Automatic equipment for assembling and heat sealing of soft shell leukocyte filter

Abstract

The application discloses an automatic equipment for assembling and heat-sealing of soft-shell leukocyte filters, which comprises a rack and a rotating workbench. A plurality of jigs are uniformly arranged on the rotating workbench. The rack is sequentially divided into an inner membrane preparation station, an inner membrane heat-sealing station, an outer membrane preparation station and an outer membrane heat-sealing station along the rotating direction of the rotating workbench. At least one jig is arranged in the range of the inner membrane preparation station and the outer membrane preparation station. An inner membrane heat-sealing machine and an outer membrane heat-sealing machine are respectively arranged in the range of the inner membrane heat-sealing station and the outer membrane heat-sealing station. The inner membrane heat-sealing machine and the outer membrane heat-sealing machine are combined into one by the rotating workbench and the plurality of jigs. When the inner membrane heat-sealing machine and the outer membrane heat-sealing machine respectively prepare and peripherally heat-seal filter membrane assemblies, an operator can complete the preparation work in the jigs of the inner membrane preparation station and the outer membrane preparation station, thereby reducing the standby time of the inner membrane heat-sealing machine and the outer membrane heat-sealing machine, improving the utilization rate of the equipment and maximizing the production efficiency.

Description

Technical Field

[0001] This invention relates to the field of medical device manufacturing equipment technology, specifically to an automated assembly and heat-sealing device for a soft-shell leukocyte filter. Background Technology

[0002] Removing non-therapeutic components, such as leukocytes, during blood transfusions and clinical treatments has many benefits, which is now widely recognized. The most effective method is leukocyte filtration using a leukocyte filter. Currently, the most widely used leukocyte filters are rigid-shell filters made of ABS or PC injection molded parts. However, rigid-shell filters are susceptible to damage during high-speed centrifugation. Based on this, patent documents CN104998311A and CN102861365B each disclose a soft-shell leukocyte filter. Its shell will not break during high-speed blood centrifugation, preventing leakage and contamination. It also boasts advantages such as a simple and aesthetically pleasing design and high material utilization.

[0003] The above-mentioned soft-shell filter preparation method consists of two steps: (a) preparation of the filter membrane assembly, in which a PVC inner membrane, a combined filter material and another PVC inner membrane are stacked in sequence, and then the inner edge of the PVC inner membrane is sealed to the outer edge of the combined filter membrane by high-frequency heat sealing; (b) peripheral heat sealing, in which a PVC outer membrane, an inlet conduit, a filter membrane assembly, a support, an outlet conduit and another PVC outer membrane are stacked in sequence, and then the edges of the PVC inner membrane and the PVC outer membrane in the filter membrane assembly are sealed by high-frequency heat sealing, while the pre-filtration liquid chamber is provided with an inlet conduit and the post-filtration liquid chamber is provided with an outlet conduit and a support.

[0004] The manufacturing equipment based on this process consists of two independent high-frequency heat sealing machines, each equipped with a fixture. These machines are used for the preparation and peripheral heat sealing of the filter membrane assembly, respectively. The various membrane layers, combined filter media, and tubing fittings within the fixtures are manually inserted and removed. The disadvantage of this equipment is that the fixtures are located below the heat sealing area of ​​the high-frequency heat sealing machine. When the fixtures are being manually operated, the high-frequency heat sealing machine must be stopped, resulting in very low utilization and significant wasted capacity. Furthermore, while the high-frequency heat sealing machine is operating, the operator is idle and waiting. Overall, the existing equipment suffers from inconsistent human-machine operation rhythms, poor coordination, and low production efficiency. In addition, because the inner and outer membranes are heat-sealed on two separate fixtures, the probability of defective products due to misalignment is relatively high. Summary of the Invention

[0005] To improve the production efficiency of soft-shell leukocyte filters while ensuring a high yield rate, this invention provides an automated assembly and heat-sealing device for soft-shell leukocyte filters.

[0006] The technical solution adopted in this invention is as follows: an automatic assembly and heat sealing device for a soft-shell leukocyte filter, comprising a frame and a rotating worktable mounted on the frame. A plurality of fixtures are evenly arranged along the circumferential direction on the rotating worktable. The frame is sequentially divided into an inner membrane preparation station, an inner membrane heat sealing station, an outer membrane preparation station, and an outer membrane heat sealing station along the rotation direction of the rotating worktable. At least one of the fixtures is arranged within the range of the inner membrane preparation station and the outer membrane preparation station, and an inner membrane heat sealing machine and an outer membrane heat sealing machine are arranged within the range of the inner membrane heat sealing station and the outer membrane heat sealing station, respectively.

[0007] Preferably, three of the aforementioned fixtures are arranged within the range of both the inner membrane preparation station and the outer membrane preparation station.

[0008] Preferably, the three fixtures at the inner membrane preparation station are used to unload the finished product, place the first inner membrane, place the filter material, and place the second inner membrane.

[0009] Preferably, the three fixtures at the outer membrane preparation station are used to remove the filter membrane assembly, place the first outer membrane, place the inlet conduit, place the filter membrane assembly, place the support, place the outlet conduit, and place the second outer membrane.

[0010] Preferably, the fixture has multiple assembly and heat-sealing positions for soft-shell leukocyte filters arranged in parallel.

[0011] Preferably, the fixture includes a base plate, on which a membrane positioning component, a filter media positioning component, a conduit positioning component, an inner membrane heat-sealing lower mold, and an outer membrane heat-sealing lower mold are disposed; the filter media positioning component and the conduit positioning component are movable parts, and the membrane positioning component is exposed after being moved outward.

[0012] Preferably, the membrane positioning assembly includes a support block and a plurality of positioning pins arranged on the support block. The support block is made of insulating material. The inner membrane heat-sealing lower mold and the outer membrane heat-sealing lower mold are embedded in the support block to form a complete membrane support surface.

[0013] Preferably, the filter media positioning assembly includes two limiting plates arranged in pairs. The limiting plates are made of insulating material. The two opposite surfaces of the two limiting plates form filter media limiting notches. The two limiting plates are installed on a first slide and move towards or away from each other under the drive of a first drive cylinder.

[0014] Preferably, the catheter positioning assembly includes a positioning rod, a flipping shaft, a second slide, and a second drive cylinder. The positioning rod is made of conductive material, and its front end forms the insertion and mounting part of the catheter. The tail end of the positioning rod is mounted on the flipping shaft and flips along the flipping shaft. The flipping shaft is mounted on the second slide and moves toward or away from the membrane positioning assembly under the drive of the second drive cylinder.

[0015] Preferably, the inner film heat sealing machine and the outer film heat sealing machine are respectively provided with an inner film heat sealing fixture and an outer film heat sealing fixture corresponding to the fixture. The inner film heat sealing fixture is provided with an inner film heat sealing upper mold corresponding to the inner film heat sealing lower mold, and the outer film heat sealing fixture is provided with an outer film heat sealing upper mold corresponding to the outer film heat sealing lower mold. An elastic pressure plate is provided on the outside of the outer film heat sealing upper mold, and the elastic pressure plate is made of insulating material.

[0016] The present invention has the following beneficial effects: The present invention integrates the inner membrane heat sealing machine and the outer membrane heat sealing machine into one unit by using a rotating worktable and multiple fixtures. When the inner membrane heat sealing machine and the outer membrane heat sealing machine are respectively preparing the filter membrane assembly and performing peripheral heat sealing, the operator can complete the preparation work in the fixtures of the inner membrane preparation station and the outer membrane preparation station. This reduces the standby time of the inner membrane heat sealing machine and the outer membrane heat sealing machine, improves the utilization rate of the equipment, maximizes production efficiency, reduces labor costs, and improves the product qualification rate. Attached Figure Description

[0017] Figure 1 This is a three-dimensional schematic diagram of an embodiment of the present invention.

[0018] Figure 2 This is a top view schematic diagram of an embodiment of the present invention.

[0019] Figure 3 This is a three-dimensional schematic diagram of the fixture in an embodiment of the present invention.

[0020] Figure 4 This is a schematic diagram of the membrane positioning component in the fixture of an embodiment of the present invention.

[0021] Figure 5 This is a schematic diagram of the filter media positioning assembly in the fixture of an embodiment of the present invention.

[0022] Figure 6 This is a schematic diagram of the catheter positioning component in the fixture of an embodiment of the present invention.

[0023] Figure 7 This is a schematic diagram of the inner membrane heat-sealing fixture in an embodiment of the present invention.

[0024] Figure 8 This is a schematic diagram of the outer membrane heat-sealing fixture in an embodiment of the present invention.

[0025] Rack 1; Rotary worktable 2; Fixture 3; base plate 301; membrane positioning assembly 302, filter media positioning assembly 303, conduit positioning assembly 304, inner membrane heat sealing lower mold 305, outer membrane heat sealing lower mold 306, support block 307, first auxiliary support block 307a, second auxiliary support block 307b, positioning pin 308, limiting plate 309, filter media limiting notch 310, first slide 311, first drive cylinder 312, positioning rod 313, flipping shaft 314, second slide 315, second drive cylinder 316, support seat 317; Inner membrane heat sealing machine 4; 5. Outer membrane heat sealing machine; Inner film heat sealing fixture 6, inner film heat sealing upper mold 601; 7 outer membrane heat sealing fixture, 701 outer membrane heat sealing upper mold, 702 elastic pressure plate; 8. Insulation device; 9. Electrical cabinet.

[0026] Inner membrane preparation station a, inner membrane heat sealing station b, outer membrane preparation station c, outer membrane heat sealing station d; Inner membrane 01, outer membrane 02, filter media 03, conduit 04, support component 05. Detailed Implementation

[0027] The present invention will be further described below with reference to the embodiments and accompanying drawings.

[0028] In the embodiments, such as Figures 1-8 As shown, an automated assembly and heat-sealing device for a soft-shell leukocyte filter is provided, including a frame 1 and a rotary worktable 2 mounted on the frame 1. Several fixtures 3 are evenly arranged along the circumference of the rotary worktable 2. The frame 1 is divided into an inner membrane preparation station a, an inner membrane heat-sealing station b, an outer membrane preparation station c, and an outer membrane heat-sealing station d along the rotation direction of the rotary worktable 2. At least one fixture 3 is arranged within the range of the inner membrane preparation station a and the outer membrane preparation station c, and an inner membrane heat-sealing machine 4 and an outer membrane heat-sealing machine 5 are arranged within the range of the inner membrane heat-sealing station b and the outer membrane heat-sealing station d, respectively.

[0029] In the embodiments, such as Figure 2 As shown, three fixtures 3 are arranged within the range of the inner membrane preparation station a and the outer membrane preparation station c. The operator performs operations on the three fixtures 3 at the inner membrane preparation station a, including unloading the finished product, placing the first inner membrane, placing the filter material, and placing the second inner membrane. The operator performs operations on the three fixtures 3 at the outer membrane preparation station c, including unloading the filter membrane assembly, placing the first outer membrane, placing the inlet conduit, placing the filter membrane assembly, placing the support, placing the outlet conduit, and placing the second outer membrane.

[0030] In the embodiments, such as Figure 3 , 4 As shown, fixture 3 is simultaneously equipped with an inner membrane heat-sealing lower mold 305 and an outer membrane heat-sealing lower mold 306; as Figure 7 As shown, the inner membrane heat sealing fixture 6 of the inner membrane heat sealing machine 4 is provided with an inner membrane heat sealing upper mold 601; as Figure 8 As shown, the outer membrane heat sealing fixture 7 of the outer membrane heat sealing machine is provided with an outer membrane heat sealing upper mold 701. The inner membrane heat sealing lower mold 305 cooperates with the inner membrane heat sealing upper mold 601 to complete the heat sealing of the filter membrane assembly of the soft shell leukocyte filter; the outer membrane heat sealing lower mold 306 cooperates with the outer membrane heat sealing upper mold 701 to complete the peripheral heat sealing of the soft shell leukocyte filter.

[0031] In the embodiments, such as Figure 3 As shown, multiple assembly and heat-sealing positions for the soft-shell leukocyte filter are arranged side by side on fixture 3. The multiple assembly and heat-sealing positions reduce the frequency of heat sealing and improve efficiency. In this embodiment, fixture 3 has four assembly and heat-sealing positions, maximizing production efficiency within the power range of the high-frequency heat sealing machine.

[0032] In the embodiments, such as Figures 3-6 As shown, the fixture 3 includes a base plate 301, on which a membrane positioning component 302, a filter media positioning component 303, a conduit positioning component 304, an inner membrane heat-sealing lower mold 305, and an outer membrane heat-sealing lower mold 306 are disposed. The filter media positioning component 303 and the conduit positioning component 304 are movable parts, and the membrane positioning component 302 is exposed after being moved outward. The fixture 3 in this embodiment is a composite fixture with multiple functions. The membrane positioning component 302 is used to position the two inner membranes 01 and the two outer membranes 02. The filter media positioning component 303 is used to position the filter media 03. The conduit positioning component 304 is used to position the conduit 04 (including the inlet conduit and the outlet conduit) and the support member 05. The inner membrane heat-sealing lower mold 305 cooperates with the inner membrane heat-sealing upper mold 306, and the outer membrane heat-sealing lower mold 306 cooperates with the outer membrane heat-sealing upper mold 701 to achieve heat sealing. The support component 05 comes in two forms. The first is a tubular structure as shown in CN102861365B, which needs to be installed independently on the catheter positioning assembly 304. The second is a strip-shaped structure as shown in CN104998311A, where the support component 05 is an integral part of the outlet catheter and is installed together with the outlet catheter on the catheter positioning assembly 304. The aforementioned functional components are ingeniously designed, do not interfere with each other, and feature automatic positioning, high automation, and convenient operation.

[0033] In the embodiments, such as Figure 4As shown, the membrane positioning assembly 302 includes a support block 307 and multiple positioning pins 308 arranged on the support block 307. The support block 307 is made of insulating material. The inner membrane heat-sealing lower mold 305 and the outer membrane heat-sealing lower mold 306 are embedded in the support block 307 to form a complete membrane support surface. The membrane positioning assembly 302 has four assembly heat-sealing positions, and the inner membrane heat-sealing lower mold 305 and the outer membrane heat-sealing lower mold 306 also have four positions each. The inner membrane 01 and the outer membrane 02 are a single, four-in-one membrane for easy operation. Each of the four corners of each assembly heat-sealing position has a positioning pin 308 to ensure accurate positioning of the inner membrane 01 and the outer membrane 02 and to avoid wrinkles. In addition, a first auxiliary support block 307a is provided in the middle of the inner membrane heat-sealing lower mold 305, and a second auxiliary support block 307b is provided in the gap between the inner membrane heat-sealing lower mold 305 and the outer membrane heat-sealing lower mold 306. The support block 307, the first auxiliary support block 307a, and the second auxiliary support block 307b together form a complete membrane support surface, which provides good support for the inner membrane 01 and the outer membrane 02 and ensures flatness.

[0034] In the embodiments, such as Figure 5 As shown, the filter media positioning assembly 303 includes two paired limiting plates 309. The limiting plates 309 are made of insulating material, and their opposing surfaces form filter media limiting notches 310. The two limiting plates 309 are mounted on a first slide 311, which is mounted on a guide rail on the base plate 301. Driven by a first drive cylinder 312, they move towards or away from each other. This embodiment uses a pneumatic clamping mechanism to position the filter media 03, allowing the limiting plates 309 to be easily removed from above the membrane positioning assembly 302, facilitating the placement or removal of the inner membrane 01, outer membrane 02, filter membrane assembly, and finished product. The operation is convenient. By replacing the limiting plates 309, the assembly can also be adapted to position filter media 03 of different shapes.

[0035] In the embodiments, such as Figure 6 As shown, the catheter positioning assembly 304 includes a positioning rod 313, a flipping shaft 314, a second slide 315, and a second drive cylinder 316. The positioning rod 313 is made of conductive material, and its front end forms the insertion and mounting part of the catheter. The tail end of the positioning rod 313 is mounted on the flipping shaft 314 and flips along the flipping shaft 314. The flipping shaft 314 is mounted on the second slide 315, which is mounted on the guide rail of the base plate 301 and moves towards or away from the membrane positioning assembly 302 under the drive of the second drive cylinder 316. In this embodiment, the positioning rod 313 can perform two actions: one is automatic flipping to facilitate the operator to insert the catheter, and the other is pneumatic movement to push the catheter into place. In addition, the limiting plate 309 is also provided with a notch to accommodate the positioning rod 313 and avoid obstructing the positioning rod 313.

[0036] In the embodiments, such as Figure 8As shown, the outer film heat sealing fixture 7 is provided with an outer film heat sealing upper mold 701 corresponding to the outer film heat sealing lower mold 306. An elastic pressure plate 702 is provided on the outside of the outer film heat sealing upper mold 701. The elastic pressure plate 702 is made of insulating material. The elastic pressure plate 702 is installed on the outer film heat sealing fixture 7 by means of a cylindrical spring and a guide rod, and presses the inner film 01 and the outer film 02 together to ensure their flatness.

[0037] In this embodiment, the inner membrane heat-sealing lower mold 305, inner membrane heat-sealing upper mold 601, outer membrane heat-sealing lower mold 306, outer membrane heat-sealing upper mold 701, and positioning rod 313 all correspond to the heat-sealing parts and require high conductivity, so brass can be used. The support block 307, first auxiliary support block 307a, second auxiliary support block 307b, limiting plate 309, and elastic pressure plate 702 will all be in direct contact with the filter material but cannot undergo heat sealing; therefore, they require good insulation and heat insulation properties, so acetal resin (POM) can be used. The materials of other components of fixture 3 can be stainless steel or aluminum alloy, depending on the actual situation.

[0038] In this embodiment, the inner membrane preparation station a and the outer membrane preparation station c are typically staffed with two operators each, for a total of four operators. The first operator is positioned at the first fixture 3 of the inner membrane preparation station a. They first remove the heat-sealed finished product, perform a visual inspection, and then place the first inner membrane 01. The second operator is positioned at the second fixture 3 of the inner membrane preparation station a. After the filter media positioning assembly 303 automatically enters its position, they place the filter media 03, and then place the second inner membrane 01. The third operator is positioned at the first fixture 3 of the outer membrane preparation station c. After the filter media positioning assembly 303 exits its position, they remove the heat-sealed filter media assembly, perform a visual inspection, and then place the first outer membrane 02 and the conduit 04 (liquid inlet), followed by the filter media assembly. The fourth operator is positioned at the second fixture 3 of the outer membrane preparation station c. They place the conduit 04 (liquid outlet) and the support 05 (the support 05 can be a separate support tube or a support strip integrated with the conduit 04), and then place the second outer mold 02. In actual operation, the work of different operators can be adjusted to each other, and more operators can be added to suit the production rhythm of the inner film heat sealing machine 4 and the outer film heat sealing machine 5.

[0039] In this embodiment, the inner membrane heat sealing machine 4 and the outer membrane heat sealing machine 5 are integrated into one unit using a rotating worktable 2 and multiple fixtures 3. When the inner membrane heat sealing machine 4 and the outer membrane heat sealing machine 5 are preparing the filter membrane assembly and performing peripheral heat sealing respectively, the decomposition of the preparatory work allows multiple operators to complete the preparatory work in the fixtures 3 at the inner membrane preparation station a and the outer membrane preparation station c. This reduces the standby time of the inner membrane heat sealing machine 4 and the outer membrane heat sealing machine 5, improves the utilization rate of the equipment, and maximizes production efficiency.

[0040] Obviously, the above embodiments of the present invention are merely illustrative examples to illustrate the invention and are not intended to limit the implementation of the invention. Other obvious variations or modifications derived from the essential spirit of the invention still fall within the protection scope of the invention.

Claims

1. An automated assembly and heat-sealing device for a soft-shell leukocyte filter, characterized in that, The machine includes a frame (1) and a rotary worktable (2) mounted on the frame (1). Several fixtures (3) are evenly arranged on the rotary worktable (2) along the circumferential direction. The frame (1) is divided into an inner film preparation station (a), an inner film heat sealing station (b), an outer film preparation station (c), and an outer film heat sealing station (d) in sequence along the rotation direction of the rotary worktable (2). At least one fixture (3) is arranged in the range of the inner film preparation station (a) and the outer film preparation station (c). An inner film heat sealing machine (4) and an outer film heat sealing machine (5) are arranged in the range of the inner film heat sealing station (b) and the outer film heat sealing station (d). The fixture (3) includes a base plate (301), on which a membrane positioning assembly (302), a filter media positioning assembly (303), a conduit positioning assembly (304), an inner membrane heat-sealing lower mold (305), and an outer membrane heat-sealing lower mold (306) are provided. The filter media positioning assembly (303) and the conduit positioning assembly (304) are movable parts, and the membrane positioning assembly (302) is exposed after being moved outward. The membrane positioning assembly (302) is used to position the two inner membranes and the two outer membranes. The filter media positioning assembly (303) is used to position the filter media. The conduit positioning assembly (304) is used to position the conduit and the support. The conduit includes an inlet conduit and an outlet conduit. The membrane positioning assembly (302) includes a support block (307) and a plurality of positioning pins (308) arranged on the support block (307). The support block (307) is made of insulating material. The inner membrane heat-sealing lower mold (305) and the outer membrane heat-sealing lower mold (306) are embedded in the support block (307) to form a complete membrane support surface. The filter media positioning assembly (303) includes two pairs of limiting plates (309), the limiting plates (309) are made of insulating material, and the two opposite surfaces of the two limiting plates (309) form filter media limiting notches (310). The two limiting plates (309) are mounted on a first slide (311) and move towards or away from each other under the drive of a first drive cylinder (312). The catheter positioning assembly (304) includes a positioning rod (313), a flipping shaft (314), a second slide (315), and a second drive cylinder (316). The positioning rod (313) is made of conductive material. The front end of the positioning rod (313) forms the insertion and mounting part of the catheter. The tail end of the positioning rod (313) is mounted on the flipping shaft (314) and flips along the flipping shaft (314). The flipping shaft (314) is mounted on the second slide (315) and moves toward or away from the membrane positioning assembly (302) under the drive of the second drive cylinder (316). A first auxiliary support block (307a) is provided in the middle of the inner membrane heat-sealing lower mold (305), and a second auxiliary support block (307b) is provided in the gap between the inner membrane heat-sealing lower mold (305) and the outer membrane heat-sealing lower mold (306). Both the first auxiliary support block (307a) and the second auxiliary support block (307b) are made of insulating material. The limiting plate (309) is also provided with a notch to accommodate the positioning rod (313) and avoid obstructing the positioning rod (313).

2. The automated assembly and heat-sealing equipment for the soft-shell leukocyte filter according to claim 1, characterized in that, Three fixtures (3) are arranged within the range of the inner membrane preparation station (a) and the outer membrane preparation station (c).

3. The automated assembly and heat-sealing equipment for the soft-shell leukocyte filter according to claim 2, characterized in that, The three fixtures (3) at the inner membrane preparation station (a) are used to unload the finished product, place the first inner membrane, place the filter material, and place the second inner membrane.

4. The automated assembly and heat-sealing equipment for the soft-shell leukocyte filter according to claim 2, characterized in that, The three fixtures (3) at the outer membrane preparation station (c) are used to remove the filter membrane assembly, place the first outer membrane, place the inlet conduit, place the filter membrane assembly, place the support, place the outlet conduit, and place the second outer membrane.

5. The automated assembly and heat-sealing equipment for the soft-shell leukocyte filter according to claim 1, characterized in that, Multiple soft-shell leukocyte filter assembly and heat sealing positions are arranged side by side on the fixture (3).

6. The automated assembly and heat-sealing equipment for the soft-shell leukocyte filter according to claim 1, characterized in that, The inner film heat sealing machine (4) and the outer film heat sealing machine (5) are respectively provided with an inner film heat sealing fixture (6) and an outer film heat sealing fixture (7) corresponding to the fixture (3). The inner film heat sealing fixture (6) is provided with an inner film heat sealing upper mold (601) corresponding to the inner film heat sealing lower mold (305). The outer film heat sealing fixture (7) is provided with an outer film heat sealing upper mold (701) corresponding to the outer film heat sealing lower mold (306). An elastic pressure plate (702) is provided on the outside of the outer film heat sealing upper mold (701). The elastic pressure plate (702) is made of insulating material.

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