Field of Art
The present disclosure relates to a transfer cap for a photoresist container.
Description of the Related Art
It is often necessary to ship chemically hazardous fluids such as photoresist. These fluids are typically shipped via a bottle that includes a cap.
Japanese Laid-Open Patent Application 2000-142772 discloses a cap that includes a filter and a pressure release valve which releases pressure from the container if the container becomes over-pressurized. While, Japanese Laid-Open Patent Application 2008-230691 discloses a bottle cap with a tube connected to the bottle cap. Also, US Patent Publication No. 2009/0049988 discloses a container with a gas-permeable vent that has a liquid-tight gas-permeable seal. U.S. Pat. No. 4,643,825 discloses a shipping container that includes a bung with at least two openings. One of the openings of the bung includes a dip tube. Another opening of the bung includes a gas filter. Both openings of the bung are sealed with plugs during shipment of the filled container.
Shipping containers with one or more ports such as a vent port and/or a dispensing port experience multiple issues. For example, a shipping container may experience leaks when opening the vent port on a resist bottle. These leaks may take the form of resist bubbling out the vent port. This can cause problems for shipping hazardous materials. In addition, during transport and shipping overseas, the liquid can flow into one or more of the ports if and when the bottle gets pressurized. If the vent port is uncapped under these conditions, there is no protection against residual fluid flowing or shooting out of the newly opened port. This situation poses a safety hazard especially when handling chemically hazardous fluids.
US Patent Publication No. 2015/0083274 discloses a universal manifold for attaching to various different storage containers. US Patent Publication No. 2001/0013882 discloses bottles that use a puncture seal to deliver the liquid to a main reservoir. US Patent Publication No. 2006/0012659 discloses a bottle that is shipped with a solid cap. Once the bottle is received the solid cap is unscrewed and a cap with a dip tube is attached. These systems can cause problems with purity by generating particles and also allowing contaminates to enter the bottle.
What is needed is a system that is both safe and allows for the purity of the material to be maintained at a high level.
At least a first embodiment, may be a cap that is capable of being fitted to a bottle. The cap may comprise a transfer port and a vent port. The vent port may include a membrane and a valve.
At least a first embodiment, may be a cap wherein the bottle is configured for storing and transporting liquid.
In an aspect of the first embodiment, the transfer port is a liquid transfer port for draining or filling fluid in and out of the bottle.
In an aspect of the first embodiment, a valve is one of a poppet valve, a check valve, and a manual vent.
In an aspect of the first embodiment, the cap may further comprise a drain port with a connector in the cap allowing the attachment of a drain tube onto the cap extending away from the bottle.
In an aspect of the first embodiment, the membrane may be made of expanded PTFE.
In an aspect of the first embodiment, the transfer port may comprise a dip connector and a transfer connector. The dip connector may allow the attachment of a dip tube onto the cap extending into the bottle. The transfer connector may allow the attachment of a transfer tube onto the cap extending out of the bottle. In an aspect of the first embodiment, the dip connector and the transfer connector may be compression fittings or screw fittings.
In an aspect of the first embodiment, a cap may further comprise an additional port. The additional port may comprise an additional dip connector allowing the attachment of an additional dip tube onto the cap extending into the bottle. In an aspect of the first embodiment, the additional port may further comprise an additional transfer connector allowing the attachment of an additional transfer tube onto the cap extending out of the bottle. In an aspect of the first embodiment, the additional transfer tube may connect the cap to at least one of a reservoir and a valve.
In an aspect of the first embodiment, when the valve is open the vent port may allow gas to pass through the vent port and does not substantially allow liquid to pass through the vent port. In addition, when the valve is closed the vent port may not substantially allow gas or liquid to pass through the vent port.
In an aspect of the first embodiment, the valve may open automatically when internal pressure on the bottle side of the cap is outside an internal pressure range. In an aspect of the first embodiment, a manual vent port may be opened if the valve that opens automatically fails.
In an aspect of the first embodiment, bulk material of the membrane may be made of a material that is compatible with cleaning techniques which are capable of removing ions and small molecules from throughout the membrane to a level of at least 1 ppb.
In an aspect of the first embodiment, the ion leaching of materials used for manufacturing of the cap may provide ion cleanliness levels <1 ppb for elements: Na, Ca, Fe, K, Zn, Al, Mg, Ni, Cr, Cu, Pb, Mn, Li, Sn, Ba, Co, Sr, and Pd.
In an aspect of the first embodiment, materials of the membrane, the valve, a surface of the transfer port, and a surface of the vent port may be made of material that is compatible with cleaning techniques which are capable of removing ions and small molecules from their surfaces to a level of at least 1 ppb.
In an aspect of the first embodiment, one or more of the materials used for fabricating the cap may be selected from: polypropylene; polyethylene; and fluorinated plastics, such as polyvinylidene fluoride; and PTFE.
An aspect of a second embodiment, is a method of using a cap attached to a bottle. The cap may comprise: a transfer port and a vent port that includes a membrane and a valve. The method may comprise: removing one of a cap or a plug from the vent port; opening the vent port with a manual valve; removing one of a cap or a plug from the fluid port; attaching the bottle to a reservoir via a transfer tube; and activating a pump to draw liquid out of the bottle via the transfer tube and into the reservoir.
An aspect of a third embodiment, is a liquid transfer system. The liquid transfer system may comprise: a bottle containing a liquid; a cap attached to the bottle; a reservoir; a transfer tube connecting the reservoir to the transfer port; and a pump to draw liquid out of the bottle via the transfer tube and into the reservoir. The cap may comprise: a transfer port and a vent port that includes a membrane and a valve.
These and other objects, features, and advantages of the present disclosure will become apparent upon reading the following detailed description of exemplary embodiments of the present disclosure, when taken in conjunction with the appended drawings, and provided claims.
Further objects, features and advantages of the present disclosure will become apparent from the following detailed description when taken in conjunction with the accompanying figures showing illustrative embodiments of the present disclosure.
Throughout the figures, the same reference numerals and characters, unless otherwise stated, are used to denote like features, elements, components or portions of the illustrated embodiments. Moreover, while the subject disclosure will now be described in detail with reference to the figures, it is done so in connection with the illustrative exemplary embodiments. It is intended that changes and modifications can be made to the described exemplary embodiments without departing from the true scope and spirit of the subject disclosure as defined by the appended claims.
What is needed is a solution that will prevent safety hazards associated with previous caps while maintaining cleanliness requirements and also adding functional features such as a having a built in transfer port in the cap. The environment in which the transfer port is used has a very high cleanliness requirement. The transfer cap is part of a larger system which should not add more than 5 ppb worth of contamination over a year of continuous use. In order to keep defects low it is important that all components and materials used can be cleaned to a high level of cleanliness, which can then be maintained over the life of the product.
First Embodiment
The bottom portion of the transfer cap 100 illustrated in
The transfer cap 100 may include a seat which also interfaces with the bottle. The seat of the transfer cap 100 may be capable of forming a liquid tight seal with the bottle. A gasket may also be used in conjunction with the transfer cap to form the liquid tight seal. In an alternative embodiment, the seat of the transfer cap may be capable of forming a gas tight seal and a liquid tight seal with the bottle.
The vent port 104 of the transfer cap 100 includes a membrane 106 and a valve 108. Because the membrane 106 may pose a cleanliness concern, it may need to be subject to harsh chemicals so that it can meet high cleanliness specifications. The membrane 106 may be made of expanded PTFE. The valve 108 may include a vent opening 110. The valve 108 may be threaded or unthreaded. The valve 108 may be opened by unscrewing or by being raised. The valve 108 may include instead of threads a snap fitting that interfaces with a lip in the vent port 104. The valve 108 may form a substantially gas tight and liquid tight seal when closed. The valve 108 may control the rate at which gas and/or liquid is released when the valve 108 is in an open position. The release rate may be controlled by the size of the vent opening 110.
The membrane 106 is configured to allow gas to pass while not allowing liquid to pass. The pore size of the membrane 106 may be configured to allow some low molecular weight gases (Nitrogen, Oxygen, etc,) to pass.
The membrane 106 may be placed in the vent port 104 as illustrated in
The transfer port 102 may be configured to accept a dip tube 312 as illustrated in
The transfer port 102 may be configured to accept a compression fitting 414 (or screw fitting). The compression fitting 414 may form a gas tight seal and liquid tight seal with the cap 100. The compression fitting 414 is configured to accept a transfer tube 416 and form a gas tight seal and a liquid tight seal with the transfer tube 416. Alternatively, the transfer tube 416 may be inserted directly into the transfer port 102. In another alternative, the transfer tube 416 and the dip tube 312 may be combined into a single tube.
During shipment, the primary vent port 604 of the transfer cap 600 may be capped with a plug 618b as illustrated in
The membrane 106 may be a porous material that allows vapor to pass and prevents liquid from escaping. The membrane 106 may made of a frit or membrane material such as: glass; metal; expanded PTFE; PEEK; Polyethylene; Polypropylene, etc. The membrane material is a chemically resistant material which does not react with the material that is intended to be stored in the bottle. The membrane material may also be chemically resistant to cleaning solvents and other materials that are to be used in combination with the bottle. The membrane 106 may have pore size between 50 nm to 500 μm. In an embodiment, the membrane pore size may be between 30 μm to 70 μm. The membrane pore size impacts the desired flow rate for venting and the time required to trigger the vent valve.
The pressure release valve 620 may be triggered to open when there is a partial vacuum and/or over pressurization above a threshold inside the bottle and may be triggered to close at the end of the fluid transfer. The close of the pressure release valve 620 can prevent the dripping of liquid out of the transfer tube when the transfer tube is disconnected from a pump. The pressure release valve 620 may be triggered open when a pressure differential inside the bottle is greater than 0.2 psi or greater than 1 psi for controlled venting.
The transfer cap may include a manual gas release valve in addition to a plug 208 that is built into the transfer cap which the user can open or close to vent gas in a controlled manner. The manual gas release valve may be a captive luer plug or a needle valve.
This transfer cap allows the bottle 626 to vent to the atmosphere while liquid 624 is being pumped out. For example, when a critical vacuum is reached within the bottle 626, the valve 620, which may be a poppet valve or duckbill valve, is triggered to open.
Materials used for the transfer cap and the associated components may meet <1 ppb ion cleanliness and are chemically resistant to material stored under the cap and in the bottle. Chemically resistant in this context is material that does not substantially get swollen, get brittle, oxidize, etc, when exposed to the material stored in the bottle and the environment in which the bottle is used. The ion leaching of materials used for manufacturing of the cap may provide ion cleanliness levels <1 ppb or alternatively <10 ppb for elements: Na, Ca, Fe, K, Zn, Al, Mg, Ni, Cr, Cu, Pb, Mn, Li, Sn, Ba, Co, Sr, and Pd. The materials of the membrane, the valve, a surface of the transfer port, and a surface of the vent port are made of material that is compatible with cleaning techniques which are capable of removing ions and small molecules from the membrane, the valve, a surface of the transfer port, and a surface of the vent port to a level of at least 1 ppb. The bulk material of the membrane may be made of material that is compatible with cleaning techniques which are capable of removing ions and small molecules from throughout the membrane to a level of at least 1 ppb. The materials used for fabricating the cap may be selected from: polypropylene; polyethylene; fluorinated plastics such as polyvinylidene fluoride; and PTFE.
In an embodiment, a transfer tube is connected to a pump pulling on liquid in the tubes and bottle. Initially, the valve 620 is closed and does not open until a target cracking pressure (like 1 psi or lower) is reached. The transfer tube is connected to the pump and continues to pump down the bottle until a low vacuum is achieved which triggers the opening of the valve 620. Then liquid flows out of the bottle and into a reservoir. In an embodiment, a transfer tube may connect the cap to one of a reservoir, a valve, or a pump.
Second Embodiment
An alternative embodiment is a transfer cap insert 700 which is used in combination with a bottle cap 728 as illustrated in
Methods
A preparation method of using the transfer cap may include preparing a bottle and transfer cap for shipment as illustrated in
The transfer cap may be used in a transfer method 830 of inserting the bottle with the transfer cap into a system in which the bottle is used as illustrated in
System
An embodiment may be used in combination with a liquid transfer system as illustrated in
The liquid transfer system may also include a reservoir 942, a transfer tube, and a pump 940. The pump 940 may draw liquid out of the bottle via the transfer tube and into the reservoir 942. The transfer tube may connect the pump or the reservoir to the transfer port. The pump may be in the reservoir, may be connected to reservoir, or may between the reservoir and the transfer port.
The valve of the vent port may open automatically when vacuum pressure inside the bottle is greater than a threshold.
In describing example embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner.
While the present disclosure has been described with reference to exemplary embodiments, it is to be understood that the present disclosure is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
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