Dialyzer manufacturing tools

Abstract

A dialyzer housing manufacturing system includes: a molding apparatus configured to mold a dialyzer housing; and a tool coupled to a robotic arm and configured to remove the dialyzer housing from the molding apparatus after molding the dialyzer housing. The tool includes a frame, a first suction cup connected to a first portion of the frame, and a second suction cup connected to a second portion of the frame, the second suction cup being oriented at about 70 degrees to about 110 degrees relative to the first suction cup.

Description

Technical Field

[0001] The present disclosure relates to a robotic arm tool for use in dialyzer manufacturing. Background Art

[0002] Hemodialysis is a treatment method used to support patients with renal insufficiency. During hemodialysis, the patient's blood passes through the dialyzer of a dialysis machine, while a dialysis solution, or dialysate, also passes through the dialyzer. The dialyzer consists of a housing and a semipermeable membrane contained within the dialyzer housing. The semipermeable membrane separates the blood from the dialysate within the dialyzer and allows diffusion and osmotic exchange between the dialysate and the bloodstream. The dialyzer housing is typically manufactured using an injection molding process. Summary of the Invention

[0003] In one aspect, a dialyzer housing manufacturing system includes: a molding apparatus configured to mold a dialyzer housing; and a tool coupled to a robotic arm and configured to remove the dialyzer housing from the molding apparatus after molding the dialyzer housing. The tool includes: a frame; a first suction cup connected to a first portion of the frame; and a second suction cup connected to a second portion of the frame, the second suction cup being oriented at about 70 degrees to about 110 degrees relative to the first suction cup.

[0004] Embodiments may include one or more of the following features, in any combination.

[0005] In some embodiments, the first suction cup and the second suction cup are fluidly coupled to a vacuum source.

[0006] In some embodiments, the dialyzer housing manufacturing system further comprises: a third suction cup connected to the first portion of the frame; a fourth suction cup connected to the first portion of the frame; a fifth suction cup connected to the first portion of the frame; a sixth suction cup connected to the second portion of the frame; a seventh suction cup connected to the second portion of the frame; and an eighth suction cup connected to the second portion of the frame, the sixth suction cup, the seventh suction cup, and the eighth suction cup being oriented at approximately 70 degrees to approximately 110 degrees relative to the third, fourth, and fifth suction cups.

[0007] In certain embodiments, the molding apparatus is configured to mold two dialyzer housings.

[0008] In some embodiments, the tool is configured to simultaneously remove two dialyzer housings from the molding apparatus.

[0009] In certain embodiments, the molding apparatus is an injection molding apparatus.

[0010] In some embodiments, the tool is rotatable between a first position and a second position.

[0011] In certain embodiments, the dialyzer housing manufacturing system further comprises a pneumatic cylinder and a rotating pin, wherein the rotating pin couples the tool to the robotic arm, the tool being configured to rotate about the rotating pin in response to a force applied to the tool by the pneumatic cylinder.

[0012] In some embodiments, the width of the tool in the first position is about 16 cm to about 17 cm.

[0013] In certain embodiments, the molding apparatus is configured to open the pair of mold halves by between about 200 mm and about 240 mm after molding the dialyzer housing.

[0014] In some embodiments, the width of the tool in the second position is about 35 cm to about 36 cm.

[0015] In certain embodiments, the mold includes alignment pins coupled to the first mold half, and when the mold is opened after molding the dialyzer housing, the alignment pins remain partially inserted into the second mold half.

[0016] In some embodiments, the dialyzer housing manufacturing system further comprises a cooling stage for cooling the dialyzer housing.

[0017] In certain embodiments, the dialyzer housing manufacturing system further includes a storage container for storing the dialyzer housings.

[0018] In another aspect, a method includes: opening a mold to expose a first dialyzer housing; coupling the first dialyzer housing to a first portion of a tool; moving the tool to remove the first dialyzer housing from the mold; rotating the tool from about 70 degrees to about 110 degrees to orient the first portion of the tool in a first orientation; placing the first dialyzer housing at a first location using the tool; rotating the tool from about 70 degrees to about 110 degrees to orient a second portion of the tool in the first orientation; coupling a second dialyzer housing at the first location to the second portion of the tool; and placing the second dialyzer housing at a second location using the tool.

[0019] Embodiments may include one or more of the following features, in any combination.

[0020] In some embodiments, the mold opens from about 200 mm to about 240 mm.

[0021] In certain embodiments, coupling the first dialyzer housing to the first portion of the tool comprises inserting the tool between the first mold half and the second mold half.

[0022] In some embodiments, inserting the tool between the first mold half and the second mold half includes extending a robotic arm coupled to the tool between the first mold half and the second mold half.

[0023] In certain embodiments, coupling the first dialyzer housing to the first portion of the tool comprises: positioning one or more suction cups coupled to the first portion of the tool proximate the first dialyzer housing; and applying vacuum suction through an opening in each of the one or more suction cups.

[0024] In some embodiments, placing the first dialyzer housing at the first location using the tool comprises: positioning the first dialyzer housing proximate the first location using the tool; and ceasing to apply vacuum suction through an opening of each of the one or more suction cups.

[0025] In certain embodiments, coupling the second dialyzer housing at the first location to the second portion of the tool comprises: positioning one or more suction cups coupled to the second portion of the tool proximate the second dialyzer housing; and applying vacuum suction through an opening in each of the one or more suction cups.

[0026] In some embodiments, placing the second dialyzer housing at the second location using the tool comprises: positioning the second dialyzer housing proximate the second location using the tool; and ceasing application of vacuum suction through the opening of each of the one or more suction cups.

[0027] In certain embodiments, the method further comprises coupling a third dialyzer housing to the first portion of the tool; and moving the tool to remove the third dialyzer housing from the mold, wherein the first dialyzer housing and the third dialyzer housing are removed from the mold simultaneously.

[0028] In some embodiments, the method further comprises coupling a fourth dialyzer housing at the first location to a second portion of the tool; and placing the fourth dialyzer housing at the second location using the tool, wherein the second dialyzer housing and the fourth dialyzer housing are placed simultaneously at the second location.

[0029] In certain embodiments, the first location comprises a cooling table.

[0030] In some embodiments, the second location comprises a storage container.

[0031] In another aspect, an apparatus for removing a dialyzer housing from a mold comprises: a tool coupled to a robotic arm; and a pin rotatably coupling the tool to the robotic arm. The tool comprises: a frame; a first suction cup connected to a first portion of the frame; and a second suction cup connected to a second portion of the frame, the second suction cup being oriented at about 70 to about 110 degrees relative to the first suction cup.

[0032] Embodiments may include one or more of the following features, in any combination.

[0033] In some embodiments, the first suction cup and the second suction cup are fluidly coupled to a vacuum source.

[0034] In some embodiments, the device further comprises: a third suction cup connected to the first portion of the frame; a fourth suction cup connected to the first portion of the frame; a fifth suction cup connected to the first portion of the frame; a sixth suction cup connected to the second portion of the frame; a seventh suction cup connected to the second portion of the frame; and an eighth suction cup connected to the second portion of the frame, the sixth suction cup, the seventh suction cup, and the eighth suction cup being oriented at approximately 70 degrees to approximately 110 degrees relative to the third suction cup, the fourth suction cup, and the fifth suction cup.

[0035] In certain embodiments, the tool is configured to rotate about the pin between the first position and the second position from about 70 degrees to about 110 degrees.

[0036] In some embodiments, the width of the tool in the first position is about 16 cm to about 17 cm.

[0037] In certain embodiments, the width of the tool in the second position is about 35 cm to about 36 cm.

[0038] In another aspect, a dialyzer housing manufacturing system includes: a molding apparatus configured to mold a dialyzer housing; and a tool coupled to a robotic arm and configured to remove the dialyzer housing from the molding apparatus after molding the dialyzer housing. The tool includes: a frame; a first suction cup connected to a first portion of the frame; and a second suction cup connected to a second portion of the frame, wherein the tool is rotatable between a first position and a second position, wherein in the first position, the first suction cup extends in a first direction, and in the second position, the second suction cup extends in the first direction, and wherein a width of the tool in the second position is greater than a width of the tool in the first position.

[0039] The width of the tool in the first position is measured linearly from the first suction cup to the opposite edge of the tool, and the width of the tool in the second position is measured linearly from the second suction cup to the opposite edge of the tool.

[0040] Advantages of the systems, devices, and methods described herein include reduced wear on the injection molding apparatus. For example, by using a rotatable arm tool to minimize the amount that the mold must open during removal of the dialyzer housing from the mold ("demolding"), the amount of wear on the injection molding apparatus is reduced. Additionally, by using a rotatable arm tool to minimize the amount that the mold must open during demolding, alignment pins of the molding apparatus can remain engaged during demolding, thereby reducing the risk of damage to the injection molding apparatus. Another advantage is that by using a rotatable arm tool to minimize the amount that the mold must open during demolding, the overall time required to perform injection molding of the dialyzer housing is reduced.

[0041] Other aspects, features, and advantages will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Figure 1 A system for manufacturing a dialyzer housing is depicted, the system comprising a molding apparatus and a robotic arm tool.

[0043] Figure 2 yes Figure 1 A perspective view of the system's robotic arm tool in a first position.

[0044] Figure 3 yes Figure 1 A perspective view of the system's robotic arm tool in a second position.

[0045] Figure 4 yes Figure 1 A side view of the molding device of the system.

[0046] Figure 5 yes Figure 1 A front view of a portion of the forming apparatus of the system.

[0047] Figure 6-21 Describes the use Figure 1 An exemplary process for manufacturing a dialyzer housing using a system. DETAILED DESCRIPTION

[0048] refer to Figure 1 The dialyzer housing manufacturing system 100 includes an injection molding device 102 , a robot arm 104 , a cooling stage 106 and a storage container 108 .

[0049] like Figure 1 As shown, the injection mold includes two mold halves 110, 112. As described in further detail herein, the mold halves 110, 112 can be moved within the injection mold 102 to form a cavity in which the dialyzer housing 124 can be molded. Figure 1 As shown, during the injection molding process of the dialyzer housing 124, the mold halves 110, 112 are pressed together and molten resin is injected into the cavity formed by the mold halves 110, 112 to mold the dialyzer housing 124. Once the dialyzer housing 124 is molded, the mold halves 110, 112 are opened to expose the dialyzer housing 124 and allow the dialyzer housing 124 to be removed from the injection molding apparatus 102.

[0050] Once the dialyzer housing has been formed by the injection molding apparatus 102, the robotic arm 104 is used to remove the dialyzer housing 124 from the injection molding apparatus 102. Figure 1As shown, the arm tool 114 is coupled to one end of the robotic arm 104. As described in further detail herein, the arm tool 114 can apply suction to the dialyzer housing 124 to remove the dialyzer housing 124 from the injection molding apparatus 102.

[0051] Once the dialyzer housing 124 has been removed from the injection molding apparatus 102 using the arm tool 114, the robotic arm 104 and the arm tool 114 are used to place the dialyzer housing 124 on the cooling table 106. For example, the arm tool 114 can be rotated about the end of the robotic arm 104 to position the dialyzer housing 124 coupled to the arm tool 114 on the cooling table 106. The cooling table 106 is configured to provide airflow around the dialyzer housing 124 to reduce the temperature of the surface of the newly molded dialyzer housing 124. Figure 1 As shown, the cooling table 106 includes a plurality of cooling racks 138 that allow a plurality of dialyzer housings 124 to be positioned on the cooling table 106 .

[0052] Once the surface of the dialyzer housing 124 has cooled to a temperature ranging from about 115° C. to about 125° C., a portion of the arm tool 114 is coupled to the dialyzer housing 124. The robotic arm 104 and the arm tool 114 lift the dialyzer housing 124 off the cooling table 106 and place the dialyzer housing 124 within the storage container 108. Once the storage container 108 is filled with dialyzer housings, a new empty storage container is provided, and the filled storage container 108 can be used to store or ship the dialyzer housings packaged within the storage container 108.

[0053] Still refer to Figure 1 , the robotic arm 104 of the dialyzer housing manufacturing system 100 includes a base 116, a cross arm 118 and a vertical protrusion 120. The base 116 is stationary relative to the injection molding device 102 and includes a set of rails 122 extending along the length of the top surface of the base 116. The position of the arm tool 114 can be adjusted by moving various components of the robotic arm 104. For example, the vertical protrusion 120 can move back and forth along the length on the cross arm 118, and the cross arm can move back and forth laterally along the length of the base 116 by traveling along the rails 122. In addition, the vertical protrusion 120 is configured to extend to lower the arm tool 114 and retract to raise the arm tool 114. By coordinating the movement of the cross arm 118 and the vertical protrusion 120, the arm tool 114 can be precisely positioned in three-dimensional space.

[0054] like Figure 1As shown, the dialyzer housing manufacturing system 100 also includes a set of controllers 160, 162. The first controller 160 is configured to control the injection molding apparatus 102, and the second controller 162 is configured to control the robotic arm 104 and the arm tool 114. The controllers 160, 162 are communicatively coupled to each other and send signals to each other to coordinate the movement of the injection molding apparatus 102, the robotic arm 104, and the arm tool 114. By controlling the timing and movement of the injection molding apparatus 102, the robotic arm 104, and the arm tool 114, the controllers 160, 162 enable the arm tool 114 to engage the dialyzer housing 124 and move the dialyzer housing 124 throughout the dialyzer housing manufacturing system 100. For example, when the molds 110, 112 are in the open position, the injection molding apparatus controller 160 sends a signal to the robotic arm controller 162, which controls the robotic arm 104 and the arm tool 114 to remove the dialyzer housing from the molds 110, 112.

[0055] Furthermore, the injection molding apparatus 102 and the robotic arm 104 each include a rotary encoder (not shown) communicatively coupled to the controllers 160 and 162, and the signals received by the controllers 160 and 162 from the rotary encoders can be used to determine the spatial positioning of components of the injection molding mold 102 and the robotic arm 104. For example, the rotary encoder is used to measure the number of revolutions completed by the motor of the robotic arm 104. The controller 162 can determine the direction and distance traveled by the cross arm 118 and / or the vertical protrusion 120 of the robotic arm 104 based on the number of revolutions completed by the motor of the robotic arm 104 detected by the rotary encoder. Based on the direction and distance traveled by the cross arm 118 and / or the vertical protrusion 120 determined based on the signals received from the rotary encoder, the controller 162 can determine the position of the arm tool 114 in three-dimensional space. Similarly, the rotary encoder is used to measure the number of revolutions completed by the motor used to move the molds 110 and 112. The controller 160 can determine the direction and distance that the half mold 112 of the injection molding device 102 has traveled based on the number of revolutions that the motor of the injection molding device 102 has completed as detected by the rotary encoder. Each component of the injection molding device 102 and the robotic arm 104 is configured to move a predetermined distance throughout the process cycle to mold and transport the dialyzer shell. In some embodiments, the rotary encoders of the injection molding device 102 and the robotic arm 104 each determine the number of revolutions that the motor of the injection molding device 102 and the robotic arm 104 has respectively completed based on a signal received from a proximity switch communicatively coupled to the encoder. In some embodiments, the rotary encoders of the injection molding device 102 and the robotic arm 104 each determine the number of revolutions that the motor of the injection molding device 102 and the robotic arm 104 has respectively completed based on a magnet of the rotary encoder.

[0056] Figure 2A perspective view of the arm tool 114 is depicted in a first position 200. Figure 2 As shown, the arm tool 114 includes eight suction cups 230 , 232 , 234 , 236 , 238 , 240 , 242 , 244 coupled to a frame 280 .

[0057] Each suction cup 230, 232, 234, 236, 238, 240, 242, 244 is configured to be coupled to a dialyzer housing 124 formed by the injection molding apparatus 102. For example, each suction cup 230, 232, 234, 236, 238, 240, 242, 244 includes an opening through a center thereof, and each suction cup 230, 232, 234, 236, 238, 240, 242, 244 is fluidly coupled to a vacuum source such that suction can be applied through the center of each suction cup 230, 232, 234, 236, 238, 240, 242, 244. As described in further detail herein, the dialyzer housing can be coupled to the suction cups 230, 232, 234, 236, 238, 240, 242, 244 by applying suction through the center of the respective suction cups.

[0058] The suction cups 230, 232, 234, 236, 238, 240, 242, 244 are divided into: a first group of suction cups 202, which includes the suction cups 230, 232, 234, 236; and a second group of suction cups 204, which includes the suction cups 238, 240, 242, 244. Figure 2 As shown, the first set of suction cups 202 is coupled to the first portion 282 of the frame 280 and the second set of suction cups 204 is coupled to the second portion 284 of the frame 280. Figure 2 and 3 As can be seen in FIG. 2 , the first set of suction cups 202 is coupled to the frame 280 such that the first set 202 is oriented approximately 90 degrees relative to the second set of suction cups 204 .

[0059] refer to Figure 1 The system 100 includes a vacuum source 150 that is fluidically coupled to each set of suction cups 202, 204 via a vacuum line 152 extending along the vertical projection 120. A controller 160 controls the application of vacuum suction through each set of suction cups 202, 204 to allow the dialyzer housing to selectively engage the respective set of suction cups 202, 204. The vacuum source 150 applies a vacuum pressure in the range of about 0.35 MPa to about 0.50 MPa to the end of each suction cup. Any of a variety of suitable pumps can be used as the vacuum source 150, such as a suction pump, a positive displacement pump, a venturi pump, and the like.

[0060] The vacuum source 150 is communicatively coupled to a controller 160, which controls the timing of the vacuum source 150 applying suction through the groups 202, 204 of suction cups of the arm tool 114. For example, the controller 160 can coordinate the vacuum suction with the movement of the robotic arm 104 and the arm tool 114 to selectively apply vacuum suction through the corresponding group when one of the suction cup groups 202, 204 is positioned proximate to a dialyzer housing to be moved by the arm tool 114.

[0061] like Figure 2 As shown, the first portion 282 of the frame 280 forms a rectangular platform 206, and the first set of suction cups 202 are attached to the rectangular platform 206. Figure 1 As shown in FIG, the rectangular platform 206 is positioned so that the first set of suction cups 202 coupled to the platform 206 are directed sideways relative to the vertical protrusion 120 of the robot arm 104. Figure 2 As shown, the first set of suction cups 202 includes two pairs of suction cups 208, 210. Each suction cup 230, 232, 234, 236 in the first set 202 is coupled to the rectangular platform 206 near a respective corner of the rectangular platform 206.

[0062] The first set of suction cups 202 is configured to be coupled to two dialyzer housings simultaneously, with the first pair of suction cups 208 coupled to the first dialyzer housing and the second pair of suction cups 210 coupled to the second dialyzer housing. As previously described, each suction cup in the first set 202 includes an opening therethrough. The first set of suction cups 202 is fluidly coupled to the vacuum line 152, which is coupled to the vacuum source 150. Vacuum suction can be provided to the first set of suction cups 202 via the vacuum line 152 to couple a pair of dialyzer housings to the first set of suction cups 202.

[0063] In some examples, the rectangular platform 206 has a total width of about 9 cm to about 11 cm (e.g., about 10.16 cm), a total length of about 16 cm to about 17 cm (e.g., about 16.51 cm), and a total thickness of about 1 cm to about 3 cm (e.g., about 2.54 cm).

[0064] Still refer to Figure 2 , the second portion 284 of the frame 280 forms a U-shaped platform 212, and the second set of suction cups 204 are attached to the U-shaped platform 212. The U-shaped platform 212 includes a first column 214, a second column 216, and a connecting rod 218. The first column 214 is coupled to a first end of the connecting rod 218, and the second column 216 is coupled to a second end of the connecting rod 218 opposite the first column 214. Figure 2 As shown, the longitudinal axis of the connecting rod 218 is substantially perpendicular to the longitudinal axis of each column 214, 216. Figure 2As shown in FIG, the longitudinal axis of each of the posts 214, 216 is substantially parallel to the longitudinal axis of the vertical projection 120 of the robot arm 104. Figure 2 As shown, the rectangular platform 206 is coupled to the connecting rod 218 of the U-shaped platform 212 .

[0065] In some examples, each column 214, 216 of the U-shaped platform 212 has an overall width of about 7 cm to about 8 cm (e.g., about 7.62 cm), an overall length of about 22 cm to about 24 cm (e.g., about 25.4 cm), and an overall thickness of about 1 cm to about 3 cm (e.g., about 3.81 cm). In some examples, the connecting rod 218 of the U-shaped platform 212 has an overall width of about 7 cm to about 8 cm (e.g., about 7.62 cm), an overall length of about 16 cm to about 17 cm (e.g., about 16.51 cm), and an overall thickness of about 1 cm to about 3 cm (e.g., about 2.54 cm).

[0066] Similar to the first set of suction cups 202, the second set of suction cups 204 also includes a first pair of suction cups 220 and a second pair of suction cups 222, for a total of four suction cups in the second set 204. Figure 2 As shown, a first pair of suction cups 220 of the second set 204 is coupled to an end of the first post 214 , and a second pair of suction cups 222 of the second set 204 is coupled to an end of the second post 216 .

[0067] like Figure 2 As shown, the second set of suction cups 204 is configured to couple to two dialyzer housings, with a first pair of suction cups 220 coupled to a first dialyzer housing 224 and a second pair of suction cups 222 coupled to a second dialyzer housing 226. For example, as previously described, each suction cup in the second set 204 includes an opening therethrough. In addition, the columns 214, 216 each include a vacuum line 154, 156, respectively, which is coupled to the vacuum line 152 to allow suction to be applied through the second set of suction cups 204 to couple a pair of dialyzer housings to the second set of suction cups 204.

[0068] Figure 3 The arm tool 114 is depicted in a second position 300. Figure 3 As shown, when the arm tool 114 is in the second position 300, the longitudinal axis of each post 214, 216 of the U-shaped platform 212 is perpendicular to the longitudinal axis of the vertical protrusion 120 of the robot arm 104. In addition, when the arm tool 114 is in the second position 300, the first set of suction cups 202 coupled to the rectangular platform 206 faces downward.

[0069] like Figure 3As shown, the arm tool 114 is coupled to the end of the vertical protrusion 120 of the robot arm 104 using a pin connector 302 and can rotate around the end of the vertical protrusion 120 via the pin connector 302. For example, the arm tool 114 can rotate from about 0 degrees to about 90 degrees around the pin connector 302. In some embodiments, the arm tool 114 is in a first position 200 (e.g., Figure 2 ) and the second position 300 (as shown Figure 3 The arm tool 114 is configured to rotate approximately 90 degrees about the pin connector 302 between the first position 200 and the second position 300 (shown). The arm tool 114 also includes an air cylinder (not shown) that applies force to the end of the arm tool 114 and rotates the arm tool about the pin connector 302. During the manufacture and packaging of the dialyzer housing, the controller 160 controls and coordinates the rotation of the arm tool 114 between the first position 200 and the second position 300. For example, the controller 160 signals the air cylinder of the arm tool 114 to extend or retract to rotate the arm tool 114 between the first position 200 and the second position 300.

[0070] like Figure 2 and Figure 3 As shown, the width 270 of the outline of the arm tool 114 in the first position 200 is smaller than the width 370 of the outline of the arm tool 114 in the second position 300. For example, the width 270 of the outline of the arm tool 114 in the first position 200 can be about 16 cm to about 17 cm (e.g., about 16.5 cm), and the width 370 of the outline of the arm tool 114 in the second position 300 can be about 35 cm to about 36 cm (e.g., about 35.5 cm). The width 270 of the outline of the arm tool 114 in the first position 200 can be about 18 cm to about 20 cm smaller than the width 370 of the outline of the arm tool 114 in the second position 300. Figure 2 As shown, the width 270 of the tool 114 in the first position 200 is measured linearly from the first set of suction cups 202 to the opposite edge of the tool. Figure 3 As shown, the width 370 of the tool 114 in the second position 300 is measured linearly from the second set of suction cups 204 to an opposite edge of the tool 114 .

[0071] Rotating the arm tool 114 between the first position 200 and the second position 300 reduces the amount that the injection molding apparatus 102 must open to enable the arm tool 114 to fit between the molds 110, 112, while still allowing the arm tool 114 to reach the bottom of the storage container 108 to place the dialyzer housing within the storage container 108. Minimizing the amount that the injection molding apparatus 102 must open to enable the arm tool 114 to remove the dialyzer housing 124 from the mold halves 110, 112 can reduce wear on the molds 110, 112. Furthermore, minimizing the amount that the mold halves 110, 112 must open during demolding can reduce the risk of misalignment of the mold halves 110, 112, and therefore can reduce the risk of damage to the injection molding mold 102. Furthermore, minimizing the amount that the injection molding apparatus 102 must open during demolding can reduce the time required to open the injection molding apparatus 102 during demolding, which can reduce the overall time required to manufacture the dialyzer housing 124.

[0072] Figure 4 A side view of the injection molding apparatus 102 of the dialyzer housing manufacturing system 100 is depicted. Figure 4 As shown, the injection molding apparatus 102 includes a first mold half 110 and a second mold half 112. The mold halves 110, 112 of the injection molding apparatus 102 are configured to simultaneously form two dialyzer housings.

[0073] Figure 5 A front view of the first mold half 110 of the injection molding apparatus 102 is depicted. Figure 5 As shown, the first mold half 110 includes two cavities 502 , 504 and a plurality of alignment pins 510 , 512 , 514 , 516 , 520 , 522 , 524 , 526 .

[0074] The die cavities 502 and 504 are respectively used to form the dialyzer housing 124. The second half mold 112 includes two corresponding cavities (not shown). During injection molding, the die cavities 502 and 504 of the first half mold 110 are aligned with the die cavities of the second half mold 112, and the half molds 110 and 112 are positioned against each other, and molten material is injected into the die cavities. As the injected material cools, the material takes the form of the die cavities in the first half mold 110 and the second half mold 112 to form the dialyzer housing 124. The dialyzer housing 124 can be formed by any material in a variety of different medical grade materials. The example of this material includes polycarbonate, polypropylene, etc.

[0075] like Figure 5As shown, the first mold half 110 includes a first set of four mold alignment pins 510, 512, 514, 516 and a second set of mold alignment pins 520, 522, 524, 526 that project outwardly from an inner surface 518 of the first mold half 110. The mold alignment pins 510, 512, 514, 516, 520, 522, 524, 526 ensure proper alignment and secure fit between the two mold halves 110, 112 during injection molding. For example, when the mold halves 110, 112 of the injection molding apparatus 102 are properly aligned, the mold alignment pins 510, 512, 514, 516, 520, 522, 524, 526 are aligned with and inserted into corresponding openings (not shown) in the second mold half 112.

[0076] like Figure 4 As shown, once injection molding is complete, the second mold half 112 is moved a predetermined distance 450 away from the first mold half 110 to expose the dialyzer housing formed by the injection molding apparatus 102. In some cases, the second mold half 112 is moved approximately 230 mm away from the first mold half 110 to allow the arm tool 114 (positioned in the first position 200) to be inserted between the mold halves 110, 112. The arm tool 114 is used to remove the dialyzer housing 424 from the second mold half 112.

[0077] like Figure 4 As shown, throughout the injection molding process, the mold alignment pins 510, 512, 514, 516 and the core alignment pins 520, 522, 524, 526 of the first mold half 110 remain at least partially inserted into the corresponding openings of the second mold half 112. During demolding, the alignment pins 510, 512, 514, 516, 520, 522, 524, 526 of the first mold half 110 can remain partially inserted into the openings of the second mold half 112 by positioning the arm tool 114 in the first position 200 to minimize the distance between the mold halves 110, 112 required to insert the arm tool 114 between the mold halves 110, 112. Leaving the alignment pins 510 , 512 , 514 , 516 , 520 , 522 , 524 , 526 of the first mold half 110 partially inserted into the second mold half 112 during demolding reduces the risk of misalignment of the mold halves 110 , 112 and reduces the risk of damaging the mold halves 110 , 112 .

[0078] The second mold half 112 also includes ejector pins (not shown) for ejecting the formed dialyzer housing 424 from the second mold half 112. As described in further detail herein, the controller 160 coordinates movement of the ejector pins with the application of suction to the arm tool 114 via the vacuum line 152 such that the ejector pins eject the dialyzer housing 424 from the mold 112 and the arm tool 114 simultaneously provides suction and couples to the dialyzer housing 424.

[0079] Now refer to Figure 6-21 Methods of manufacturing and packaging dialyzer housings are described.

[0080] like Figure 6 As shown, the mold halves 110, 112 are closed when the injection molding apparatus 102 performs injection molding of a pair of dialyzer shells (not shown). When the injection molding apparatus 102 performs injection molding of the dialyzer shells, the robotic arm 104 is in a retracted position so that the arm tool 114 is positioned above the mold halves 110, 112. Figure 6 As shown, the arm tool 114 is in the first position 200 such that the posts 214 , 216 of the U-shaped platform and the second set of suction cups 204 are pointing downward, and the first set of suction cups 202 are oriented laterally relative to the vertical protrusion 120 .

[0081] Reference Figure 7 Once the dialyzer housing is injection molded by the injection molding apparatus 102, the second mold half 112 is retracted and moved away from the first mold half 110 to expose the dialyzer housing. The distance between the mold halves 110, 112 is sized to allow the arm tool 114 in the first position 200 to be inserted between the mold halves 110, 112, with the first set of suction cups 202 facing the second mold half 112. For example, the distance between the mold halves 110, 112 in the open position after injection molding is approximately 230 mm, allowing the arm tool 114 in the first position 200 to be inserted between the mold halves 110, 112. As previously described, throughout the manufacturing process, the alignment pins 510, 512, 514, 516, 520, 522, 524, 526 of the first mold half 1102 remain partially inserted into the openings of the second mold half 112. The controller 160 controls the movement of the second mold half 112 to move a predetermined distance away from the first mold half 110 to open the mold.

[0082] like Figure 8As shown, once the injection molding process is completed and the controller determines that the second mold half 112 has moved a predetermined amount (e.g., approximately 230 mm) to expose the dialyzer housing based on a signal received from a rotary encoder (not shown) in the injection molding apparatus 102, the controller 160 for the injection molding apparatus 102 transmits a signal to the controller 162 for the robotic arm 104 to instruct the molds 110, 112 to open. In response to the signal received from the controller 160 of the injection molding apparatus 102 instructing the molds 110, 112 to open, the controller 162 of the robotic arm 104 controls the vertical protrusion 120 of the robotic arm 104 to extend to insert the arm tool 114 between the first mold half 110 and the second mold half 112. The vertical protrusion 120 of the robotic arm 104 continues to extend until the controller 162 for the robotic arm 104 determines, based on feedback received from a rotary encoder (not shown) of the robotic arm 104, that the vertical protrusion 120 has extended a predetermined distance corresponding to the first pair of suction cups 208 of the first group 202 being vertically aligned with the first dialyzer housing in the second half-mold 112 and the second pair of suction cups 210 of the first group 202 being vertically aligned with the second dialyzer housing in the second half-mold 112.

[0083] Figure 9 A side view of the molding apparatus 102 is depicted with the arm tool 114 inserted between the mold halves 110, 112 of the molding apparatus 102. Figure 9 As shown, the first pair of suction cups 208 of the first set 202 are vertically aligned with the first dialyzer housing 902 in the second mold half 112. In addition, the second pair of suction cups 210 (not shown) of the first set 202 are vertically aligned with the second dialyzer housing 904 in the second mold half 112. As previously described, the controller 162 is capable of determining the position of the arm tool 114 in three-dimensional space based on signals received from a rotary encoder (not shown) of the robotic arm 104. Once the controller has reached a fixed spatial position corresponding to the alignment between the pairs of suction cups 208, 210 and the dialyzer housings 902, 904, the controller 162 stops extending the vertical protrusion 120.

[0084] Once the pairs of suction cups 208, 210 are vertically aligned with the dialyzer housings 902, 904, the vertical protrusion 120 travels along the cross arm 118 of the robotic arm 104 until each of the pairs of suction cups 208, 210 moves into contact with a surface of the dialyzer housings 902, 904. For example, once the first set of suction cups 202 are vertically aligned with the dialyzer housings 902, 904, as determined by the controller 162 based on the rotary encoder signals, the controller 162 controls the vertical protrusion 120 of the robotic arm 104 to move laterally along the cross arm 118 toward the second mold half 112. The vertical protrusion 120 continues to move toward the second mold half 112 until the controller 162 determines, based on the signals received from the rotary encoders of the robotic arm 104, that the coordinates of the arm tool 114 correspond to a predetermined position corresponding to contact between the first and second pairs of suction cups 208, 210, respectively, and the surfaces of the dialyzer housings 902, 904.

[0085] Once the pairs of suction cups 208, 210 are aligned with and positioned adjacent to the dialyzer housings 902, 904, respectively, the controller 162 begins applying suction through the pairs of suction cups 208, 210 and sends a signal to the controller 160 of the injection molding apparatus 102 to move the ejector pins (not shown) of the second mold half 112. The outward extension of the ejector pins from the second mold half 112 forces the dialyzer housings 902, 904 out of the corresponding cavities in the second mold half 112. As the ejector pins of the second mold half 112 force the dialyzer housings 902, 904 out of the mold half 112, vacuum suction is applied through each pair of suction cups 208, 210 to couple the dialyzer housings 902, 904 to the first pair of suction cups 208 and the second pair of suction cups 210, respectively. As previously described, each of the pair of suction cups 208, 210 includes an opening through its center, and each of the pair of suction cups 208, 210 is fluidly coupled to a vacuum source (e.g., a vacuum source) via vacuum lines 152, 154, 156. Figure 1 A vacuum source 150 is provided to enable suction to be applied through the center of each suction cup. The suction applied through the pairs of suction cups 208, 210 is transferred to the surface of the dialyzer housing 902, 904, thereby coupling the housing 902, 904 to the pairs of suction cups 208, 210 in the first set 202.

[0086] Reference Figure 10Once each dialyzer housing 902, 904 is removed from the second mold half 112 and coupled to the first set of suction cups 202 via vacuum suction, the vertical protrusion 120 of the robotic arm 104 retracts and continues to provide suction through the first set of suction cups 202 to lift the dialyzer housing 902, 904 from the injection molding apparatus 102. In some examples, the controller 160 determines that the dialyzer housing 902, 904 is coupled to the first set of suction cups 202 based on a signal received from a vacuum confirmation sensor (not shown) on the arm tool 114. Once the vertical protrusion 120 has retracted to a predetermined position to lift the dialyzer housing 902, 904 from the injection molding apparatus 102, the controller 162 of the robotic arm 104 sends a signal to the controller 160 of the injection molding apparatus 102. In response to the signal received from the controller 162, the controller 160 of the injection molding apparatus 102 controls the second mold half 112 to move the second mold half 112 toward the first mold half 110 by a predetermined distance corresponding to contact between the mold halves 110, 112 and mold closure. Figure 10 Furthermore, as the vertical protrusions 120 are retracted, suction continues to be applied through the first set of suction cups 202 to maintain the dialyzer housings 902, 904 coupled to the arm tool 114.

[0087] After lifting the dialyzer housings 902 , 904 out of the injection molding apparatus 102 , the robotic arm 104 and arm tool 114 are used to place the dialyzer housings 902 , 904 on a cooling table 106 . Figure 11-15 The process of placing the dialyzer housings 902 , 904 on the cooling table 106 using the arm tool 114 is depicted.

[0088] Reference Figure 11 , with the dialyzer housings 902, 904 coupled to the first set of suction cups 202 of the arm tool 114 via vacuum suction, the cross arm 118 of the robotic arm 104 travels forward a predetermined distance along the base 116 of the robotic arm 104. As previously described, the base 116 includes a set of tracks 122 along its length to allow the cross arm 118 to move smoothly forward and backward along the base 116. The cross arm 118 continues to travel forward along the base 116 until the controller 160 receives a signal from the rotary encoder of the robotic arm 104 indicating that the cross arm 118 has traveled the predetermined distance, which corresponds to the arm tool 114 being positioned so that the first set of suction cups 202 are positioned above a pair of empty cooling shelves 918, 920 on the cooling table 106.

[0089] Still refer to Figure 11In addition to the cross arm 118 traveling along the base 116, the vertical protrusion 120 moves laterally along the cross arm 118 a predetermined distance to position the arm tool 114 so that the first set of suction cups 202 are positioned above a pair of empty cooling shelves 918, 920 on the cooling table 106. For example, the vertical protrusion 120 continues to travel laterally along the cross arm 118 until the controller 160 receives a signal from the rotary encoder of the robotic arm 104 indicating that the vertical protrusion 120 has traveled the predetermined distance, which corresponds to the arm tool 114 being positioned so that the first set of suction cups 202 are positioned above a pair of empty cooling shelves 918, 920 on the cooling table 106.

[0090] As the robot 104 moves to position the arm tool 114 over the cooling racks 918, 920, the arm tool 114 rotates about the pin connector 302 to move the arm tool 114 from the first position 200 (eg, Figure 10 ) is rotated to the second position 300 (as shown Figure 12 shown). Figure 11 The arm tool 114 is depicted rotating between a first position 200 and a second position 300 as the robotic arm 104 travels toward the cooling table 106. As previously described, the arm tool 114 includes a pneumatic cylinder (not shown) that applies force to the end of the arm tool 114 and causes the arm tool to rotate about the pin connector 302. The controller 160 coordinates the rotation of the arm tool 114 between the first fixed position 200 and the second fixed position 300 based on the current position of the arm tool 114 in three-dimensional space (as determined based on signals received from a rotary encoder of the arm tool 114). For example, the controller 162 is programmed to rotate the arm tool 114 from the first position 200 to the second position 300 at a specific point in the move sequence of the manufacturing cycle and based on the position of the arm tool 114 in three-dimensional space.

[0091] Figure 12 The arm tool 114 is depicted positioned in the second position 300 with the dialyzer housings 902 , 904 coupled to the first set of suction cups 202 facing downward and aligned upwardly with empty cooling racks 918 , 920 on the cooling table 106 .

[0092] Reference Figure 13Once the arm tool 114 is in the second position 300 with the dialyzer housings 902, 904 aligned above the empty cooling racks 918, 920, as determined based on signals received by the controller 162 from the rotary encoders of the robotic arm 104, the vertical protrusions 120 of the robotic arm 104 extend a predetermined amount (as detected by the rotary encoders of the robotic arm) to lower the dialyzer housings 902, 904 into the respective cooling racks 918, 920. Once the robotic arm 104 has lowered the dialyzer housings 902, 904 the predetermined amount into the cooling racks 918, 920, the vacuum suction provided by the first set of suction cups 202 ceases, which decouples the dialyzer housings 902, 904 from the arm tool 114 and releases the housings 902, 904 onto the cooling racks 918, 920. Figure 14 A perspective view of the arm tool 114 in the second position 300 is depicted releasing a pair of dialyzer housings 1002 , 1004 into a pair of cooling racks 1018 , 1020 on the cooling table 106 .

[0093] Once the dialyzer housings 902 , 904 have been placed on the cooling table 106 and released from the arm tool 114 , the arm tool 114 is used to move another pair of dialyzer housings into the storage container 108 . Figure 15-21 The process of moving a pair of dialyzer housings from a cooling station 106 to a storage container 108 is depicted.

[0094] refer to Figure 15 Once the dialyzer housings 902, 904 have been placed on the cooling racks 918, 920 and released from the arm tool 114, the vertical protrusion 120 of the robotic arm 104 is retracted to lift the arm tool 114 above the cooling table 106. Once lifted to a predetermined distance above the cooling table 106 as measured by the rotary encoder of the robotic arm 104, the controller 162 controls the arm tool 114 to move from the second position 300 (e.g., about the pin connector 302) to the second position 300 (e.g., about the pin connector 302). Figure 15 ) is rotated to the first position 200 (as shown Figure 16 As previously described, the arm tool 114 includes a pneumatic cylinder (not shown) that applies force to the end of the arm tool 114 and causes the arm tool to rotate about the pin connector 302. The controller 160 coordinates the rotation of the arm tool 114 from the second fixed position 300 to the first fixed position 200 based on the spatial positioning of the arm tool 114. For example, the controller 162 is programmed to rotate the arm tool 114 from the second position 300 to the first position 200 at a specific point in the move sequence of the manufacturing cycle and based on the position of the arm tool 114 in three-dimensional space.

[0095] refer to Figure 17Once the arm tool 114 is in the first position and the second set of suction cups 204 is facing downwardly toward the cooling table 106, the vertical protrusion 120 of the robotic arm 104 is translated along the cross arm frame 118 until the controller 160 receives a signal having coordinates indicating that the second set of suction cups 204 is positioned above the center of the second pair of dialyzer housings 906, 908 on the cooling table 106. Additionally, if necessary, the cross arm frame 118 of the robotic arm 104 travels along the track 122 of the base 116 of the robotic arm 104 until the controller 160 receives a signal from the rotary encoder indicating that the robotic arm has reached a position corresponding to the second set of suction cups 204 being positioned above the center of the second pair of dialyzer housings 906, 908 on the cooling table 106. Figure 17 As shown, the first pair of suction cups 220 of the second set 202 is aligned with the first dialyzer housing 906 and the second pair of suction cups 222 of the second set 202 is aligned with the second dialyzer housing 908 so that each pair of suction cups 220 , 222 can be coupled with the corresponding dialyzer housing 906 , 908 .

[0096] Still refer to Figure 17 Once the second set 204 of pairs of suction cups 220, 222 are positioned above the center of the corresponding dialyzer housing 906, 908, the controller 162 controls the vertical protrusion 120 of the robotic arm 104 to extend a predetermined distance to lower the arm tool 114 toward the dialyzer housing 906, 908. In addition, the controller 162 controls vacuum suction to be applied to the pairs of suction cups 220, 222 through the vacuum lines 152, 154, 156 and through the center of each of the pairs of suction cups 220, 222 to couple the dialyzer housing 906, 908 to the pairs of suction cups 220, 222. The vertical protrusion 120 continues to extend until the controller 160 receives a signal from the rotary encoder indicating that the vertical protrusion 120 has extended a predetermined distance and receives a signal from the vacuum confirmation sensor indicating that the first pair of suction cups 220 and the second pair of suction cups 222 are in contact with the surface of the dialyzer housing 906, 908 and are coupled to the dialyzer housing 906, 908, respectively.

[0097] As previously described, each of the pair of suction cups 220, 222 includes an opening through its center, and each of the pair of suction cups 220, 222 is fluidly coupled to a vacuum source (e.g., Figure 1 The vacuum source 150 is configured to enable suction to be applied through the center of each suction cup. The suction force applied by the pair of suction cups 220, 222 is transferred to the surface of the dialyzer housing 906, 908, coupling the dialyzer housing 906, 908 to the pair of suction cups 220, 222. Figure 18A perspective view of the arm tool 114 is depicted positioned to couple a pair of dialyzer housings 1006 , 1008 to the first and second pairs of suction cups 220 , 222 , respectively, of the second set of suction cups 204 to remove the dialyzer housings 1006 , 1008 from the cooling table 106 .

[0098] Reference Figure 19 Once suction has been applied to the dialyzer housings 906, 908 to couple the dialyzer housings 906, 908 to the pair of suction cups 220, 222, as determined based on a signal received by the controller 162 from a vacuum confirmation sensor (not shown), the controller 162 controls the vertical protrusions 120 of the robotic arm 104 to retract to lift the dialyzer housings 906, 908 off the cooling table 106. As the vertical protrusions 120 retract, suction continues to be applied through the pair of suction cups 220, 222 to maintain the dialyzer housings 906, 908 coupled to the arm tool 114.

[0099] The vertical projection 120 travels along the cross arm 118 of the robotic arm 104 until the controller 162 receives a signal from the rotary encoder indicating that the vertical projection 120 has traveled a predetermined distance corresponding to the position of the arm tool 114 in three-dimensional space that positions the second set of suction cups 204 above the storage container 108, as shown. Figure 20 Additionally, if necessary, the cross arm 118 of the robot 104 travels along the track 122 of the base 116 of the robot 104 until the controller 160 receives a signal from the rotary encoder indicating that the cross arm 118 has traveled a predetermined distance corresponding to the position of the arm tool 114 in three-dimensional space that positions the second set of suction cups 204 above the storage container 108.

[0100] Reference Figure 21Once the arm tool 114 is positioned over the storage container 108, the vertical protrusion 120 of the robotic arm 104 extends a predetermined amount, as determined by the rotary encoder of the robotic arm 104, to lower the dialyzer housings 906, 908 into the storage container 108. The controller controls the movement of the robotic arm 104 components to position the housings 906, 908 at programmed positions in three-dimensional space. Once the housings 906, 908 are positioned in the predetermined positions, as determined by the position of the arm tool 114 determined based on the signals transmitted by the rotary encoder of the robotic arm 104, the controller 162 stops applying vacuum suction through the second set of suction cups 204 to decouple the housings 906, 908 from the suction cups 204 and place the housings 906, 908 in the predetermined positions in the container 108. As the container 108 is filled with dialyzer housings, the controller 162 counts the number of housings placed in the container to determine a unique position for placing each housing within the spatial volume of the container 108. By coupling the cooled dialyzer housing 906, 908 to the second set of suction cups 204 with the arm tool 114 in the first position 200, the length of the posts 214, 216 is maximized, which allows the dialyzer housing 906, 908 to be placed on the bottom of the storage container 108 without causing the dialyzer housing 906, 908 to fall a significant distance. Thus, the risk of damaging the dialyzer housing 906, 908 during placement of the housing 906, 908 in the storage container 108 is reduced.

[0101] The surfaces of the second pair of dialyzer housings 906, 908 are allowed to cool on the cooling table 106 to a temperature between about 200°F and about 250°F before being moved into the storage container 108. In some examples, the dialyzer housings 906, 908 are each placed on the cooling table 106 for about 51 seconds to about 70 seconds before being loaded into the storage container 108.

[0102] Once the dialyzer housings 906, 908 have been placed in the storage container 108 and released from the arm tool 114, the vertical protrusion 120 of the robotic arm 104 is retracted to lift the arm tool 114 out of the storage container 108. In some embodiments, after lifting the arm tool 114 out of the storage container 108, the vertical protrusion 120 moves along the cross arm frame 118 and the cross arm frame 118 moves along the base 116 to reposition the robotic arm 104 and the arm tool 114 above the injection molding apparatus 102 in preparation for removing another set of dialyzer housings from the injection molding apparatus 102. For example, after lifting the arm tool 114 out of the storage container 108, the robotic arm moves to Figure 6 , in preparation for removing another pair of dialyzer housings from the injection molding mold 102.

[0103] This dialyzer housing manufacturing process continues until the dialyzer housing is filled in the storage container 108. Once filled, the storage container 108 is replaced with a new empty storage container and the process continues. The filled storage container 108 can be used to package or store the dialyzer housing in the storage container 108.

[0104] While certain embodiments have been described above, other embodiments are possible.

[0105] For example, although the demolding and packaging method of the dialyzer shell has been described as relying on signals received from a rotary encoder to determine the coordinates of the arm tool 114 in three-dimensional space to coordinate the movement of the injection molding apparatus 102, the movement of the robotic arm 104, the rotation of the arm tool 114, and the application of vacuum suction, alternatively, the movement of the injection molding apparatus 102 and the robotic arm 104, the rotation of the arm tool 114, and / or the application of vacuum suction through the suction cups 202, 204 can be coordinated based on time. For example, the robotic arm 104 moves between each position of the manufacturing cycle at a predictable rate. Therefore, the time when the arm tool 114 should rotate between the first position 200 and the second position 300 can be determined. In addition, the time when vacuum suction should be applied by each set of suction cups 202, 204 to couple the dialyzer shell to the appropriate set of suction cups 202, 204 can be determined. Based on this determination, the controller 160 may be programmed to automatically move the robotic arm 104 , rotate the arm tool 114 , and apply vacuum suction through the suction cup sets 202 , 204 at predetermined times throughout the manufacturing cycle.

[0106] While the system 100 has been described as including a robotic arm 104 having a cross arm 118 and a vertical protrusion 120, other types of robotic components may be used to position the arm tool 114 and perform the method of demolding and packaging the dialyzer housing.

[0107] Although the arm tool 114 has been described as including a rectangular platform 206 and a U-shaped platform 212 having specific dimensions, platforms of other sizes and shapes may be used to support the suction cups of the arm tool 114. Furthermore, although the widths 270, 370 of the profile of the arm tool 114 in the first position 200 and the second position 300 have been described as being approximately 16 cm to approximately 17 cm (e.g., approximately 16.5 cm) and approximately 35 cm to approximately 36 cm (e.g., approximately 35.5 cm), respectively, the arm tool 114 may be configured to have a different profile width in each position 200, 300.

[0108] Although the arm tool 114 has been described as including a total of 8 suction cups, other numbers of suction cups are possible. For example, in some embodiments, the arm tool includes a total of four suction cups, two suction cups in the first group 202 and two suction cups in the second group 204. In this arrangement, one suction cup is coupled to each column 214, 216 of the U-shaped platform 212, and one suction cup is attached to each end of the rectangular platform 206. In addition, in embodiments where the arm tool 114 includes a total of four suction cups, a single suction cup is used to couple the arm tool 114 to a single dialyzer housing. Alternatively, the arm tool may include a greater number of suction cups (e.g., a total of 12 suction cups, a total of 16 suction cups, etc.).

[0109] Furthermore, although the arm tool 114 has been described as having the same number of suction cups in the first group 202 and the second group 204 , alternatively, the first group 202 and the second group 204 may each include a different number of suction cups.

[0110] Furthermore, while the arm tool 114 has been described with its first set of suction cups 202 oriented at approximately 90 degrees relative to the second set of suction cups 204, other orientations of the first and second sets of suction cups may be used. For example, in some embodiments, the first set of suction cups 202 are oriented at approximately 70 degrees to approximately 110 degrees relative to the second set of suction cups 204. In some embodiments, the first set of suction cups 202 are oriented at approximately 70 degrees to approximately 110 degrees relative to the second set of suction cups 204.

[0111] Although it has been described that the arm tool 114 is configured to be coupled to two dialyzer housings at the same time, alternatively, the arm tool 114 can be configured to be coupled to other numbers of dialyzer housings. In some embodiments, the arm tool 114 can be configured to be coupled to a single dialyzer housing. For example, the arm tool 114 can include a total of two suction cups: a first suction cup coupled to a first portion of the tool's frame (e.g., a rectangular platform 206), a second suction cup coupled to a second portion of the tool's frame (e.g., a U-shaped platform 212), and the tool 114 can be configured to be coupled to a single dialyzer housing. Alternatively, the arm tool 114 can be configured to be coupled to three or more dialyzer housings at the same time.

[0112] Similarly, although the injection molding apparatus 102 has been described as being configured to simultaneously form two dialyzer housings, alternatively, the injection molding apparatus 102 may be configured to form a different number of dialyzer housings (eg, 1, 3, 4, etc.).

[0113] Although the robotic arm tool 114 has been described as rotating approximately 90 degrees between the first position 200 and the second position 300, the arm tool 114 may be controlled to rotate a different amount between the first position 200 and the second position 300. For example, in some embodiments, the arm tool 114 rotates between approximately 70 degrees and approximately 110 degrees between the first position 200 and the second position 300.

[0114] Furthermore, while the arm tool 114 has been described as rotating between the first fixed position 200 and the second fixed position 300 , the arm tool 114 may alternatively move fluidly between various positions during a manufacturing cycle without stopping at a fixed position.

[0115] Although the robot arm 104 and the arm tool 114 have been described as being used in a system for manufacturing dialyzer housings, the robot arm 104 and the arm tool 114 can alternatively be used to manufacture other items. For example, the robot arm 104 and the arm tool 114 can be used to demold other types of parts from injection molds.

[0116] Although the arm tool 114 has been described as being coupled to the robotic arm 104 via the pin connector 302 , other coupling mechanisms may alternatively be used to couple the arm tool 114 to the robotic arm 104 .

[0117] Although the injection molding apparatus 102 has been described as having four mold alignment pins, the injection molding apparatus 102 may alternatively include a different number of mold alignment pins (e.g., 2, 3, 5, 6, etc.). Similarly, although the injection molding apparatus 102 has been described as having four core alignment pins, the injection molding apparatus 102 may alternatively include a different number of core alignment pins (e.g., 2, 3, 5, 6, etc.).

[0118] Furthermore, while the molding process has been described as moving the second mold half 112 approximately 230 mm from the first mold half 110, the mold may be opened by other distances. For example, in some embodiments, the second mold half 112 is moved approximately 200 mm to approximately 240 mm from the first mold half 110 to allow the arm tool 114 (positioned in the first position 200) to be inserted between the mold halves 110, 112.

[0119] A number of embodiments have been described. However, it will be appreciated that various modifications can be made without departing from the spirit and scope of the present disclosure. Accordingly, other embodiments are within the scope of the following claims.

Claims

1. A dialyzer housing manufacturing system comprising: a molding device configured to mold a dialyzer housing; and a tool coupled to the robotic arm and configured to remove the dialyzer shell from the molding device by applying vacuum suction to the dialyzer shell after the dialyzer shell is molded, the tool comprising: a frame; a first suction cup connected to a first portion of the frame; a second suction cup connected to a second portion of the frame, the second suction cup oriented at approximately 70 degrees to approximately 110 degrees relative to the first suction cup; and a vacuum confirmation sensor configured to determine that the dialyzer shell is coupled to the first suction cup, wherein the first portion of the frame forms a rectangular platform; the second portion of the frame forms a U-shaped platform, the U-shaped platform comprising a first column, a second column parallel to the first column, and a connecting rod, the first column, the second column and the rectangular platform being coupled to the connecting rod, and wherein the tool is rotatable between a first position and a second position, in the first position, the first suction cup extends along a first direction, in the second position, the second suction cup extends along the first direction, and the width of the tool in the second position is greater than the width of the tool in the first position.

2. The dialyzer housing manufacturing system according to claim 1, wherein: The first suction cup and the second suction cup are fluidly coupled to a vacuum source.

3. The dialyzer housing manufacturing system according to claim 1 or 2, wherein: The dialyzer housing manufacturing system also includes: a third suction cup, wherein the third suction cup is connected to the first portion of the frame; a fourth suction cup, wherein the fourth suction cup is connected to the first portion of the frame; a fifth suction cup, wherein the fifth suction cup is connected to the first portion of the frame; a sixth suction cup, wherein the sixth suction cup is connected to the second portion of the frame; a seventh suction cup, wherein the seventh suction cup is connected to the second portion of the frame; and an eighth suction cup, wherein the sixth suction cup, the seventh suction cup and the eighth suction cup are oriented at approximately 70 degrees to approximately 110 degrees relative to the third suction cup, the fourth suction cup and the fifth suction cup.

4. The dialyzer housing manufacturing system according to claim 1 or 2, wherein: The molding device is configured to mold two dialyzer housings.

5. The dialyzer housing manufacturing system according to claim 4, wherein: The tool is configured to simultaneously remove two dialyzer housings from the molding apparatus.

6. The dialyzer housing manufacturing system according to any one of claims 1, 2, and 5, wherein: The molding device is an injection molding device.

7. The dialyzer housing manufacturing system according to claim 1, wherein: The dialyzer housing manufacturing system further includes: an air cylinder; and a rotating pin, wherein: the rotating pin couples the tool to the robotic arm; and the tool is configured to rotate about the rotating pin in response to a force applied to the tool by the air cylinder.

8. The dialyzer housing manufacturing system according to claim 1, wherein: The width of the tool in the first position is about 16 cm to about 17 cm.

9. The dialyzer housing manufacturing system according to claim 8, wherein: The molding apparatus is configured to open the pair of mold halves by about 200 mm to about 240 mm after molding the dialyzer housing.

10. The dialyzer housing manufacturing system according to claim 1, wherein: The width of the tool in the second position is about 35 cm to about 36 cm.

11. The dialyzer housing manufacturing system according to any one of claims 1, 2, 5, 7-10, wherein: The mold includes an alignment pin coupled to the first mold half; and when the mold is opened after molding the dialyzer housing, the alignment pin remains partially inserted into the second mold half.

12. The dialyzer housing manufacturing system according to any one of claims 1, 2, 5, 7-10, wherein: The dialyzer housing manufacturing system further includes a cooling stage for cooling the dialyzer housing.

13. The dialyzer housing manufacturing system according to any one of claims 1, 2, 5, 7-10, wherein: The dialyzer housing manufacturing system further includes a storage container for storing the dialyzer housings.

14. A method for manufacturing a dialyzer housing, comprising: opening the mold to expose the first dialyzer housing; coupling the first dialyzer housing to the first portion of the tool by applying vacuum suction to the first dialyzer housing; determining, using a vacuum confirmation sensor of the tool, that the first dialyzer housing is coupled to the first portion of the tool; moving the tool to remove the first dialyzer housing from the mold; Rotating the tool about 70 degrees to about 110 degrees to orient the first portion of the tool in a first direction; placing the first dialyzer housing at a first location using the tool; rotating the tool about 70 degrees to about 110 degrees to orient the second portion of the tool in the first direction; coupling the second dialyzer housing at the first location to the second portion of the tool; and placing the second dialyzer housing at a second location using the tool, wherein the first portion of the tool forms a rectangular platform; the second portion of the tool forms a U-shaped platform comprising a first column, a second column parallel to the first column, and a connecting rod, the first column, the second column, and the rectangular platform being coupled to the connecting rod; and / or rotating the tool about 70 degrees to about 110 degrees to orient the first portion of the tool in the first direction comprises rotating the tool to a first position; and rotating the tool about 70 degrees to about 110 degrees to orient the second portion of the tool in the first direction comprises rotating the tool to a second position, wherein the width of the tool in the first position is less than the width of the tool in the second position.

15. The method according to claim 14, wherein The mold is opened from about 200 mm to about 240 mm; and / or the alignment pins of the first mold half remain partially inserted into the second mold half when the mold is opened; and / or coupling the first dialyzer housing to the first portion of the tool by applying vacuum suction to the first dialyzer housing comprises: moving an ejection pin of the mold to eject the first dialyzer housing from the mold, wherein the movement of the ejection pin is coordinated with the vacuum suction applied to the first dialyzer housing; and / or placing the second dialyzer housing in a second location using the tool comprises: determining, using a vacuum confirmation sensor of the tool, that the second dialyzer housing is coupled to the second portion of the tool; and in response to determining that the second dialyzer housing is coupled to the second portion of the tool, moving the tool to place the second dialyzer housing in the second location; and / or a pin rotatably couples the tool to the robotic arm; and rotating the tool comprises rotating the tool about the pin; and / or rotating the tool comprises applying a force to the tool by a cylinder.

16. The method according to claim 14 or 15, wherein: coupling the first dialyzer housing to the first portion of the tool by applying vacuum suction to the first dialyzer housing comprises inserting the tool between the first mold half and the second mold half; and / or the width of the tool in the first position is about 16 cm to about 17 cm; and / or the width of the tool in the second position is about 35 cm to about 36 cm; and / or the tool includes four suction cups, each suction cup coupled to the rectangular platform at a corner of the rectangular platform, and coupling the first dialyzer housing to the first portion of the tool by applying vacuum suction to the first dialyzer housing comprises: applying vacuum suction through an opening of each of the four suction cups; or the tool includes a first pair of suction cups coupled to the end of the first column and a second pair of suction cups coupled to the end of the second column, and coupling the second dialyzer housing at the first location to the second portion of the tool comprises applying vacuum suction through an opening of each of the first pair of suction cups and the second pair of suction cups.

17. The method according to claim 16, wherein Inserting the tool between the first mold half and the second mold half includes extending a robotic arm coupled to the tool between the first mold half and the second mold half; and / or placing the first dialyzer housing at the first location using the tool includes positioning the first dialyzer housing near the first location using the tool and stopping applying vacuum suction through an opening of each of the four suction cups; or placing the second dialyzer housing at the second location using the tool includes positioning the second dialyzer housing near the second location using the tool and stopping applying vacuum suction through an opening of each suction cup of the first pair of suction cups and the second pair of suction cups.

18. The method according to any one of claims 14, 15 and 17, wherein: Coupling the first dialyzer housing to the first portion of the tool by applying vacuum suction to the first dialyzer housing includes: positioning one or more suction cups coupled to the first portion of the tool near the first dialyzer housing; and applying vacuum suction through an opening in each of the one or more suction cups.

19. The method according to claim 18, wherein Placing the first dialyzer housing at the first location using the tool includes: positioning the first dialyzer housing proximate the first location using the tool; and ceasing application of vacuum suction through the opening of each of the one or more suction cups.

20. The method according to any one of claims 14, 15, 17, and 19, wherein: Coupling the second dialyzer housing at the first location to the second portion of the tool includes: positioning one or more suction cups coupled to the second portion of the tool proximate the second dialyzer housing; and applying vacuum suction through an opening in each of the one or more suction cups.

21. The method according to claim 20, wherein Using the tool to place the second dialyzer housing at the second location includes: using the tool to position the second dialyzer housing proximate the second location; and ceasing to apply vacuum suction through the opening of each of the one or more suction cups.

22. The method according to any one of claims 14, 15, 17, 19, and 21, wherein: The method further includes coupling a third dialyzer housing to the first portion of the tool; and moving the tool to remove the third dialyzer housing from the mold, wherein the first dialyzer housing and the third dialyzer housing are removed from the mold simultaneously.

23. The method according to any one of claims 14, 15, 17, 19, and 21, wherein: The method further includes coupling a fourth dialyzer housing at the first location to a second portion of the tool; and placing the fourth dialyzer housing at the second location using the tool, wherein the second dialyzer housing and the fourth dialyzer housing are placed simultaneously at the second location.

24. The method according to any one of claims 14, 15, 17, 19, and 21, wherein: The first location includes a cooling table.

25. The method according to any one of claims 14, 15, 17, 19, and 21, wherein: The second location includes a storage container.

26. A device for removing a dialyzer housing from a mold, the device comprising: A tool is coupled to a robotic arm and configured to remove a dialyzer shell from a mold after the dialyzer shell is formed by applying vacuum suction to the dialyzer shell, the tool comprising: a frame; a first suction cup, the first suction cup being connected to a first portion of the frame; a second suction cup, the second suction cup being connected to a second portion of the frame, the second suction cup being oriented at about 70 degrees to about 110 degrees relative to the first suction cup; a vacuum confirmation sensor, the vacuum confirmation sensor being configured to determine that the dialyzer shell is coupled to the first suction cup; and a pin, the pin rotatably coupling the tool to the robotic arm, wherein the first portion of the frame forms a rectangular platform; the second portion of the frame forms a U-shaped platform, the U-shaped platform comprising a first column, a second column parallel to the first column, and a connecting rod, the first column, the second column and the rectangular platform being coupled to the connecting rod, and wherein the tool is rotatable between a first position and a second position, in which the first position the first suction cup extends in a first direction, and in which the second position the second suction cup extends in the first direction, the width of the tool in the second position being greater than the width of the tool in the first position.

27. The apparatus of claim 26, wherein: The first suction cup and the second suction cup are fluidly connected to a vacuum source.

28. The apparatus according to claim 26 or 27, further comprising: a third suction cup connected to the first portion of the frame; and a fourth suction cup connected to the first portion of the frame. a fifth suction cup connected to the first portion of the frame; a sixth suction cup connected to the second portion of the frame; a seventh suction cup connected to the second portion of the frame; and an eighth suction cup connected to the second portion of the frame, the sixth suction cup, the seventh suction cup, and the eighth suction cup being oriented at approximately 70 degrees to approximately 110 degrees relative to the third suction cup, the fourth suction cup, and the fifth suction cup.

29. The device according to claim 26 or 27, wherein The tool is configured to rotate about the pin between a first position and a second position from about 70 degrees to about 110 degrees.

30. The apparatus according to claim 29, wherein The width of the tool in the first position is about 16 cm to about 17 cm.

31. The apparatus according to claim 29, wherein The width of the tool in the second position is about 35 cm to about 36 cm.

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