# US 2024/0200550 A1 · High-throughput diaphragm compressor > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2024/0200550 A1 - Document ID: US20240200550A1 - Status: Published application - Kind: A1 - Application number: 18/516,210 - Filed: 2023-11-21 - Published: 2024-06-20 - Earliest claimed: 2021-11-08 - Assignees: PDC Machines Inc. - Applicants: Pdc Machines, Inc. - Inventors: Guy Babbitt; Garrett Casassa; Bryce Whitehill; Alex Beckerman; Kristina Weyer; Chris Turner; Kareem Afzal; Christopher Basilico - Web page: https://patentgrep.com/patent/US20240200550A1 ## CPC - F04B 45/0533: {the fluid being actuated directly by a piston} - F04B 41/02: having reservoirs - F04B 41/06: Combinations of two or more pumps - F04B 43/073: the actuating fluid being controlled by at least one valve - F04B 45/043: {two or more plate-like pumping flexible members in parallel} - F04B 45/053: Pumps having fluid drive - F04B 45/0536: {the actuating fluid being controlled by one or more valves} - F04B 49/22: by means of valves (F04B49/03 takes precedence) - F04B 53/06: Venting - F04B 53/14: Pistons, piston-rods or piston-rod connections - F04B 2201/0201: Position of the piston - F04B 2201/0202: Linear speed of the piston - F04B 2205/05: Pressure after the pump outlet - F04B: POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS (machines for liquids, or pumps, of rotary-piston or oscillating-piston type F04C; non-positive-displacement pumps F04D; pumping of fluid by direct contact of another fluid or by using inertia of fluid to be pumped F04F) ## Abstract Devices and methods for operating a diaphragm compressor system provide high output pressure and high throughput. In some embodiments, modular diaphragm compressors are stacked with a clamping mechanism pressing the compressor modules together. In embodiments, multiple stacks are provided as stages of a pressurization process. In embodiments, a main stage valve controls one or more pressure circuits for one or more hydraulic actuators of compressor modules. In embodiments, orifices configured for damping are incorporated to control actuator piston movement within a compressor module. ## Claims ### Claim at position 1 1-20. (canceled) ### Claim 21 A diaphragm compressor system, comprising: a plurality of compressor modules mounted in a stack configuration, each compressor module comprising: a first compressor head and a second compressor head; a diaphragm piston between the first compressor head and the second compressor head; a variable volume region between each of the diaphragm piston and the first compressor head and the second compressor head; each of the first compressor head and second compressor head comprising: a head cavity; and a diaphragm mounted in the head cavity and dividing the head cavity into a work oil region and a process gas region; the diaphragm configured to actuate from a first position to a second position during a discharge cycle to pressurize a process gas in the process gas region from an inlet pressure to a discharge pressure, and discharge the pressurized process gas through the respective compressor head; wherein the diaphragms of the first and second compressor heads of each compressor module are centered on a compressor axis; a hydraulic drive configured to pressurize work oil and provide the pressurized work oil to the first compressor head and second compressor head, wherein, during the discharge cycle of a compressor head, the hydraulic drive is configured to drive the respective diaphragm piston toward one of the corresponding first compressor head and second compressor head, intensifying the work oil in the respective variable volume region to an intensified pressure, and actuating the diaphragm to the second position; and a clamping mechanism configured to apply a clamping force parallel to the compressor axis, the clamping mechanism comprising a base plate and an end plate on opposing sides of the plurality of compressor modules, the base plate and end plate configured to be compressed, wherein the stack configuration of the plurality of compressor modules is configured such that the first or second compressor head of each compressor module that is not adjacent to the base plate or adjacent to the end plate, contacts a first or second compressor head of an adjacent compressor module. ### Claim 22 (depends on 21) The diaphragm compressor system of claim 21, wherein each compressor head comprises a work oil head support plate and a process gas head support plate; wherein the clamping force of the clamping mechanism is configured to clamp together each work oil head support plate with the respective process gas head support plate for each compressor module of the plurality of compressor modules. ### Claim 23 (depends on 21) The diaphragm compressor system of claim 21, wherein the plurality of compressor modules are in a staged configuration configured to discharge process gas at a first pressure and a second pressure; and wherein the system is configured to provide the discharged process gas at the first pressure from the first compressor head of the first compressor module of the plurality of compressor modules as an inlet supply of process gas to another compressor head of the system. ### Claim 24 (depends on 23) The diaphragm compressor system of claim 23, wherein one or more of the compressor modules of the plurality of compressor modules comprises a bypass check valve configured to bypass process gas past the respective compressor module. ### Claim 25 (depends on 23) The diaphragm compressor system of claim 23, wherein each compressor module comprises the first compressor head outputting process gas at a first pressure and the second compressor head outputting process gas at a second pressure; and wherein the system is configured to provide the discharged pressurized process gas from the first compressor head as an inlet supply of process gas to the second compressor head. ### Claim 26 (depends on 21) The diaphragm compressor system of claim 21, wherein the plurality of compressor modules comprising four compressor modules. ### Claim 27 (depends on 26) The diaphragm compressor system of claim 26, wherein the four compressor modules are configured to provide four sequential stages of increasing process gas pressurization. ### Claim 28 (depends on 27) The diaphragm compressor system of claim 27, wherein the four compressor modules comprise: a first compressor module configured to output pressurized process gas of at least 50 bar, a second compressor module configured to output pressurized gas of at least 200 bar, a third compressor module configured to output pressurized gas of at least 600 bar, and a fourth compressor module configured to output pressurized gas of at least 800 bar. ### Claim 29 (depends on 21) The diaphragm compressor system of claim 21, wherein the clamping mechanism connecting the base plate and the end plate is at least one of: two or more tie rods and a reactionary frame. ### Claim 30 (depends on 21) The diaphragm compressor system of claim 21, the clamping mechanism comprising: one or more tie rods; and at least one of a plurality of pre-tensioning nuts and a plurality of Belleville spring washers; wherein the clamping mechanism is configured to provide a pre-tension load on at least one of the base plate and the end plate. ### Claim 31 (depends on 21) The diaphragm compressor system of claim 21, wherein the clamping mechanism further comprising a clamp actuator configured to provide a dynamic clamping force to the plurality of compressor modules. ### Claim 32 (depends on 21) The diaphragm compressor system of claim 21, wherein the clamping mechanism comprises: a plurality of tie rods and a plurality of tensioner nuts. ### Claim 33 (depends on 21) The diaphragm compressor system of claim 21, wherein the hydraulic drive comprises: a hydraulic power unit configured to provide a variable-pressure supply of work oil to the hydraulic drive; a plurality of pressure circuits comprising: a first pressure circuit of work oil at a first pressure, and a second pressure circuit of work oil at a second pressure; a first diaphragm piston, wherein a first variable volume region is defined between the first diaphragm piston and the diaphragm of the first compressor head; and a second diaphragm piston, wherein a second variable volume region is defined between the second diaphragm piston and the diaphragm of the second compressor head. ### Claim 34 (depends on 23) The diaphragm compressor system of claim 23, wherein the hydraulic drive of each compressor module further comprises an actuator piston defining an actuator axis; and wherein the actuator piston is configured to move along the actuator axis to drive the diaphragm piston. ### Claim 35 (depends on 24) The diaphragm compressor system of claim 24, wherein the compressor axis and the actuator axis are coaxial. ### Claim 36 (depends on 24) The diaphragm compressor system of claim 24, wherein the compressor axis and the actuator axis are not coaxial. ### Claim 37 (depends on 23) The diaphragm compressor system of claim 23, wherein the diaphragm compressor system is configured to supply work oil from one or more hydraulic power units and from one or more pressure circuits of the plurality of pressure circuits to each hydraulic drive of two or more compressor modules of the plurality of compressor modules. ### Claim 38 (depends on 21) The diaphragm compressor system of claim 21, wherein each compressor module of the plurality of compressor modules is configured to be selectively deactivated; and wherein the compressor system is configured to operate the remaining compressor modules of the plurality of compressor modules when a compressor module of the plurality of compressor modules is deactivated. ### Claim 39 (depends on 21) The diaphragm compressor system of claim 21, wherein the clamping mechanism is configured to increase a distance between the base plate and the end plate in response to thermal expansion of one or more compressor modules of the plurality of compressor modules. ### Claim 40 A diaphragm compressor system, comprising: a plurality of compressor modules mounted in a stack configuration, each compressor module comprising: a first compressor head and a second compressor head; a diaphragm piston between the first compressor head and the second compressor head; a variable volume region between each of the diaphragm piston and the first compressor head and the second compressor head, each of the first compressor head and second compressor head comprising: a head cavity, and a diaphragm mounted in the head cavity and dividing the head cavity into a work oil region and a process gas region, the diaphragm configured to actuate from a first position to a second position during a discharge cycle to pressurize process gas in the process gas region from an inlet pressure to a discharge pressure, and discharge the pressurized process gas through the respective compressor head, wherein the diaphragms of the first and second compressor heads of each compressor module are centered on a compressor axis; a hydraulic drive configured to pressurize work oil and provide the pressurized work oil to the first compressor head and second compressor head, wherein, during the discharge cycle of a compressor head, the hydraulic drive is configured to drive the respective diaphragm piston toward one of the corresponding first diaphragm compressor head and second compressor head, intensifying the work oil in the respective variable volume region to an intensified pressure, and actuating the diaphragm to the second position; and a clamping mechanism configured to apply a clamping force, parallel to the compressor axis, to the first and second compressor head of each compressor module of the plurality of compressor modules, the clamping mechanism comprising a base plate and an end plate on opposing sides of the plurality of compressor modules, the base plate and end plate configured to be compressed, wherein the stack configuration is continuous such that it comprises no gaps along a line parallel to the compressor axis adjacent the first compressor head and second compressor head of each compressor module.