <NUM>, in embodiments having more than one offset passage. In other embodiments, as shown in <FIG>, the insert <NUM>' may include a web portion <NUM>' that is more centrally positioned axially between the upper bearing surfaces <NUM>', <NUM>' and the lower annular sealing surfaces <NUM>', <NUM>', for example, to provide increased flexibility between the outer and inner sealing beads, for example, in embodiments for which flow capacity is less critical or where only one offset passage is provided.

According to another exemplary aspect of the present application, in some fluid systems, it may be desirable to add a new fluidic connection to add or divert flow to the central passage at one or more positions, for example, to introduce a purge or chemical flow, take a pressure reading, or divert chemical to another portion of the system. In an exemplary embodiment, a valve cavity cap arrangement may include a flow diverting cartridge or insert having a central passage extending through the cap, for example, for connection with a flow loop or other flow control arrangement.

In an exemplary embodiment, as shown in <FIG>, a valve cavity cap arrangement <NUM> includes a flow diverting cartridge or insert <NUM> sized to be received in a valve cavity <NUM> of a manifold body <NUM>, and a threaded cap <NUM> having an outer threaded portion <NUM> threadably engageable with the internal threaded portion <NUM> of the valve cavity. The exemplary insert <NUM> includes a tubular extension <NUM> extending from an apertured central portion <NUM>, which is surrounded by an inner annular sealing surface <NUM> sized to seal against a seal portion 34a of the recessed surface <NUM> surrounding the central passage <NUM>. The apertured central portion <NUM> includes a central port <NUM> that extends from the tubular extension <NUM> to an end surface of the insert, radially inward of the inner annular sealing surface <NUM>, to provide a fluid passage between the central passage <NUM> and the tubular extension <NUM>. A solid web portion <NUM> of the insert <NUM> extends between the inner annular sealing surface <NUM> and an outer annular sealing surface <NUM> sized to seal against an outer periphery 34b of the recessed surface <NUM>, surrounding the offset passage(s) <NUM>, <NUM>, to provide a seal around the offset passage(s), while maintaining fluid communication between the offset passages <NUM>, <NUM>, in embodiments having more than one offset passage. The insert <NUM> is metal (e.g., stainless steel) to provide a metal-to-metal seal between the valve cavity <NUM> and the insert <NUM>.

The threaded cap <NUM> includes a central end portion <NUM> defining a central bore <NUM>, receiving the tubular extension <NUM> of the insert <NUM> therethrough, surrounded by an annular end face 222a configured to apply a first sealing force to the inner annular sealing surface <NUM>, and an outer end portion <NUM> configured to apply a second sealing force to the outer annular sealing surface <NUM>. While this may be accomplished with a single-piece cap configuration, in the illustrated embodiment, the cap <NUM> is a two-piece configuration having an inner cap plug <NUM>, defining the central end portion <NUM>, assembled with, and axially adjustable with respect to, an outer cap nut <NUM> defining the outer end portion <NUM>, for example, by threaded engagement between an outer threaded portion <NUM> of the cap plug <NUM> and an inner threaded portion <NUM> of the cap nut <NUM>. In such an arrangement, the cap plug <NUM> may be threadably adjusted within the cap nut <NUM> for independent axial adjustment of the first and second sealing forces. Tightening adjustments of the cap plug <NUM> and the cap nut <NUM> may be made, for example, based on tightening torque or incremental turns from a snug tight condition. As shown in <FIG>, the cap plug <NUM> and the cap nut <NUM> may include outer grippable portions 221a, 223a to facilitate tightening with a tool (e.g., wrench flats 221a) or user hand grip (e.g., contoured hand grip portions 223a), and the cap nut <NUM> may be provided with one or more vent ports <NUM>, for example, to detect leakage past the insert <NUM>.

Additionally, according to another aspect of the present disclosure, the web portion <NUM> of the insert <NUM> may be thin enough to provide a degree of axial flexing between the outer and inner sealing beads so that differences in the valve cavity recessed surface can be accommodated and the load transfer from outer to inner seal is minimized, for example, similar to the web portion <NUM> of the insert <NUM> of <FIG>, as described above.

In the illustrated embodiment, the web portion <NUM> is substantially coplanar with the outer bearing surface <NUM>, for example, to provide an enlarged space between the valve cavity recessed surface <NUM> and the web portion <NUM> to maximize flow between the offset passages <NUM>, <NUM>. In other embodiments, as shown in <FIG>, the insert <NUM>' may include a web portion <NUM>' that is more centrally positioned between the upper bearing surfaces <NUM>', <NUM>' and the lower annular sealing surfaces <NUM>', <NUM>', for example, to provide increased flexibility between the outer and inner sealing beads, for example, in embodiments for which flow capacity is less critical or where only one offset passage is provided.

According to another exemplary aspect of the present application, in some fluid systems, it may be desirable to add a new fluidic connection to add or divert flow to the radially offset passage(s) at one or more positions, for example, to introduce a purge or chemical flow, take a pressure reading, or divert chemical to another portion of the system. In an exemplary embodiment, a valve cavity cap arrangement may include a flow diverting cartridge or insert having a radially offset passage extending through the cap, for example, for connection with a flow loop or other flow control arrangement.

In an exemplary embodiment, as shown in <FIG>, a valve cavity cap arrangement <NUM> includes a flow diverting cartridge or insert <NUM> sized to be received in a valve cavity <NUM> of a manifold body <NUM>, and a threaded cap <NUM> having an outer threaded portion <NUM> threadably engageable with the internal threaded portion <NUM> of the valve cavity. The exemplary insert <NUM> includes a tubular extension <NUM> extending from a solid central portion <NUM> surrounded by an inner annular sealing surface <NUM> sized to seal against a seal portion 34a of the recessed surface <NUM> surrounding the central passage <NUM>, to block flow to and/or from the central passage <NUM>. The insert <NUM> includes one or more ports <NUM> extending radially outward and axially downward from the tubular extension <NUM> to an end surface of the insert, radially outward of the inner annular sealing surface <NUM>, to provide one or more fluid passages between the offset passage(s) <NUM>, <NUM> and the tubular extension <NUM>. A solid web portion <NUM> of the insert <NUM> extends between the ports <NUM> and an outer annular sealing surface <NUM> sized to seal against an outer periphery 34b of the recessed surface <NUM>, surrounding the offset passage(s) <NUM>, <NUM>, to provide a seal around the offset passage(s), while maintaining fluid communication between the offset passages <NUM>, <NUM>, in embodiments having more than one offset passage. The insert <NUM> is metal (e.g., stainless steel) to provide a metal-to-metal seal between the valve cavity and the insert.

The threaded cap <NUM> includes a central end portion <NUM> defining a central bore <NUM>, receiving the tubular central portion <NUM> of the insert <NUM> therethrough, surrounded by an annular end face 322a configured to apply a first sealing force to the inner annular sealing surface <NUM>, and an outer end portion <NUM> configured to apply a second sealing force to the outer annular sealing surface <NUM>. While this may be accomplished with a single-piece cap configuration, in the illustrated embodiment, the cap <NUM> is a two-piece configuration having an inner cap plug <NUM> defining the central end portion <NUM> assembled with, and axially adjustable with respect to, an outer cap nut <NUM> defining the outer end portion <NUM>, for example, by threaded engagement between an outer threaded portion <NUM> of the cap plug <NUM> and an inner threaded portion <NUM> of the cap nut <NUM>. In such an arrangement, the cap plug <NUM> may be threadably adjusted within the cap nut <NUM> for independent axial adjustment of the first and second sealing forces. Tightening adjustments of the cap plug <NUM> and the cap nut <NUM> may be made, for example, based on tightening torque or incremental turns from a snug tight condition. Similar to the features shown in the embodiments of <FIG> and <FIG>, the cap plug <NUM> and the cap nut <NUM> may include outer flatted portions to facilitate tightening with a tool (e.g., wrench), and the cap nut <NUM> may be provided with one or more vent ports, for example, to detect leakage past the insert <NUM>.

<FIG> illustrate upper and lower views of the exemplary insert <NUM>. As shown in <FIG>, the insert <NUM> may include multiple ports <NUM> circumferentially spaced around the insert, for example, to provide for increased flow between the offset passage(s) <NUM>, <NUM> and the tubular extension <NUM>. While the insert <NUM> may be machined with the multiple port configuration, the insert <NUM> (as well as any of the other components described herein) may be manufactured using additive manufacturing (e.g., 3D printing) and/or welded configurations (e.g., an insert formed from a tubular extension welded to a ported base).

In the illustrated embodiment, the web portion <NUM> is substantially coplanar with the outer bearing surface <NUM>, for example, to provide an enlarged space between the valve cavity recessed surface <NUM> and the web portion <NUM> to maximize flow between the offset passages <NUM>, <NUM>. In other embodiments (not shown), the insert may include a web portion that is more centrally positioned between the upper bearing surfaces and the lower annular sealing surfaces, for example, to provide increased flexibility between the outer and inner sealing beads, for example, in embodiments for which flow capacity is less critical or where only one offset passage is provided.

Claim 1:
In combination, a valve cavity cap arrangement (<NUM>, <NUM>, <NUM>) and a valve body (<NUM>) defining a valve cavity (<NUM>) having a recessed surface (<NUM>) from which a central passage (<NUM>) and at least one radially offset passage (<NUM>, <NUM>) extend, the valve cavity (<NUM>) adapted to receive a flow control valve, the valve cavity cap arrangement being installed within the valve cavity in place of the flow control valve and comprising:
a metal insert (<NUM>, <NUM>, <NUM>) received in the valve cavity, the insert including an inner annular sealing bead (<NUM>, <NUM>, <NUM>) sized to provide a metal-to-metal seal against a portion (34a) of the recessed surface surrounding the central passage, an outer annular sealing bead (<NUM>, <NUM>, <NUM>) sized to provide a metal-to-metal seal against an outer periphery (34b) of the recessed surface, surrounding the at least one radially offset passage, and a solid web portion (<NUM>, <NUM>, <NUM>) extending between the inner annular sealing bead and the outer annular sealing bead (<NUM>, <NUM>, <NUM>);
and
a threaded cap (<NUM>, <NUM>, <NUM>) having an outer threaded portion (<NUM>, <NUM>, <NUM>) threadably engaged with an internal threaded portion (<NUM>) of the valve cavity, a central end portion (<NUM>, <NUM>, <NUM>) configured to apply a first sealing force to the inner annular sealing bead, and an outer end portion (<NUM>, <NUM>, <NUM>) configured to apply a second sealing force to the outer annular sealing bead (<NUM>, <NUM>, <NUM>).