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BR-122025016278-B1 - Fluid Handling Cassettes

BR122025016278B1BR 122025016278 B1BR122025016278 B1BR 122025016278B1BR-122025016278-B1

Abstract

FLUID HANDLING CASSETTES. A fluid handling cassette (80) comprises at least one fluidically actuated diaphragm valve (82) and one fluidically actuated diaphragm pump (84), wherein the actuating fluid is supplied to the cassette (80) through actuating orifices (96) located along a thin or narrow edge of the cassette (80). Actuating channels (110) within the cassette lead from the actuating orifices (96) to the actuating chambers of the valves and pumps in a space between the plates (86, 90, 88) comprising the cassette (80). The individual plates (86, 90, 88) have a nominal thickness that is sufficient to provide a rigid roof for the actuating channels (110), but sufficiently thin to minimize the overall thickness of the cassette. A plurality of these cassettes (80) can be stacked together or separated from each other to form a cassette assembly, providing a convenient way to install and remove the cassette assembly from its actuation receptacle. The arrangement allows an improved way of connecting a complex cassette assembly to its associated pressure distribution manifold without the use of a plurality of flexible connecting tubes between the two.

Inventors

  • KEVIN L. GRANT
  • BENJAMIN E. COLBURN
  • JOSEPH M. RAUSEO
  • BENJAMIN J. DOUCETTE
  • MARC J. GORAYEB

Assignees

  • DEKA PRODUCTS LIMITED PARTNERSHIP

Dates

Publication Date
20260310
Application Date
20190329
Priority Date
20180330

Claims (20)

  1. 1. Fluid handling cassette (80) CHARACTERIZED in that it comprises an intermediate plate (90) positioned between a first plate (86) and a second plate (88), said plates having a length, a width and a plate thickness, a first side of the intermediate plate opposing the first plate and a second side of the intermediate plate opposing the second plate; the first plate (86) separated from the intermediate plate (90) defining a width of a first interplate space, and the second plate (88) separated from the intermediate plate (90) defining a width of a second interplate space; an edge of the cassette (80) having a cassette thickness defined by the thickness of each plate plus the width of the first and second interplate spaces, and a face of the cassette (80) being defined by the length and width of the first or second plate (86, 88); the intermediate plate (90) comprising first and second valve stations, the first valve station (116) defined by a first valve diaphragm and on the first side of the intermediate plate (90), and the second valve station defined by a second valve diaphragm and on the second side of the intermediate plate (90), said first valve diaphragm seated against the first side of the intermediate plate (90) and having an excursion range defined by the width of the first interplate space, and said second valve diaphragm seated against the second side of the intermediate plate (90) and having an excursion range defined by the width of the second interplate space; a first valve actuation channel (114) for the first valve station (116) and extending parallel to the face of the cassette (80) in the first interplate space, and a second valve actuation channel for the second valve station and extending parallel to the face of the cassette (80) in the second interplate space; said first valve actuation channel connecting a first valve actuation chamber connected by the first plate (86) and the first valve diaphragm to a first cassette valve actuation orifice located within the first interplate space on a first edge of the cassette (80); and said second valve actuation channel connecting a second valve actuation chamber connected by the second plate (88) and the second valve diaphragm to a second cassette valve actuation orifice located within the second interplate space on the first edge of the cassette (80).
  2. 2. Fluid handling cassette (80) CHARACTERIZED in that it comprises an intermediate plate (90) positioned between a first plate (86) and a second plate (88), said plates having a length, a width and a plate thickness, a first side of the intermediate plate (90) opposing the first plate (86) and a second side of the intermediate plate opposing the second plate (88); the first plate (86) separated from the intermediate plate (90) defining a width of a first interplate space, and the second plate (88) separated from the intermediate plate (90) defining a width of a second interplate space; an edge of the cassette (80) having a cassette thickness defined by the thickness of each plate plus the width of the first and second interplate spaces, and a face of the cassette (80) being defined by the length and width of the first or second plate (86, 88); the intermediate plate (90) comprising first and second pump stations (84), the first pump station defined by a first pump diaphragm and the first side of the intermediate plate (90), and the second pump station defined by a second pump diaphragm and the second side of the intermediate plate (90), said first pump diaphragm seated against the first side of the intermediate plate (90) and having a range of excursion defined by the width of the first interplate space, and said second pump diaphragm seated against the second side of the intermediate plate (90) and having a range of excursion defined by the width of the second interplate space; a first pump actuation channel (110) for the first pump station and extending parallel to the face of the cassette (80) in the first interplate space, and a second pump actuation channel for the second pump station and extending parallel to the face of the cassette (80) in the second interplate space; said first pump actuation channel connecting a first pump actuation chamber connected by the first plate (86) and the first pump diaphragm with a first cassette pump actuation orifice located within the first interplate space on a first edge of the cassette (80); and said second pump actuation channel connecting a second pump actuation chamber connected by the second plate (88) and the second pump diaphragm with a second cassette pump actuation orifice located in the second interplate space on the first edge of the cassette (80).
  3. 3. Fluid handling cassette (80) CHARACTERIZED in that it comprises an intermediate plate (90) positioned between a first plate (86) and a second plate (88), the intermediate plate (90) comprising a first side with a plurality of channel walls (110) projecting from the first side and a second side with a plurality of channel walls projecting from the second side, wherein the first plate (86) contacts the channel walls (110) on the first side of the intermediate plate (90) and the second plate (88) contacts the channel walls on the second side of the intermediate plate (90); a plurality of edges, each of which being perpendicular to the first side and coincident with an outer edge of the intermediate plate (90); a pump station with a pump actuation chamber defined by a pump diaphragm and the first plate (86), said pump diaphragm being seated against the first side of the intermediate plate (90); a pump actuation channel (110) defined by at least two channel walls of the plurality of channel walls (110) on the first side of the intermediate plate (90) and fluidically connecting the pump actuation chamber to a cassette pump actuation orifice (96) positioned on a first edge of the plurality of edges and located between the intermediate plate (90) and the first plate (86).
  4. 4. Fluid handling cassette (80), according to claim 3, CHARACTERIZED in that the plurality of channel walls on the second side of the intermediate plate (90) defines one or more fluid channels.
  5. 5. Fluid handling cassette (80), according to claim 3, CHARACTERIZED in that the cassette pump actuation orifice (96) is an integral part of the intermediate plate (90).
  6. 6. Fluid handling cassette (80), according to claim 4, CHARACTERIZED in that the pump station further comprises a first and a second pump orifice (24a, 24b) fluidically connecting a pumping chamber to, respectively, a first and a second fluid channels, the pumping chamber being defined by the pump diaphragm and the first side of the intermediate plate (90).
  7. 7. Fluid handling cassette (80), according to claim 4, CHARACTERIZED in that it comprises a pump orifice (24a) in the pump station fluidically connecting a fluid channel on the second side of the intermediate plate (90), with a pumping chamber defined by the pump diaphragm (122) and the first side of the intermediate plate (90).
  8. 8. Fluid handling cassette (80), according to claim 4, CHARACTERIZED in that it comprises an opening (42) in the intermediate plate (90) in the pump station, said opening (42) allowing the pump diaphragm to move from the first plate (86) to the second plate (88) when actuated by positive or negative pressure supplied through the pump actuation channel.
  9. 9. Fluid handling cassette (80), according to claim 7, CHARACTERIZED in that it comprises a fluid channel on the second side of the intermediate plate (90) fluidically connecting the pumping chamber to a fluid orifice of the cassette located on the first edge of the cassette and between the intermediate plate and the second plate (88).
  10. 10. Fluid handling cassette (80), according to claim 7, CHARACTERIZED in that it comprises a fluid channel on the second side of the intermediate plate (90) fluidically connecting the pumping chamber to a cassette fluid orifice located on a second edge of the cassette (80) and between the intermediate plate (90) and the second plate (88).
  11. 11. Fluid handling cassette (80), according to claim 3, CHARACTERIZED in that the first plate (86) is fixed to the channel walls on the first side of the intermediate plate (90).
  12. 12. Fluid handling cassette (80), according to claim 3, CHARACTERIZED in that the first plate (86) is laser welded to the channel walls of the intermediate plate (90) on the first side.
  13. 13. Fluid handling cassette (80), according to claim 3, CHARACTERIZED in that the first plate (86) and the second plate (88) allow transmission of laser wavelengths, while the intermediate plate (90) is opaque, and wherein the first plate (86) and the second plate (88) are laser welded to the intermediate plate (90).
  14. 14. Fluid handling cassette (80), according to claim 11, CHARACTERIZED in that the first plate (86) is fixed to the channel walls on the first side of the intermediate plate (90) by ultrasonic welding.
  15. 15. Fluid handling cassette (80) CHARACTERIZED in that it comprises an intermediate plate (90, 12) positioned between a first plate (86, 14) and a second plate (88, 16), the intermediate plate (90, 12) comprising a plurality of channel walls projecting from a first side, and a second side with a plurality of channel walls projecting from the second side, wherein the first plate (86) contacts the channel walls on the first side of the intermediate plate (90, 12) and the second plate (88, 16) contacts the channel walls on the second side of the intermediate plate (90, 12); a plurality of edges, each of which being perpendicular to the first side and coincident with an outer edge of the intermediate plate (90, 12); a valve station (116) comprising a valve actuation chamber defined by a valve diaphragm (124) and the first plate (86), the said valve diaphragm (124) seated against the first side of the intermediate plate (90, 12); and a valve actuation channel (110) defined by at least two channel walls of the plurality of channel walls on the first side of the intermediate plate (90, 12) and fluidically connecting the pump actuation chamber to a cassette valve actuation orifice positioned on a first edge of the plurality of edges and located between the intermediate plate (90, 12) and the first plate (86, 14).
  16. 16. Fluid handling cassette (80), according to claim 15, CHARACTERIZED in that the plurality of channel walls on the second side of the intermediate plate (90, 12) defines one or more fluid channels.
  17. 17. Fluid handling cassette (80), according to claim 16, CHARACTERIZED in that the valve station further comprises a first and a second valve fluid orifice (34a, 34b) fluidically connecting, respectively, a first and a second fluid channel on the second side of the intermediate plate (90, 12) to a valve fluid chamber defined by the valve diaphragm and the first side of the intermediate plate (90, 12).
  18. 18. Fluid handling cassette (80), according to claim 17, CHARACTERIZED in that one or both valve fluid orifices (34a, 34b) comprise a raised valve seat (40) for sealing the valve diaphragm (36) over the first or second valve fluid orifice when a positive pressure is applied to the valve diaphragm through the valve actuation channel.
  19. 19. Fluid handling cassette (80), according to claim 17, CHARACTERIZED in that the first fluid channel is fluidically isolated from the second fluid channel, except through the first and second valve fluid orifices (34a, 34b).
  20. 20. Fluid handling cassette (80), according to claim 17, CHARACTERIZED in that it comprises a fluid channel positioned on the second side of the intermediate plate (12), which fluidically connects a valve fluid chamber defined by the valve diaphragm (36) and the first side of the intermediate plate (12) to a cassette fluid orifice located on the first edge and between the intermediate plate (12) and the second plate (14).

Description

FIELD OF THE INVENTION [001] The present disclosure relates, in general, to improvements in the design and construction of pumping or mixing cassettes for fluids, cassette assemblies, their constituent parts and associated devices. FUNDAMENTALS [002] Liquid handling cassettes comprising pumps and/or diaphragm valves may be fluidically (either hydraulically or pneumatically) actuated. In some examples, a cassette is designed to be fluidically connected to a pneumatically actuated manifold having electromechanical valves that selectively distribute positively or negatively pressurized gas or air to the cassette. A programmable electronic controller may be used to control the electromechanical valves to selectively deliver positive or negative pneumatic pressure to various pumps or valves in the cassette in a predetermined manner. [003] Some fluid handling cassettes may be substantially planar in shape, having a wide side flanked by a thin or narrow side having a thickness relatively smaller than the overall wide-side dimensions of the cassettes. Liquid inlet and outlet orifices may be incorporated into the edge or thin side of the cassette. However, in many of these devices, the actuation orifices for the cassette have been located on the face or wide side of the cassette directly above the actuation chambers of the pumps or valves being controlled. In general, the shortest route to an actuation channel in the cassette is provided from a cassette actuation orifice external to the actuation chamber and diaphragm of a pump or valve in the cassette. Additionally, in many cases, the pump or valve stations or regions of the cassette – comprising the actuation chamber on one side of the liquid-carrying chamber on the opposite side – may be defined by spheroidal or hemi-spheroidal chamber walls that extend above the plane of the cassette face, which makes the overall cassette thicker than desirable in some applications. In other cases, a pump module may comprise an assembly of blocks sandwiched or laminated together, with the pneumatic actuation channels or fluid channels embedded in one or more of the blocks. This arrangement may also result in an overall device thickness greater than desirable for certain applications. Some applications may require a plurality of fluid handling cassettes to be mounted close to each other in tight spaces. In these cases, it may be desirable to position a number of cassettes adjacent to each other, stack them against each other, or at least their broad sides face to face in close proximity. Reducing or minimizing the thickness of the individual cassettes that make up these assemblies may be particularly desirable. [004] It may be advantageous to have a pump cassette that plugs directly into its associated pressure distribution manifold (e.g., a manifold that selectively delivers pneumatic pressure to the pump cassette under the control of an electronic controller). In previously disclosed embodiments of a hemodialysis system using pneumatically actuated stand-alone pump cassettes, the pump cassettes were connected to a corresponding pneumatic manifold via flexible tubing, which led to significant challenges during assembly and operation. If a pump cassette can be located close to its associated manifold, a direct plug-in connection between the two would have substantial advantages. Under these circumstances, it would be particularly advantageous to have a compact manifold that allows a direct interface to a pump cassette, arranged so as to allow the cassette or cassette assembly to be plugged and unplugged from the manifold actuation ports with minimal effort. [005] In the design and operation of a pneumatic distribution manifold, the ability to use binary pressure control valves instead of continuously variable orifice valves would also provide significant advantages in both cost and reliability. However, in this case, controlling pressure delivery to individual pumps or cassette valves by binary pressure control valves poses additional challenges that must be overcome. A sufficiently robust electronic controller can be programmed to use control to manage the frequency and duration of binary valve actuation to achieve precise control of associated pneumatically actuated pumps or valves. SUMMARY [006] In one embodiment, a pump and/or valve cassette has a relatively flat shape, with one wide side flanked by a narrower, thinner side or edge. It comprises an intermediate plate positioned between two outer plates: a first outer plate facing one side of the intermediate plate, and a second outer plate facing the opposite side of the intermediate plate. The first outer plate is separated from the intermediate plate to form a first interplate space. The second outer plate is separated from the intermediate plate to form a second interplate space. The thickness of the first and second outer plates is limited to a thickness sufficient to provide rigidity to the plate and to provide a sealing