Equipment for sterilizing welding

Abstract

The invention relates to an apparatus for sterilization welding. The scheme provided by the invention comprises the following steps: generating plasma treatment and applying the plasma treatment to end contact surfaces of a first profile and a second profile in a sterile environment; manipulating at least one of the first profile and the second profile to forcibly contact between the end contact surface of the first profile and the end contact surface of the second profile to permanently join, join or weld together the end contact surfaces of the first profile and the second profile, therefore, sterile connection is formed between the first section bar and the second section bar.

Description

[0001] This application is a divisional application of the Chinese invention patent application with application number 202080082247.6, application date November 19, 2020, and invention name “Equipment for Sterilization Welding”. Technical Field

[0002] The present disclosure relates to plasma welding equipment and methods Background Art

[0003] Aseptic connection is used to connect various profiles to deliver and remove fluid. Such aseptic connection can be used for various industries including medical industry and pharmaceutical industry. Thermoplastic elastomers and thermosetting elastomers are generally used for such applications because these elastomers are non-toxic, flexible, heat-stable, have lower chemical reactivity, and can be produced in various sizes. In many instances, it is necessary to connect two different profiles to form aseptic fluid connection. Unfortunately, the traditional welding equipment using high temperature method can not effectively join thermosetting elastomer (such as silicone elastomer that can not be melted) to another thermosetting elastomer or other polymeric materials. Further, joining these materials also presents a challenge to the sterility of the connection. Summary of the invention

[0004] The present disclosure generally relates to a plasma welding apparatus and methods for applying plasma treatment to end contact surfaces of a first profile and a second profile, preferably in a sterile environment; manipulating at least one of the first profile and the second profile to force contact between the end contact surface of the first profile and the end contact surface of the second profile to permanently connect, join or weld the end contact surfaces of the first profile and the second profile together, thereby forming a sterile connection between the first profile and the second profile. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] For a more detailed understanding of the manner in which the features and advantages of the embodiments are achieved, a more comprehensive description may be made with reference to the embodiments shown in the accompanying drawings. However, the accompanying drawings only illustrate some embodiments and therefore should not be considered limiting of the scope, as there may be other equally effective embodiments.

[0006] Figure 1 is a schematic diagram of a plasma welding device according to an embodiment of the present disclosure.

[0007] Figure 2 is a schematic diagram of a mechanical motion module according to an embodiment of the present disclosure.

[0008] Figure 3 is a schematic diagram of a mechanical motion module according to an embodiment of the present disclosure.

[0009] Figure 4A first profile and a second profile are shown in an open position for plasma welding.

[0010] Figure 5 The first and second profiles for plasma welding are shown in a closed position of the distal ends of each of the first and second profiles.

[0011] Figure 6 The first and second profiles are shown in a closed position away from distal ends of each of the first and second profiles for plasma welding.

[0012] Figure 7 The present invention is a flowchart of a method for operating a plasma welding device according to an embodiment of the present disclosure.

[0013] FIG. 8A to FIG. 8G It is a schematic diagram of a mechanical motion module according to an embodiment of the present disclosure, and illustrates various steps of operating the mechanical motion module in a welding device.

[0014] Fig. 9 is a schematic diagram of a mechanical motion module according to another embodiment of the present disclosure.

[0015] Fig.10 is a schematic diagram of a portion of a mechanical motion module according to an embodiment of the present disclosure.

[0016] The use of the same reference symbols in different drawings indicates similar or identical items. DETAILED DESCRIPTION

[0017] Figure 1A schematic diagram of a plasma welding device 100 according to one embodiment of the present disclosure is shown. Most generally, the plasma welding device 100 can be configured to join two profiles (e.g., tubes, hoses, or other shapes or structures having an inner cavity through which a fluid can be conveyed, pumped, or otherwise delivered) in a sterile environment. The joining of the two profiles can be accomplished by simultaneously welding the first end of the first profile with the second end of the second profile through a surface activation treatment. When the first end of the first profile is in direct contact with the second end of the second profile, the surface activation treatment simultaneously and chemically welds the first end of the first profile with the second end of the second profile. Any surface activation treatment is contemplated and includes processing the input energy to the surface of the first profile, the second profile, or a combination thereof. In one embodiment, processing the input energy is accomplished by wave radiation, specific radiation, or a combination thereof. In one embodiment, the wave radiation includes any wave radiation contemplated, such as radio waves, microwaves, infrared rays, visible light, ultraviolet rays, X-rays, gamma radiation, or a combination thereof. In a specific embodiment, the wave radiation includes microwaves, ultraviolet rays, X-rays, gamma radiation, or a combination thereof. In one embodiment, the particle radiation includes alpha radiation, beta radiation, charged ions, neutron radiation, or a combination thereof.The surface activation treatment provides an effective seal between the two profiles.

[0018] The plasma welding apparatus 100 may generally include an operating chamber 102, a plasma generator 104, a mechanical motion module 106, and a control system 108. The operating chamber 102 may generally include an enclosure defining a substantially sealed internal environment 110 in which sterile cutting and / or plasma welding operations of a first profile 112 and a second profile 114 may occur. The plasma generator 104 may generally be configured to generate ionized particles by a plasma treatment (e.g., corona treatment, C-treatment, flame treatment, ion treatment, plasma treatment, or a combination thereof) within the operating chamber 102, which may be selectively applied to the first profile 112 and the second profile 114 to activate materials on end contact surfaces of the first profile 112 and the second profile 114. The mechanical motion module 106 can be generally configured to axially or otherwise align the first profile 112 and the second profile 114 and / or force contact between the end contact surfaces of the first profile 112 and the second profile 114, so as to connect, join or weld the end contact surfaces of the first profile 112 and the second profile 114 together. The control system 108 can generally include a user interface 116 and a plurality of sensors 118, indicators, meters or a combination thereof to facilitate control, monitoring and operation of the plasma welding process.

[0019] It should be understood that conventional welding equipment using high temperature methods cannot effectively join a thermosetting elastomer (such as a silicone elastomer that cannot be melted) to another thermosetting elastomer or other polymer material. However, the plasma welding equipment 100 is configured to connect, join or weld a variety of materials. In some embodiments, at least one of the first profile and the second profile can be formed of a polymer material. However, in some embodiments, both the first profile and the second profile can be formed of a polymer material. Therefore, in some embodiments, the first profile and the second profile can be formed of the same polymer material. In other embodiments, the first profile and the second profile can be formed of different polymer materials. In some embodiments, the first profile and the second profile can be formed of a thermoplastic elastomer, a thermosetting elastomer, or a combination thereof. Further, in some embodiments, the thermoplastic elastomer of the first profile and / or the second profile may include polystyrene, polyester, silicone copolymer, silicone thermoplastic vulcanizate, copolyester, polyamide, fluoropolymer, polyolefin, polyether-ester copolymer, thermoplastic polyurethane, polyetheramide block copolymer, polyamide copolymer, styrene block copolymer, polycarbonate, thermoplastic vulcanizate, ionomer, polyoxymethylene (POM), acrylonitrile butadiene styrene (ABS), acetal, acrylic, polyvinyl chloride (PVC), blends, or combinations thereof. In some embodiments, the thermosetting elastomer of the first profile and / or the second profile may include silicone elastomer, diene elastomer, butyl rubber, natural rubber, polyurethane rubber, ethylene propylene diene rubber, isoprene rubber, nitrile rubber, styrene butadiene rubber, blends, or combinations thereof.

[0020] In some embodiments, the operating chamber 102 can include an enclosure defining a substantially sealed internal environment 110 that is separated from an external environment such as a clean room 120 and / or an ambient atmosphere 122 outside the clean room 120 and / or a structure such as a medical facility. In some embodiments, the operating chamber 102 can be configured to at least partially contain the first profile 112 and the second profile 114 to facilitate aseptic cutting and / or plasma welding operations. However, in order to maintain a sterile internal environment 110 within the operating chamber 102, the operating chamber 102 can be configured to maintain a liquid-tight seal when the first profile 112 and the second profile 114 are contained within the operating chamber 102 and partially protrude therefrom. Therefore, in some embodiments, the operating chamber can function to confine the plasma or plasma processing within the internal environment 110.

[0021] In some embodiments, the process chamber 102 can include at least one transparent surface 124 through which the first profile 112 and the second profile 114 can be viewed. In other embodiments, the process chamber 102 can include multiple transparent surfaces 124 through which the first profile 112 and the second profile 114 can be viewed. In still other embodiments, the process chamber 102 can be formed of a transparent material (e.g., acrylic, acrylic glass, plexiglass, polycarbonate, or a combination thereof) that allows an operator to observe the first profile 112 and the second profile 114 from all angles and / or sides of the process chamber 102. These embodiments can allow an operator to observe the plasma welding process and / or inspect the completion, quality, or a combination thereof of the final connection between the first profile 112 and the second profile 114. Additionally, in some embodiments, the transparent surface can at least partially block ultraviolet light from entering or leaving the package in order to protect the safety of the operator and / or the integrity of the plasma process.

[0022] As described above, the operating room 102 can maintain a substantially sterile internal environment 110 within the operating room 102. In some embodiments, this can be facilitated by a two-way ventilation system 126. In some embodiments, the ventilation system 126 can exchange and / or filter the air within the internal environment 110 through a first exchange system 128. In some embodiments, the ventilation system 126 can exchange and / or filter the air between the clean room 120 and the internal environment 110 through a second exchange system 130. Further, in some embodiments, the ventilation system 126 can exchange and / or filter the air between the ambient atmosphere 122 and the internal environment 110 through a third exchange system 132. Thus, the ventilation system 126 can include a filter, a catalytic converter, a radiation element, or a combination thereof, which processes (e.g., filters, sterilizes, reduces ozone, temperature conditions, or a combination thereof) the air received from the clean room 120 through the second exchange system 130 and enters or leaves the internal environment 110 of the operating room 102 through the first exchange system 128. Furthermore, the ventilation system 126 may also include filters, catalytic converters, radiation elements, or combinations thereof that process air received from the ambient atmosphere 122 via the third exchange system 132 and entering or exiting the interior environment 110 of the operating room 102 via the first exchange system 128 .

[0023] The plasma generator 104 may generally include a gas supply source 134, an electric power supply source 136, and at least one plasma head 138, and is configured to generate ionized particles by a plasma treatment (e.g., corona treatment, C-treatment, flame treatment, ion treatment, plasma treatment, or a combination thereof) within the operating chamber 102, which may be selectively applied to the first profile 112 and the second profile 114 to activate the materials on the end contact surfaces of the first profile 112 and the second profile 114. The gas supply source 134 may be configured to provide one or more gas streams, such as an inert gas, an oxygen-containing gas, a nitrogen-containing gas, a fluorine-containing gas, or a combination thereof. In some embodiments, the gas supply source 134 may include an atmospheric air supply source, a compressor, a compressed gas cylinder, an internal gas line, an internal compressed gas line, a fan, a turbine, or any combination thereof to generate a gas stream. In some embodiments, the inert gas may include argon, neon, helium, or any combination thereof. In other embodiments, the oxygen-containing gas may include atmospheric air, pure oxygen, ethanol, water vapor, or a combination thereof. In some other embodiments, the nitrogen-containing gas may include atmospheric air, pure nitrogen, ammonia or a combination thereof. In addition, in other embodiments, the fluorine-containing gas may include sulfur hexafluoride (SF6), trifluoromethane (CHF3), tetrafluoromethane (CF4), octafluorocyclobutane (C4F8) or a combination thereof.

[0024] The power supply 136 can generally be configured to ionize the gas flow by imparting an electrical charge to the gas flow to produce a plasma treatment. In some embodiments, the power supply 136 can be configured to provide an AC voltage of at least 110VAC, at least 120VAC, at least 220VAC, or at least 240VAC. However, in other embodiments, the power supply 136 can be configured to provide a DC voltage of at least 6VDC, at least 9VDC, at least 12VDC, at least 24VDC, or at least 48VDC.

[0025] The plasma treatment may be delivered to at least one plasma head 138 disposed within the interior environment 110 of the operating chamber 102 via at least one supply line 137. The plasma head 138 may be disposed within the interior environment 110 of the operating chamber 102 and positioned within the operating chamber such that the at least one plasma head 138 applies the plasma treatment to the end contact surfaces of the first profile 112 and the second profile 114. Thus, applying the plasma treatment to the end contact surfaces of the first profile 112 and the second profile 114 may include exposing or subjecting the end contact surfaces of the first profile 112 and the second profile 114 to the plasma treatment, or delivering or directing the plasma treatment to contact or substantially encapsulate the end contact surfaces of the first profile 112 and the second profile 114. By applying the plasma treatment to the end contact surfaces, the material at the end contact surfaces may be activated to weld the first profile to the second profile when the first profile 112 and the second profile 114 are forced into contact.

[0026] In some embodiments, the plasma generator 104 may include a single plasma head 138 disposed within the interior environment 110 of the operating chamber 102. However, in some embodiments, the plasma generator 104 may include a plurality of plasma heads 138 disposed within the interior environment 110 of the operating chamber 102. In a particular embodiment, at least one of the plurality of plasma heads 138 may be disposed adjacent to the first profile 112 within the operating chamber 102, and at least one of the plurality of plasma heads 138 may be disposed adjacent to the second profile 114 within the interior environment 110 of the operating chamber 102. Furthermore, in another particular embodiment, at least one of the plurality of plasma heads 138 may be configured to sterilize the interior environment 110 within the operating chamber 102.

[0027] The mechanical motion module 106 can generally be configured to axially or otherwise align the first profile 112 and the second profile 114 and / or force contact between the end contact surfaces of the first profile 112 and the second profile 114, so that the end contact surfaces of the first profile 112 and the second profile 114 are connected, joined or welded together. In some embodiments, the mechanical motion module 106 can be at least partially disposed within the operating room 102, or at least partially form a lower barrier or perimeter of the internal environment 110 of the operating room 102. In some embodiments, the mechanical motion module 106 can include a cutting system 140. However, in some embodiments, the cutting system 140 can be a separate component. In some embodiments, the cutting system 140 can be disposed in the internal environment 110 of the operating room 102. The cutting system 140 can generally be configured to selectively cut the first tubular component to form the first profile 112 and selectively cut the second tubular component to form the second profile 114. Thus, in some embodiments, the cutting system 140 may include at least one cutting device, such as at least one blade, and the at least one blade may be heated, pre-sterilized, sterilized by plasma treatment, or a combination thereof. In some embodiments where the at least one blade of the cutting system 140 is heated and the first tubular component 111 and the second tubular component 113 are formed of a thermoplastic elastomer, the at least one blade may be used to cut the first tubular component 111 to form the first profile 112 and cut the second tubular component 113 to form the second profile 114, the blade melts the ends of the profiles 112, 114, and the melted ends of the profiles 112, 114 may be joined to the ends of the profiles 112, 114 in the plasma sterilized interior environment 110 of the operating chamber 104 without using plasma treatment. However, in some embodiments, the cutting device may include a laser cutting device or system.

[0028] Figure 2A schematic diagram of a mechanical motion module 106 according to one embodiment of the present disclosure is shown. In the illustrated embodiment, the mechanical motion module 106 includes a linear motion module. In order to prepare the first profile 112 and the second profile 114 for plasma welding, the cutting system 140 can be selectively operated to cut the two parts to form the first profile 112 and the second profile 114. In some embodiments, a plasma treatment can be applied before, during and / or after the cutting process to activate the material on the end contact surfaces of the first profile 112 and the second profile 114. The mechanical motion module 106 can be configured to axially align the end contact surfaces of the first profile 112 and the second profile 114. In some embodiments, the mechanical motion module 106 can linearly displace at least one of the first profile 112 and the second profile 114 (substantially perpendicular to the axial direction) to axially align the end contact surfaces of the first profile 112 and the second profile 114. In other embodiments, the mechanical motion module 106 can linearly displace both the first profile 112 and the second profile 114 to axially align the end contact surfaces of the first profile 112 and the second profile 114. In addition, once axially aligned, the mechanical motion module 106 can also be configured to force the end contact surfaces of the first profile 112 and the second profile 114 activated by the plasma treatment to contact each other to weld the first profile 112 and the second profile 114 at the end contact surfaces of the first profile 112 and the second profile 114, thereby forming a joint or plasma welded connection 142. In some embodiments, the plasma treatment can continue after the first profile 112 is joined to the second profile 114 to ensure a sterile connection, thereby forming a joint or plasma welded connection 142.

[0029] Figure 3A schematic diagram of a mechanical motion module 106 according to another embodiment of the present disclosure is shown. In the illustrated embodiment, the mechanical motion module 106 includes a rotational motion module. In order to prepare the first profile 112 and the second profile 114 for plasma welding, the two parts captured by the rotational motion device 144 can be selectively rotated to contact the two parts with the corresponding cutting device to form the first profile 112 and the second profile 114. In some embodiments, a plasma treatment can be applied before, during and / or after the cutting process to activate the material on the end contact surface of the first profile 112 and the second profile 114. The rotational motion device 144 of the mechanical motion module 106 can be configured to continuously rotate the first profile and the second profile to axially align the end contact surface of the first profile 112 and the second profile 114 to axially align the end contact surface of the first profile 112 and the second profile 114. In other embodiments, the mechanical motion module 106 can linearly displace both the first profile 112 and the second profile 114 to axially align the end contact surface of the first profile 112 and the second profile 114. In addition, once axially aligned, the rotary motion device 144 of the mechanical motion module 106 can also be configured to force the end contact surfaces of the first profile 112 and the second profile 114 activated by the plasma treatment to contact each other to weld the first profile 112 and the second profile 114 at the end contact surfaces of the first profile 112 and the second profile 114, thereby forming a joint or plasma welded connection 142. In some embodiments, the plasma treatment can continue after the first profile 112 is joined to the second profile 114 to ensure that a sterile joint or plasma welded connection 142 is formed.

[0030] In some embodiments, the mechanical motion module 106 can be configured to manipulate one or more internal cavities of the first profile 112 and the second profile 114 prior to plasma welding. Thus, in some embodiments, the first profile 112 and the second profile 114 can remain open during plasma processing and / or joining of the first profile 112 and the second profile 114. Figure 4 The first profile 112 and the second profile 114 are shown in an open position for plasma welding. In other embodiments, the mechanical movement module 106 can at least partially close one or more internal cavities of the first profile 112 and the second profile 114 before plasma welding. In some embodiments, the first profile 112 and the second profile 114 can be closed and / or sealed before joining the first profile 112 and the second profile 114. Figure 5 The first profile 112 and the second profile 114 are shown in a closed position at the distal end of each of the first profile 112 and the second profile 114 for plasma welding. Figure 6The first and second profiles 112 and 114 are shown in a closed position away from distal ends of each of the first and second profiles 112 and 114 for plasma welding.

[0031] As described above, plasma treatment may be applied before, during, and / or after the cutting process and / or the joining process to activate the material on the end contact surface of the first profile 112 and the second profile 114. In some embodiments, plasma treatment may be applied before cutting the first profile 112 and the second profile to ensure aseptic connection. In some embodiments, plasma treatment may be started at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds, or at least 120 seconds before cutting the first profile 112 and the second profile 114. In some embodiments, plasma treatment may continue after the first profile is joined to the second profile to ensure aseptic connection. In some embodiments, plasma treatment may continue at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds, or at least 120 seconds after joining the first profile 112 and the second profile 114.

[0032] Ensuring a sterile connection between the first profile 112 and the second profile 114 may be a result of pre-treating the interior environment 110 of the operating room 104 with a plasma treatment or starting the plasma treatment before the cutting operation of the first profile 112 and the second profile 114. Further, ensuring a sterile connection between the first profile 112 and the second profile 114 may also be a result of continuing to apply the plasma treatment after joining the first profile 112 and the second profile 114 by plasma welding. Thus, the plasma treatment provides a sterile environment for the interior environment 110 of the operating room 102, wherein the sterile environment is defined by a reduction in the number of viable microorganisms within the interior environment 110 of the operating room by at least 106 after exposure to the plasma treatment or plasma for at least 10 seconds, at least 15 seconds, at least 20 seconds, at least 25 seconds, at least 30 seconds, or at least 60 seconds.

[0033] Furthermore, it should be appreciated that the plasma welding process can be performed at various temperatures within the internal environment 110 of the operating room 102. For example, in some embodiments, the plasma welding process can be performed at room temperature, such as within the clean room 120. However, it should be appreciated that the plasma welding process can be performed and configured to provide a sterile connection between the first profile 112 and the second profile 114 at any temperature between approximately 10 degrees Celsius and 350 degrees Celsius.

[0034] The control system 108 may generally include a user interface 116 and a plurality of sensors 118, indicators, meters, or combinations thereof, to facilitate control, monitoring, and operation of the plasma generator 104, the mechanical motion module 106, and the plasma welding process. The user interface 116 may generally include a display configured to display temperature, gas flow rate, gas pressure, gas detection level, material of the first profile and the second profile, plasma processing progress level, duty cycle, total number of duty cycles, or combinations thereof. In certain embodiments, the user interface 116 may include a material selection input for selecting the characteristics of the material of each of the first profile 112 and the second profile 114. In addition, in some embodiments, the user interface 116 may include a warning system configured to warn an operator when an out-of-spec condition exists. The user interface 116 may also be configured to automatically stop the plasma processing when an out-of-spec condition exists. Examples of out-of-spec conditions include, but are not limited to, low temperature, high temperature, low pressure, high pressure, low gas flow rate, high gas flow rate, detection of plasma byproducts, invalid selection of materials, leaks in the operating chamber, or combinations thereof. When this occurs, the control system 108 may prevent the opening and / or removal of the process chamber 102. Further, the control system 108 may also prevent the opening and / or removal of the process chamber 102 during the application of the plasma treatment.

[0035] The plurality of sensors 118, indicators, meters, or combinations thereof may generally be configured to transmit data (e.g., operating parameters) regarding the plasma welding operation to an operator and allow the operator to monitor the plasma welding process. In some embodiments, the plurality of sensors 118 may include temperature sensors, gas flow rate sensors, gas pressure sensors, gas detection sensors, plasma byproduct sensors, tension sensors, or combinations thereof. Further, in some embodiments, the control system 108 may be configured to record or store data transmitted from the sensors 118 related to the operation of the plasma welding device 100. The data may be used to troubleshoot and / or adjust operating parameters of the components 102, 104, 106, 108 of the plasma welding device 100 or the plasma welding process.

[0036] Further, in some embodiments, the control system 108 may include at least one vision system (e.g., a camera, an inspection device, a video device) configured to verify the axial alignment of the end contact surfaces of the first profile 112 and the second profile 114, confirm the successful engagement of the first profile 112 with the second profile 114, or a combination thereof. In some embodiments, confirming the successful engagement of the first profile 112 with the second profile 114 may be accomplished by inspecting the welded profiles at a certain angle (e.g., 30 degrees, 45 degrees), wherein the unsuccessfully engaged areas appear darker than the successfully engaged areas. Further, in some embodiments, the control system 108 may also include a marking system configured to mark the first profile 112, the second profile 114, the joint or welded connection 142 formed between the first profile 112 and the second profile 114, or a combination thereof by laser marking, ink marking, or any combination thereof, which allows one or more features of the joint or welded connection 142 formed between the first profile 112 and the second profile 114 to be identified, verified, troubleshooted, or any combination thereof.

[0037] The plasma welding apparatus 100 can be configured to form a sterile plasma welded connection 142 between the first profile 112 and the second profile 114. The resulting plasma welded connection 142 can maintain specific performance characteristics commensurate with an unmodified control bulk material of the first profile 112 or the second profile 114. Therefore, in some embodiments, after the joint or plasma welded connection 142 between the first profile 112 and the second profile 114 is formed, the control system 108 can be configured to perform a burst test, a tensile test, or a combination thereof between the first profile 112 and the second profile 114 to ensure that the plasma welded connection 142 between the first profile 112 and the second profile 114 is successfully formed. In some embodiments, the joint or welded connection 142 formed between the first profile 112 and the second profile 114 may include a tensile strength of at least 10%, at least 15%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, or at least 50% of the tensile strength of the unmodified control bulk material of the first profile 112 or the second profile 114. In addition, in some embodiments, the joint or welded connection 142 formed between the first profile 112 and the second profile 114 can include a burst pressure of at least 10%, at least 25%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 76%, at least 77%, at least 78%, at least 79%, at least 80%, at least 81%, at least 82%, at least 83%, at least 84%, at least 85%, at least 86%, at least 87%, at least 88%, at least 89% or at least 90% of the burst pressure of the unmodified control bulk material of the first profile or the second profile.

[0038] Furthermore, in some embodiments, a reinforcement may be applied at least partially around the plasma welded connection 142 between the first profile 112 and the second profile 114. The reinforcement may include tape, polymer tape, overmolded polymer, plasma welded polymer or polymer tape, or combinations thereof.

[0039] The plasma welding apparatus 100 may generally be configured such that the operating chamber 102 and the mechanical motion module 106 are configured for mobile use and are remotely coupled to the plasma generator 104 and / or the control system 108. In addition, in some embodiments, the plasma welding apparatus 100 may be an integrated apparatus mounted to a cart or other apparatus for mobile use, in which the entire plasma welding apparatus 100 may be moved or repositioned.

[0040] refer to Figure 7 , a flow chart of a method 700 of operating a plasma welding apparatus 100 according to one embodiment of the present disclosure is shown. The method 700 may start at block 702 by generating a plasma process with a plasma generator 104. The method 700 may continue at block 704 by applying plasma to an end contact surface of a first profile 112 and an end contact surface of a second profile 114 within the operating chamber 102. The method 700 may continue at block 706 by manipulating at least one of the first profile 112 and the second profile 114 to force contact between the end contact surface of the first profile 112 and the end contact surface of the second profile 114 to join the first profile 112 and the second profile 114.

[0041] FIG. 8A to FIG. 8G is a schematic diagram of a mechanical motion module 800 according to one embodiment of the present disclosure, and illustrates various steps of operating the mechanical motion module 800 in the plasma welding apparatus 100. According to the embodiments disclosed herein, the mechanical motion module 800 may generally be substantially similar to the mechanical motion module 106, and configured to operate in the plasma welding apparatus 100. Thus, the mechanical motion module 800 may generally be configured to selectively cut the first tubular component 111 to form the first profile 112 and selectively cut the second tubular component 113 to form the second profile 114, axially align the first profile 112 and the second profile 114, and when subjected to plasma treatment, force contact between end contact surfaces of the first profile 112 and the second profile 114 to connect, join or weld the end contact surfaces of the first profile 112 and the second profile 114 together. Further, it should be understood that in some embodiments, the mechanical motion module 800 can be at least partially disposed within the operating chamber 102 of the plasma welding device 100, or at least partially form a lower barrier or perimeter of the internal environment 110 of the operating chamber 102 of the plasma welding device 100.

[0042] The mechanical motion module 800 may include a cutting system that may be substantially similar to the cutting system 140. In some embodiments, the cutting system may be configured to selectively cut the first tubular component 111 to form the first profile 112 and to selectively cut the second tubular component 113 to form the second profile 114. The cutting system may generally include at least one cutting device 803, 805, and the cutting devices 803, 805 may include a blade or a laser cutting device or system. In some embodiments, the cutting system may include a first cutting device 803 and a second cutting device 805. More specifically, the first cutting device 803 may be configured to cut the first tubular component 111 to form the first profile 112, and the second cutting device may be configured to cut the second tubular component 113 to form the second profile 114. According to embodiments disclosed herein, cutting the first profile 112 and the second profile 114 may generally expose end contact surfaces of the first profile 112 and the second profile 114. Further, in some embodiments, according to the embodiments disclosed herein, the first cutting device 803 and the second cutting device 805 can be heated, pre-sterilized, or a combination thereof. In some embodiments where at least one blade of the cutting system 140 is heated and the first tubular component 111 and the second tubular component 113 are formed of a thermoplastic elastomer, the at least one blade can be used to cut the first tubular component 111 to form the first profile 112 and cut the second tubular component 113 to form the second profile 114, the blade melts the ends of the profiles 112, 114, and the melted ends of the profiles 112, 114 can be joined to the ends of the profiles 112, 114 in the plasma-sterilized internal environment 110 of the operating chamber 104 without using plasma treatment.

[0043] The mechanical motion module 800 may include a plurality of actuators 802, 804, 806, 808, 810 configured to move various components of the mechanical motion module 800 along a plurality of rails or tracks 812, 814, 816, 818, 820 to perform a plasma welding process. In some embodiments, the actuators 802, 804, 806, 808, 810 may include electric stepper motors, electromechanical actuators, pneumatic actuators or cylinders, or any other suitable actuator module that can move components of the mechanical motion module 800 along the plurality of tracks 812, 814, 816, 818, 820. In some embodiments, each actuator 802, 804, 806, 808, 810 may include a sensor, such as the sensor 118, coupled to the control system 108 of the plasma welding apparatus 100. In some embodiments, each sensor can monitor and relay information associated with the operation of the actuators 802, 804, 806, 808, 810 to the control system 118. In some embodiments, the information relayed by the sensors to the control system 108 can include directional information, position information, and / or other operational information. In some embodiments, the plurality of tracks 812, 814, 816, 818, 820 can include a plurality of guides 822, 824, 826. The guides can generally be configured to control relative motion and / or maintain proper alignment of components along the plurality of tracks 812, 814, 816, 818, 820.

[0044] The mechanical motion module 800 may also include a stationary pipe support 828 and a movable pipe support 830. The stationary pipe support 828 may be configured to remain stationary and secure the first pipe component 111 and the second pipe component 113 in the mechanical motion module 800. In some embodiments, the stationary pipe support 828 and the movable pipe support 830 may at least partially extend circumferentially around each of the first pipe component 111 and the second pipe component 113 by at least 25%, at least 50%, or at least 75%. However, in some embodiments, the stationary pipe support 828 and the movable pipe support 830 may extend completely circumferentially around each pipe component 111, 113. In some embodiments, the stationary pipe support 828 may include an adjustable pipe clamp that allows pipe components 111, 113 of various sizes to be inserted into the stationary pipe support 828. The movable pipe support 830 may also be configured to secure the first pipe component 111 and the second pipe component 113 in the mechanical motion module 800. Once the first and second pipe parts 111 and 113 are cut to form the first and second profiles 112 and 114, respectively, the movable pipe support 114 may also be configured to move axially and laterally to axially align end contact surfaces of the first and second profiles 112 and 114 for welding operations.

[0045] FIG. 8A to FIG. 8G The various steps of operating the mechanical motion module 800 in the plasma welding device 100 according to one embodiment of the present disclosure are further described. Fig. 8A As shown, the first profile 112 and the second profile 114 have been inserted into the stationary pipe support 828 and the movable pipe support 830 and are ready for welding operations. In some embodiments, before cutting the first part 111 to form the first profile 112 and cutting the second part 113 to form the second profile 114, the stationary pipe support 828 and the movable pipe support 830 can be separated by a predetermined distance. In some embodiments, the predetermined distance between the stationary pipe support 828 and the movable pipe support 830 can be at least 1.0 mm, at least 2.0 mm, at least 3.0 mm, at least 4.0 mm, or at least 5.0 mm. In some embodiments, the predetermined distance between the stationary pipe support 828 and the movable pipe support 830 can be no greater than 15.0 mm, no greater than 14.0 mm, no greater than 13.0 mm, no greater than 12.0 mm, no greater than 11.0 mm, or no greater than 10.0 mm. Further, it should be understood that the predetermined distance between the stationary pipe support 828 and the movable pipe support 830 can be between any of these minimum and maximum values, such as at least 1.0 mm to no more than 15.0 mm, or even at least 5.0 mm to no more than 10.0 mm.

[0046] like Figure 8B As shown, the first actuating device 802 can generally be operated to move the first cutting device 803 laterally along the first track 812 to cut the first profile 112. The guide device 822 coupled to the movable pipe support 830 can maintain the proper alignment of the first cutting device 803 and the first profile 112. The second actuating device 804 can generally be operated to move the second cutting device 805 laterally along the second track 814 to cut the second profile 114. The guide device 824 can maintain the proper alignment of the second cutting device 805 and the second profile 114. In some embodiments, the first cutting device 803 and the second cutting device 805 can be aligned in the lateral direction. However, in other embodiments, the first cutting device 803 and the second cutting device 805 can be misaligned in the lateral direction. In some embodiments, the first cutting device 803 and the second cutting device 805 can be configured to cut the first profile 112 and the second profile 114 at an angle less than 90 degrees relative to the length of the first profile 112 and the second profile 114. However, in other embodiments, the first cutting device 803 and the second cutting device 805 may be configured to cut the first profile 112 and the second profile 114 substantially orthogonally relative to the length of the first profile 112 and the second profile 114 .

[0047] like Figure 8CAs shown, the third actuator can be generally operated to laterally move the movable pipe support 830 along the third track 816 to axially align the first profile 112 and the second profile 114. During the movement of the movable pipe support 830, the stationary pipe support 828 remains stationary, so that the movable pipe support 830 is laterally displaced relative to the stationary pipe support 828 to axially align the first profile 112 and the second profile 114.

[0048] like Fig.8D As shown, plasma treatment may be applied to the first profile 112 and the second profile 114. More specifically, in some embodiments, according to embodiments disclosed herein, plasma treatment may be applied to the first profile 112 and the second profile 114 to activate the material on the end contact surfaces of the first profile 112 and the second profile 114. Further, it should be understood that in some embodiments, plasma treatment may be applied before, during, and / or after the cutting process.

[0049] like Fig. 8E As shown, once the plasma treatment has been activated, the first actuating device 802 can be generally operated to retract the first cutting device 803 along the track 812 to expose the end contact surface and / or the inner cavity of the first profile 112 to the plasma treatment, and the second actuating device 804 can be generally operated to retract the second cutting device 805 along the track 814 to expose the end contact surface and / or the inner cavity of the second profile 114 to the plasma treatment. It should be understood that the plasma treatment can remain activated during this step in the welding process.

[0050] like Fig.8F As shown, after retracting the second cutting device 805, the fourth actuator 808 can generally be operated to axially move the second cutting device 805 along the fourth track 818. In some embodiments, the axial movement of the second cutting device 805 can provide clearance for the axial movement of the movable pipe support 830. It should be understood that the plasma treatment can remain activated during this step in the welding process.

[0051] like Figure 8G As shown, after axially moving the second cutting device 805, the fifth actuating device 810 can be generally operated to axially move the movable pipe support 830 along the fifth track 820, so that the end contact surfaces of the first profile 112 and the second profile 114 activated by the plasma treatment are forced to contact, so as to weld the first profile 112 and the second profile 114 at their end contact surfaces, thereby forming a joint or a plasma welding connection. In some embodiments, the plasma treatment can continue after the first profile 112 and the second profile 114 are joined to ensure a sterile connection, thereby forming a joint or a plasma welding connection according to the embodiments disclosed herein.

[0052] Fig. 9 A schematic diagram of a mechanical motion module 900 according to another embodiment of the present disclosure is shown. According to embodiments disclosed herein, the mechanical motion module 900 may generally be substantially similar to the mechanical motion module 800 and configured to operate in the plasma welding apparatus 100. Similarly, the mechanical motion module 900 includes a first cutting device 910, a second cutting device 905, a plurality of actuating devices 902, 904, 906, 910, a stationary pipe support 928, and a movable pipe support 930, which are configured to move the various components of the mechanical motion module 800 along a plurality of rails or tracks 916, 918, 920. In some embodiments, the mechanical motion module 900 may also include a pair of guides 926. However, in the depicted embodiment, the mechanical motion module 900 may not include the fourth actuating device 808, the first track 812, the second track 814, the fourth track 818, and / or the guide 824. Instead, the second cutting device 905 is axially translated by the fifth actuating device 910 to provide clearance for the axial movement of the movable pipe support 930. Therefore, in some embodiments, this can simplify the operation of the welding process by eliminating the step of axially moving the second cutting device 905 (e.g., Figure 8G As shown), to provide clearance for the axial movement of the movable pipe support 930.

[0053] Fig.101 is a schematic diagram of a portion of a mechanical motion module 1000 according to one embodiment of the present disclosure. In some embodiments, the mechanical motion module 1000 may include one or more alignment rods 1002, 1004. More specifically, in the illustrated embodiment, the fixed pipe bracket 1028 may include one or more alignment rods 1002, and the movable pipe bracket 1030 may include one or more alignment rods 1004. In some embodiments, before the pipe components 111, 113 are cut to form the profiles 112, 114, each pipe component 111, 113 may be supported by the alignment rods 1002 of the fixed pipe bracket 1028 and the alignment rods of the movable pipe bracket 1030. In some embodiments, the one or more alignment rods 1002 of the fixed pipe bracket 1028 and the one or more alignment rods 1004 of the movable pipe bracket 1030 may be configured to abut, engage, or otherwise interact to align the fixed pipe bracket 1028 and the movable pipe bracket 1030. In some embodiments, the one or more alignment rods 1002 of the stationary pipe holder 1028 and the one or more alignment rods 1004 of the movable pipe holder 1030 can be configured to selectively extend and guide the first profile 112 and the second profile 114 to contact each other so that the end contact surfaces of the first profile 112 and the second profile 114 contact and the first profile 112 and the second profile 114 are axially aligned. In some embodiments, this can be done during activation or application of the plasma treatment. Further, in some embodiments, the one or more alignment rods 1002 of the stationary pipe holder 1028 and the one or more alignment rods 1004 of the movable pipe holder 1030 can be configured to selectively extend and support the first pipe component 111 and the second component 113 prior to the cutting operation to form the first profile 112 and the second profile 114.

[0054] In some embodiments, the mechanical motion module 106, 800, 900, 1000 can include more than one of the components depicted. For example, in some embodiments, the mechanical motion module 800 can include two fixed pipe holders 828 and two movable pipe holders 830, so that four pipe parts 111, 113 can be cut and two profiles 112, 114 can be subjected to a plasma welding process to form two plasma welded pipes.

[0055] Further, in some embodiments, the plasma welding device 100 may include one or more mechanical motion modules 106, 800, 900, 1000. In some embodiments, the plurality of mechanical motion modules 106, 800, 900, 1000 may be independent systems or may be at least partially integrated. In some embodiments, the plurality of mechanical motion modules 106, 800, 900, 1000 may be configured to simultaneously cut a plurality of pipe components 111, 113 and weld a plurality of profiles 112, 114.

[0056] In some embodiments, the method 700 may include one or more of the following: ionizing a gas flow including an inert gas, an oxygen-containing gas, a nitrogen-containing gas, a fluorine-containing gas, or a combination thereof to generate a plasma treatment; sterilizing the internal environment 110 in the operating chamber 102 by applying the plasma treatment in the operating chamber 102; cutting the first profile 112 and the second profile 114 to expose the end contact surfaces of the first profile 112 and the second profile 114; subjecting the first profile 112 and the second profile 114 to the plasma treatment before cutting the first profile 112 and the second profile 114, wherein the plasma is applied to the first profile 112 and the second profile 114 before cutting the first profile 112 and the second profile 114. The first profile 112 and the second profile 114 are bonded for at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds, or at least 120 seconds; after the first profile 112 and the second profile 114 are bonded, plasma is applied to the first profile 112 and the second profile 114, wherein after the first profile 112 and the second profile 114 are bonded, plasma is applied to the first profile and the second profile for at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds, or at least 120 seconds.

[0057] In some embodiments, the method 700 may further include one or more of the following: axially aligning the end contact surfaces of the first profile 112 and the second profile 114 after cutting the first profile 112 and the second profile 114; verifying the axial alignment of the end contact surfaces of the first profile 112 and the second profile 114 by a camera system; monitoring temperature, gas flow rate, gas pressure, gas detection level, material of the first profile 112 and the second profile, plasma treatment progress level, working cycle, total number of working cycles, or a combination thereof; displaying temperature, gas flow rate, gas pressure, gas detection level, material of the first profile 112 and the second profile 114, plasma treatment progress level, working cycle, total number of working cycles, or a combination thereof on a user interface; alerting a user interface when a non-compliant condition exists; a user interface; automatically stopping plasma processing when an out-of-specification condition exists, wherein the out-of-specification condition includes low temperature, high temperature, low pressure, high pressure, low gas flow rate, high gas flow rate, detection of plasma byproducts, invalid selection of materials, leaks in the operating chamber, or a combination thereof; storing data related to the operation of the plasma welding device 100; performing a burst test, a tensile test, or a combination thereof between the first profile and the second profile after the first profile is joined to the second profile; selecting the material of each of the first profile 112 and the second profile 114 through a user interface; and applying a reinforcement at least partially around the overlapping weld formed between the first profile and the second profile, wherein the reinforcement includes a tape, a polymer tape, an overmolded polymer, a plasma welding polymer, or a combination thereof.

[0058] In other embodiments, the plasma welding equipment may include one or more of the following:

[0059] Embodiment 1 A plasma welding device comprises: an operating chamber and a plasma generator, wherein the plasma generator has at least one plasma head, wherein the plasma head is arranged in the operating chamber and is close to an end contact surface of a first profile in the operating chamber and an end contact surface of a second profile in the operating chamber, wherein the plasma head is configured to apply plasma treatment to the end contact surfaces of the first profile and the second profile to join the first profile and the second profile.

[0060] Embodiment 2 A plasma welding device for aseptically connecting a first profile and a second profile, comprising: an operating chamber with a sterile environment and a plasma generator, the plasma generator having at least one plasma head, the plasma head being arranged in the operating chamber and close to an end contact surface of the first profile in the operating chamber and an end contact surface of the second profile in the operating chamber, wherein the plasma head is configured to apply plasma treatment to the end contact surfaces of the first profile and the second profile to join the first profile and the second profile.

[0061] Embodiment 3 The plasma welding apparatus according to any one of Embodiments 1 to 2, wherein at least one of the first profile and the second profile is formed of a polymer material.

[0062] Embodiment 4 The plasma welding apparatus according to any one of Embodiments 1 to 3, wherein each of the first profile and the second profile is formed of a polymer material.

[0063] Embodiment 5 The plasma welding apparatus according to Embodiment 4, wherein the first profile and the second profile are formed of the same polymer material.

[0064] Embodiment 6 is a plasma welding apparatus according to Embodiment 4, wherein the first profile and the second profile are formed of different polymer materials.

[0065] Embodiment 7 According to any one of Embodiments 1 to 6, the plasma welding equipment, wherein the first profile and the second profile are formed of thermoplastic elastomer, thermosetting elastomer or a combination thereof.

[0066] Embodiment 8 The plasma welding equipment according to embodiment 7, wherein the thermoplastic elastomer comprises polystyrene, polyester, silicone copolymer, silicone thermoplastic vulcanizate, copolyester, polyamide, fluoropolymer, polyolefin, polyether-ester copolymer, thermoplastic polyurethane, polyether amide block copolymer, polyamide copolymer, styrene block copolymer, polycarbonate, thermoplastic vulcanizate, ionomer, polyoxymethylene (POM), acrylonitrile butadiene styrene (ABS), acetal, acrylic, polyvinyl chloride (PVC), blends or combinations thereof.

[0067] Example 9 The plasma welding equipment according to Example 7, wherein the thermosetting elastomer includes a silicone elastomer, a diene elastomer, butyl rubber, natural rubber, polyurethane rubber, EPDM rubber, isoprene rubber, nitrile rubber, styrene-butadiene rubber, a blend or a combination thereof.

[0068] Embodiment 10: The plasma welding apparatus according to any one of Embodiments 1 to 9, wherein the operating chamber comprises an enclosure having at least one transparent surface, through which the first profile and the second profile are visible.

[0069] Embodiment 11 The plasma welding apparatus according to any one of Embodiments 1 to 10, wherein the operating chamber comprises an enclosure having a plurality of transparent surfaces, through which the first profile and the second profile are visible.

[0070] Embodiment 12 The plasma welding apparatus of any one of Embodiments 10 to 11, wherein the transparent surface at least partially blocks ultraviolet light from entering or leaving the enclosure.

[0071] Embodiment 13 is a plasma welding apparatus according to any one of Embodiments 1 to 12, wherein the operation chamber forms a substantially sealed environment.

[0072] Embodiment 14 According to any one of embodiments 1 to 13, the plasma welding equipment, wherein the operating chamber confines the plasma processing within the substantially sealed environment.

[0073] Embodiment 15 is a plasma welding device according to any one of Embodiments 1 to 14, wherein the operation chamber includes a ventilation system, and the ventilation system provides two-way ventilation with the operation chamber.

[0074] Embodiment 16 The plasma welding apparatus of embodiment 15, wherein the ventilation system comprises filters, catalytic converters, radiation elements, or a combination thereof, which treat the atmospheric air before the air enters or leaves the operating chamber.

[0075] Embodiment 17 The plasma welding apparatus according to any one of Embodiments 1 to 16, wherein the operating chamber is prevented from being opened or removed during application of the plasma treatment.

[0076] Embodiment 18 The plasma welding apparatus according to any one of Embodiments 1 to 17, wherein the plasma generator includes a gas supply source and an electric power supply source.

[0077] Embodiment 19 is a plasma welding apparatus according to embodiment 18, wherein the gas supply source comprises an atmospheric air supply source, a compressor, a compressed gas cylinder, an internal gas pipeline, an internal compressed gas pipeline, a fan, a turbine, or a combination thereof.

[0078] Embodiment 20 The plasma welding apparatus according to Embodiment 19, wherein the gas supply source provides a gas flow including an inert gas, an oxygen-containing gas, a nitrogen-containing gas, a fluorine-containing gas, or a combination thereof.

[0079] Embodiment 21 According to the plasma welding equipment described in Embodiment 20, the inert gas includes argon, neon, helium or any combination thereof.

[0080] Embodiment 22 The plasma welding apparatus according to Embodiment 20, wherein the oxygen-containing gas comprises atmospheric air, pure oxygen, ethanol, water vapor, or a combination thereof.

[0081] Embodiment 23 The plasma welding apparatus according to Embodiment 20, wherein the nitrogen-containing gas comprises atmospheric air, pure nitrogen, ammonia, or a combination thereof.

[0082] Embodiment 24: The plasma welding equipment according to Embodiment 20, wherein the fluorine-containing gas comprises sulfur hexafluoride (SF6), trifluoromethane (CHF3), tetrafluoromethane (CF4), octafluorocyclobutane (C4F8), or a combination thereof.

[0083] Embodiment 25 The plasma welding apparatus according to embodiment 18, wherein the power supply source ionizes the gas flow to generate plasma processing.

[0084] Embodiment 26 The plasma welding apparatus of Embodiment 25, wherein the power supply provides at least 110 VAC, at least 120 VAC, at least 220 VAC, or at least 240 VAC.

[0085] Embodiment 27 The plasma welding apparatus of Embodiment 25, wherein the power supply provides at least 6 VDC, at least 9 VDC, at least 12 VDC, at least 24 VDC, or at least 48 VDC.

[0086] Embodiment 28 The plasma welding apparatus of any one of Embodiments 1 to 27, wherein the plasma generator comprises a supply line coupled to the at least one plasma head.

[0087] Embodiment 29: The plasma welding equipment according to any one of Embodiments 1 to 28, further comprising: a plurality of plasma heads, wherein the plasma heads are arranged in the operating chamber.

[0088] Embodiment 30 The plasma welding equipment according to Embodiment 29, wherein at least one of the plurality of plasma heads is disposed in the operating chamber adjacent to the first profile, and wherein at least one of the plurality of plasma heads is disposed in the operating chamber adjacent to the second profile.

[0089] Embodiment 31 The plasma welding equipment according to any one of Embodiments 29 to 30, wherein at least one of the plurality of plasma heads is configured to sterilize the environment within the operating room.

[0090] Embodiment 32 The plasma welding equipment according to any one of Embodiments 1 to 31 further comprises: a cutting device, which is disposed in the operation chamber and configured to cut the first profile and the second profile.

[0091] Embodiment 33 The plasma welding apparatus according to embodiment 32, wherein the cutting device comprises at least one blade.

[0092] Embodiment 34 The plasma welding apparatus of Embodiment 33, wherein the at least one blade is heated, pre-sterilized, or a combination thereof.

[0093] Embodiment 35 is a plasma welding device according to embodiment 32, wherein the cutting device includes a laser cutting system.

[0094] Embodiment 36 The plasma welding equipment according to any one of embodiments 1 to 34 further includes: a mechanical motion module.

[0095] Embodiment 37 The plasma welding apparatus according to Embodiment 36, wherein the mechanical movement module is configured to axially align the end contact surfaces of the first profile and the second profile.

[0096] Embodiment 38 The plasma welding apparatus according to Embodiment 37, wherein the mechanical motion module linearly displaces at least one of the first profile and the second profile to axially align the end contact surfaces of the first profile and the second profile.

[0097] Embodiment 39 The plasma welding apparatus according to Embodiment 37, wherein the mechanical motion module rotates at least one of the first profile and the second profile to axially align the end contact surfaces of the first profile and the second profile.

[0098] Embodiment 40 The plasma welding apparatus according to any one of Embodiments 36 to 39, wherein the mechanical motion module forces the end contact surfaces of the first profile and the second profile to contact each other to weld the first profile and the second profile together.

[0099] Embodiment 41 The plasma welding apparatus according to any one of Embodiments 36 to 40, wherein during the joining of the first profile and the second profile, the first profile and the second profile are opened.

[0100] Embodiment 42 The plasma welding apparatus according to any one of Embodiments 36 to 40, wherein the first profile and the second profile are closed before joining the first profile and the second profile.

[0101] Embodiment 43 The plasma welding apparatus according to Embodiment 42, wherein the first profile and the second profile are closed at a distal end of each of the first profile and the second profile for plasma welding.

[0102] Embodiment 44 The plasma welding apparatus according to Embodiment 42, wherein the first profile and the second profile are closed at a distal end of each of the first profile and the second profile away from plasma welding.

[0103] Embodiment 45 The plasma welding equipment according to any one of Embodiments 1 to 44 further includes: a control system.

[0104] Embodiment 46 The plasma welding apparatus according to embodiment 45, wherein the control system comprises a user interface and a plurality of sensors, indicators, meters or a combination thereof.

[0105] Embodiment 47 The plasma welding apparatus according to Embodiment 46, wherein the user interface includes a display.

[0106] Embodiment 48 The plasma welding equipment according to Embodiment 47, wherein the display is configured to display temperature, gas flow rate, gas pressure, gas detection level, materials of the first profile and the second profile, plasma processing progress level, working cycle, total number of working cycles, or a combination thereof.

[0107] Embodiment 49 The plasma welding apparatus according to Embodiment 46, wherein the user interface includes a material selection input portion for selecting a property of a material of each of the first profile and the second profile.

[0108] Embodiment 50 The plasma welding apparatus of embodiment 46, wherein the user interface includes a warning system configured to warn the user when an out-of-specification condition exists.

[0109] Embodiment 51 The plasma welding apparatus according to embodiment 50, wherein the user interface is configured to automatically stop the plasma processing when an out-of-specification condition exists.

[0110] Embodiment 52 is a plasma welding device according to embodiment 51, wherein the non-compliant conditions include low temperature, high temperature, low pressure, high pressure, low gas flow rate, high gas flow rate, detection of plasma byproducts, ineffective selection of materials, leaks in the operating chamber, or a combination thereof.

[0111] Embodiment 53 is a plasma welding device according to embodiment 46, wherein the plurality of sensors include a temperature sensor, a gas flow rate sensor, a gas pressure sensor, a gas detection sensor, a plasma byproduct sensor, a tension sensor, or a combination thereof.

[0112] Embodiment 54 A plasma welding apparatus according to any one of Embodiments 45 to 53, wherein the control system includes at least one vision system configured to verify the axial alignment of the end contact surfaces of the first profile and the second profile, the engagement of the first profile with the second profile, or a combination thereof.

[0113] Embodiment 55 The plasma welding apparatus according to any one of Embodiments 45 to 54, wherein the control system is configured to perform a burst test, a tensile test, or a combination thereof between the first profile and the second profile after the first profile is joined with the second profile.

[0114] Embodiment 56 The plasma welding apparatus according to any one of Embodiments 45 to 55, wherein the control system is configured to store data related to the operation of the plasma welding apparatus.

[0115] Embodiment 57 The plasma welding apparatus according to any one of Embodiments 1 to 56, wherein the plasma treatment activates the material at the end contact surfaces of the first profile and the second profile.

[0116] Embodiment 58 According to any one of embodiments 1 to 57, the plasma welding equipment, wherein the plasma treatment occurs between 10 degrees Celsius and 350 degrees Celsius.

[0117] Embodiment 59 The plasma welding apparatus according to any one of Embodiments 1 to 58, wherein the plasma processing is started before cutting the first profile and the second profile.

[0118] Embodiment 60 is a plasma welding device according to embodiment 59, wherein the plasma treatment starts at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds or at least 120 seconds before cutting the first profile and the second profile.

[0119] Embodiment 61 The plasma welding apparatus according to any one of Embodiments 1 to 60, wherein the plasma treatment is continued after joining the first profile and the second profile.

[0120] Embodiment 62 is a plasma welding device according to embodiment 61, wherein after joining the first profile and the second profile, the plasma treatment continues for at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds or at least 120 seconds.

[0121] Embodiment 63 A plasma welding apparatus according to any one of Embodiments 1 to 62, wherein the overlapping weld formed between the first profile and the second profile comprises a tensile strength of at least 10%, at least 15%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45% or at least 50% of the tensile strength of an unmodified control bulk material of the first profile or the second profile.

[0122] Embodiment 64 According to any one of embodiments 1 to 63, the plasma welding equipment, wherein the overlapping weld formed between the first profile and the second profile includes a burst pressure of at least 10%, at least 25%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 76%, at least 77%, at least 78%, at least 79%, at least 80%, at least 81%, at least 82%, at least 83%, at least 84%, at least 85%, at least 86%, at least 87%, at least 88%, at least 89% or at least 90% of the burst pressure of the unmodified control bulk material of the first profile or the second profile.

[0123] Embodiment 65 A method for operating plasma welding equipment, comprising: generating plasma treatment with a plasma generator; applying the plasma treatment to the end contact surface of a first profile and the end contact surface of a second profile in an operating chamber; and manipulating at least one of the first profile and the second profile to force contact between the end contact surface of the first profile and the end contact surface of the second profile to join the first profile and the second profile.

[0124] Embodiment 66 A method according to Embodiment 65, wherein the operating chamber forms a substantially sealed environment around the end contact surface of the first profile and the end contact surface of the second profile.

[0125] Embodiment 67 The method according to Embodiment 65 further comprises: ionizing a gas flow including an inert gas, an oxygen-containing gas, a nitrogen-containing gas, a fluorine-containing gas or a combination thereof to generate the plasma treatment.

[0126] Embodiment 68 The method according to embodiment 67 further comprises: sterilizing the environment within the operating room by applying the plasma treatment within the operating room.

[0127] Embodiment 69 A method according to any one of Embodiments 65 to 68, wherein the plasma treatment is applied within the operating chamber by at least one plasma head disposed within the operating chamber.

[0128] Embodiment 70 The method according to any one of Embodiments 65 to 69, further comprising: cutting the first profile and the second profile to expose the end contact surfaces of the first profile and the second profile.

[0129] Embodiment 71 The method according to Embodiment 70 further comprises: applying the plasma treatment to the first profile and the second profile before cutting the first profile and the second profile.

[0130] Embodiment 72 is a method according to Embodiment 71, wherein before cutting the first profile and the second profile, the plasma treatment is applied to the first profile and the second profile for at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds or at least 120 seconds.

[0131] Embodiment 73 The method according to any one of Embodiments 65 to 72 further comprises: after joining the first profile and the second profile, applying the plasma treatment to the first profile and the second profile.

[0132] Embodiment 74 is a method according to Embodiment 73, wherein after joining the first profile and the second profile, the plasma treatment is applied to the first profile and the second profile for at least 1 second, at least 2 seconds, at least 3 seconds, at least 5 seconds, at least 10 seconds, at least 15 seconds, at least 30 seconds, at least 45 seconds, at least 60 seconds, at least 90 seconds or at least 120 seconds.

[0133] Embodiment 75 The method according to any one of Embodiments 70 to 74 further comprises: after cutting the first profile and the second profile, axially aligning the end contact surfaces of the first profile and the second profile.

[0134] Embodiment 76 The method according to embodiment 75 further comprises: verifying the axial alignment of the end contact surfaces of the first profile and the second profile by a camera system.

[0135] Embodiment 77 A method according to any one of Embodiments 75 to 76, wherein axially aligning the end contact surfaces of the first profile and the second profile includes linearly displacing or rotating at least one of the first profile and the second profile.

[0136] Embodiment 78 A method according to any one of Embodiments 65 to 77, wherein during the joining of the first profile and the second profile, the first profile and the second profile are open.

[0137] Embodiment 79 The method according to any one of Embodiments 65 to 77 further comprises: closing the first profile and the second profile before joining the first profile and the second profile.

[0138] Embodiment 80 According to the method of embodiment 79, the first profile and the second profile are closed at the distal end of each of the first profile and the second profile.

[0139] Embodiment 81 The method according to Embodiment 79, wherein the first profile and the second profile are closed at a distal end away from each of the first profile and the second profile.

[0140] Embodiment 82 The method according to any one of Embodiments 65 to 81 further comprises: monitoring temperature, gas flow rate, gas pressure, gas detection level, materials of the first profile and the second profile, plasma processing progress level, working cycle, total number of working cycles, or a combination thereof.

[0141] Embodiment 83 The method according to embodiment 82 further comprises: displaying the temperature, the gas flow rate, the gas pressure, the gas detection level, the material of the first profile and the second profile, the plasma processing progress level, the working cycle, the total number of the working cycles, or a combination thereof on a user interface.

[0142] Embodiment 84 is a method according to any one of embodiments 82 to 83, further comprising: alerting a user when a condition that does not meet the specification exists.

[0143] Embodiment 85 The method according to embodiment 84 further comprises: automatically stopping the plasma processing when out-of-specification conditions exist.

[0144] Embodiment 86 is a method according to embodiment 85, wherein the non-compliant conditions include low temperature, high temperature, low pressure, high pressure, low gas flow rate, high gas flow rate, detection of plasma byproducts, invalid selection of materials, leaks in the operating chamber, or a combination thereof.

[0145] Embodiment 87 The method according to any one of Embodiments 65 to 86 further comprises: storing data related to the operation of the plasma welding equipment.

[0146] Embodiment 88 The method according to any one of Embodiments 65 to 87 further comprises: after the first profile is joined with the second profile, performing a burst test, a tensile test, or a combination thereof between the tests of the first profile and the second profile.

[0147] Embodiment 89 The method according to Embodiment 83 further comprises: selecting a material of each of the first profile and the second profile through the user interface.

[0148] Embodiment 90 The method according to any one of Embodiments 65 to 89, wherein at least one of the first profile and the second profile is formed of a polymer material.

[0149] Embodiment 91 The method of any one of Embodiments 65 to 90, wherein each of the first profile and the second profile is formed of a polymer material.

[0150] Embodiment 92 The method according to any one of Embodiments 90 to 91, wherein the first profile and the second profile are formed of the same polymer material.

[0151] Embodiment 93 A method according to any one of Embodiments 90 to 91, wherein the first profile and the second profile are formed of different polymer materials.

[0152] Embodiment 94 The method according to any one of Embodiments 65 to 93, wherein the first profile and the second profile are formed of a thermoplastic elastomer, a thermosetting elastomer, or a combination thereof.

[0153] Embodiment 95 The method according to embodiment 94, wherein the thermoplastic elastomer comprises polystyrene, polyester, silicone copolymer, silicone thermoplastic vulcanizate, copolyester, polyamide, fluoropolymer, polyolefin, polyether-ester copolymer, thermoplastic polyurethane, polyetheramide block copolymer, polyamide copolymer, styrene block copolymer, polycarbonate, thermoplastic vulcanizate, ionomer, polyoxymethylene (POM), acrylonitrile butadiene styrene (ABS), acetal, acrylic, polyvinyl chloride (PVC), blends or combinations thereof.

[0154] Embodiment 96 The method according to Embodiment 94, wherein the thermosetting elastomer comprises a silicone elastomer, a diene elastomer, butyl rubber, natural rubber, polyurethane rubber, EPDM rubber, isoprene rubber, nitrile rubber, styrene-butadiene rubber, a blend or a combination thereof.

[0155] Embodiment 97 A method according to any one of Embodiments 65 to 96, wherein the overlapping weld formed between the first profile and the second profile comprises a tensile strength of at least 10%, at least 15%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45% or at least 50% of the tensile strength of an unmodified control bulk material of the first profile or the second profile.

[0156] Embodiment 98 A method according to any one of Embodiments 65 to 97, wherein the overlapping weld formed between the first profile and the second profile comprises a burst pressure of at least 10%, at least 25%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 76%, at least 77%, at least 78%, at least 79%, at least 80%, at least 81%, at least 82%, at least 83%, at least 84%, at least 85%, at least 86%, at least 87%, at least 88%, at least 89% or at least 90% of the burst pressure of an unmodified control bulk material of the first profile or the second profile.

[0157] Embodiment 99 The method according to any one of embodiments 65 to 98 further comprises: applying a reinforcement at least partially around the overlapping weld between the first profile and the second profile.

[0158] Embodiment 100 The method according to Embodiment 99, wherein the reinforcement comprises a tape, a polymer tape, an overmolded polymer, a plasma welded polymer, or a combination thereof.

[0159] Embodiment 101 A plasma welding device according to any one of Embodiments 1 to 64 or a method according to any one of Embodiments 65 to 100, wherein applying the plasma treatment to the end contact surfaces of the first profile and the second profile includes exposing or subjecting the end contact surfaces of the first profile and the second profile to the plasma treatment, or directing the plasma treatment to contact or substantially enclose the end contact surfaces of the first profile and the second profile.

[0160] Embodiment 102 The plasma welding apparatus according to any one of embodiments 1 to 64 or the method according to any one of embodiments 65 to 101, wherein the plasma treatment is generated by generating ionized particles through corona treatment, C-treatment, plasma treatment, flame treatment or any combination thereof.

[0161] Embodiment 103 The plasma welding device according to any one of embodiments 1 to 64 or the method according to any one of embodiments 65 to 102 further comprises: a marking system, wherein the marking system is configured to mark the first profile, the second profile, the joint formed between the first profile and the second profile, or a combination thereof by laser marking, ink marking, or any combination thereof, wherein these marking methods allow one or more features of the joint between the first profile and the second profile to be identified, verified, troubleshooted, or any combination thereof.

[0162] Embodiment 104 The plasma welding apparatus of any one of embodiments 1 to 64 or the method of any one of embodiments 65 to 102, wherein the plasma treatment is applied to provide a sterile environment for the internal environment of the operating room, wherein the sterile environment is defined by a reduction in the number of viable microorganisms within the internal environment of the operating room to a level of at least 106 after exposure to the plasma treatment for at least 10 seconds, at least 15 seconds, at least 20 seconds, at least 25 seconds, or at least 30 seconds.

[0163] Embodiment 105 According to any one of embodiments 1 to 64, the plasma welding equipment or the method according to any one of embodiments 65 to 102, wherein the operating chamber, the mechanical motion module or a combination thereof is configured for mobile use and is remotely connected to the plasma generator, the control system or a combination thereof.

[0164] Embodiment 106 The plasma welding apparatus of any one of Embodiments 1 to 64 or the method of any one of Embodiments 65 to 102, wherein the plasma welding apparatus comprises an all-in-one apparatus configured for use in a mobile facility.

[0165] Embodiment 107 The plasma welding equipment according to any one of Embodiments 1 to 31 or 36 to 64 or 101 to 106 further comprises: a mechanical movement module.

[0166] Embodiment 108 is a plasma welding device according to Embodiment 107, wherein the mechanical motion module includes a first cutting device and a second cutting device.

[0167] Embodiment 109 is the plasma welding equipment according to Embodiment 108, wherein the first cutting device is configured to cut the first pipe member to form the first profile, and the second cutting device is configured to cut the second pipe member to form the second profile.

[0168] Embodiment 110 is a plasma welding apparatus according to Embodiment 109, wherein the first cutting device is controlled by a first actuator, the first actuator is configured to move the first cutting device in a transverse direction to cut the first tube component to form the first profile, and wherein the second cutting device is controlled by a second actuator, the second actuator is configured to move the second cutting device in an opposite transverse direction to cut the second tube component to form the second profile.

[0169] Embodiment 111 The plasma welding equipment according to Embodiment 110, wherein the first cutting device and the second cutting device are aligned in the transverse direction.

[0170] Embodiment 112 is a plasma welding apparatus according to Embodiment 110, wherein the first cutting device and the second cutting device are not aligned in the transverse direction.

[0171] Embodiment 113 is a plasma welding device according to any one of Embodiments 108 to 110, wherein the first cutting device and the second cutting device cut the first profile and the second profile at an angle less than 90 degrees relative to the length of the first profile and the second profile, respectively.

[0172] Embodiment 114 is a plasma welding apparatus according to any one of Embodiments 108 to 110, wherein the first cutting device and the second cutting device cut the first profile and the second profile substantially orthogonally relative to the lengths of the first profile and the second profile, respectively.

[0173] Embodiment 115 is a plasma welding device according to any one of Embodiments 108 to 114, wherein after cutting the first pipe component to form the first profile, the first actuator is operated to retract the first cutting device to expose the end contact surface of the first profile to the plasma treatment, and wherein after cutting the second pipe component to form the second profile, the second actuator is operated to retract the second cutting device to expose the end contact surface of the second profile to the plasma treatment.

[0174] Embodiment 116 A plasma welding apparatus according to any one of Embodiments 108 to 115, wherein the first cutting device and the second cutting device are heated, pre-sterilized, or a combination thereof.

[0175] Embodiment 117 The plasma welding equipment according to any one of Embodiments 107 to 116, wherein the mechanical motion module includes a stationary pipe support and a movable pipe support.

[0176] Embodiment 118 The plasma welding apparatus according to Embodiment 117, wherein the stationary pipe support is configured to remain stationary and fix a first pipe member to be cut to form the first profile and a second pipe member to be cut to form the second profile.

[0177] Embodiment 119 The plasma welding apparatus of Embodiment 118, wherein the stationary pipe holder includes an adjustable pipe clamp that allows pipe components of various sizes to be inserted into the stationary pipe holder.

[0178] Embodiment 120 The plasma welding apparatus according to any one of Embodiments 117 to 119, wherein the movable pipe support is configured to fix the first pipe part to be cut to form the first profile and the second pipe part to be cut to form the second profile.

[0179] Embodiment 121 is a plasma welding device according to Embodiment 120, wherein the movable pipe support is configured to move axially and laterally to axially align end contact surfaces of the first profile and the second profile after cutting the first component to form the first profile and cutting the second component to form the second profile.

[0180] Embodiment 122 The plasma welding apparatus according to Embodiment 121, wherein the first profile is fixed in the movable pipe holder, and wherein the second profile is fixed in the stationary pipe holder.

[0181] Embodiment 123 The plasma welding apparatus according to Embodiment 122, wherein the movable pipe support is controlled by a third actuator, and the third actuator is configured to move the movable pipe support laterally relative to the stationary pipe support to axially align the first profile and the second profile.

[0182] Embodiment 124 is a plasma welding apparatus according to any one of Embodiments 117 to 123, wherein the second cutting device is controlled by a fourth actuating device, and the fourth actuating device is configured to axially move the second cutting device to provide a gap for axial movement of the movable pipe support.

[0183] Embodiment 125 is a plasma welding device according to Embodiment 124, wherein the movable cutting device is controlled by a fifth actuator, and the fifth actuator is configured to axially move the movable pipe support to force the end contact surfaces of the first profile and the second profile to contact each other to join the first profile and the second profile.

[0184] Embodiment 126 is a plasma welding device according to any one of Embodiments 117 to 123, wherein the second cutting device is controlled by a fifth actuator, and the fifth actuator is configured to axially move the second cutting device to provide a gap for the axial movement of the movable pipe support, and wherein the movable pipe support is simultaneously controlled by the fifth actuator to axially move the movable pipe support so that the end contact surfaces of the first profile and the second profile are forced to contact to join the first profile and the second profile.

[0185] Embodiment 127 The plasma welding apparatus of any one of Embodiments 107 to 126, wherein each of the actuating devices comprises a sensor coupled to the control system of the plasma welding apparatus.

[0186] Embodiment 128 The plasma welding apparatus of Embodiment 127, wherein the sensor is configured to relay information to the control system, and wherein the information includes directional information, position information, or other operational information.

[0187] Embodiment 129 is a plasma welding device according to any one of Embodiments 107 to 128, wherein the mechanical motion module includes a plurality of tracks, along which the first cutting device, the second cutting device and the movable pipe support are translated by respective actuators.

[0188] Embodiment 130 The plasma welding apparatus according to any one of Embodiments 117 to 129, wherein before cutting the first component to form the first profile and cutting the second component to form the second profile, the stationary pipe support and the movable pipe support are separated by a predetermined distance.

[0189] Embodiment 131 The plasma welding apparatus according to Embodiment 130, wherein the predetermined distance is at least 1.0 mm, at least 2.0 mm, at least 3.0 mm, at least 4.0 mm, or at least 5.0 mm.

[0190] Embodiment 132 The plasma welding apparatus according to any one of Embodiments 130 to 131, wherein the predetermined distance is no greater than 15.0 mm, no greater than 14.0 mm, no greater than 13.0 mm, no greater than 12.0 mm, no greater than 11.0 mm, or no greater than 10.0 mm.

[0191] Embodiment 133 According to any one of embodiments 107 to 129, the plasma welding equipment, wherein the mechanical movement module includes one or more alignment rods.

[0192] Embodiment 134 The plasma welding apparatus of Embodiment 133, wherein the stationary pipe support comprises one or more alignment rods, and wherein the movable pipe support comprises one or more alignment rods.

[0193] Embodiment 135 The plasma welding apparatus according to Embodiment 134, wherein the one or more alignment rods of the stationary pipe support and the one or more alignment rods of the movable pipe support are configured to abut, engage or otherwise interact to align the stationary pipe support and the movable pipe support.

[0194] Embodiment 136 is a plasma welding device according to Embodiment 134, wherein the one or more alignment rods of the stationary pipe support and the one or more alignment rods of the movable pipe support are configured to selectively extend and guide the first profile and the second profile to contact each other, so that the end contact surfaces of the first profile and the second profile are in contact, and the first profile and the second profile are axially aligned.

[0195] Embodiment 137 is a plasma welding device according to Embodiment 136, wherein the one or more alignment rods of the stationary pipe support and the one or more alignment rods of the movable pipe support extend to guide the first profile and the second profile to contact each other, so that the end contact surfaces of the first profile and the second profile are in contact, and the first profile and the second profile are axially aligned during the application of the plasma treatment.

[0196] This written description uses examples, including the best mode, to illustrate the embodiments and also to enable one of ordinary skill in the art to make and use the invention. The scope of this patent is defined by the claims and may include other examples that occur to one of ordinary skill in the art. These other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the written language of the claims, or if they include equivalent structural elements that do not differ substantially from the written language of the claims.

[0197] Note that not all of the actions in the general description or examples above are required, that a portion of a specific action may not necessarily be required, and that one or more further actions may be performed in addition to those described. Furthermore, the order in which the actions are listed is not necessarily the order in which they are performed.

[0198] In the above description, these concepts are described with reference to specific embodiments. However, it is understood by those skilled in the art that various modifications and variations may be made without departing from the scope of the present invention as described in the following claims. Therefore, the description and the accompanying drawings are to be regarded as illustrative rather than restrictive, and all such modifications are to be included within the scope of the present invention.

[0199] As used herein, the terms "consisting of," "including," "comprising," "having," "having" or any other variation thereof are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that includes a list of features is not necessarily limited to only the corresponding features, but may include other features not expressly listed or inherent to such process, method, article, or apparatus. In addition, unless expressly stated otherwise, "or" refers to an inclusive "or" rather than an exclusive "or." For example, any of the following may satisfy condition A or B: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0200] Moreover, "a" or "an" is used to describe the elements and components described herein. This is done only for convenience and to give a general sense of the scope of the invention. Unless it is obvious that it is intended otherwise, this description should be understood to include one or at least one, and the singular also includes the plural.

[0201] Benefits, other advantages, and solutions to problems have been described above with reference to specific embodiments. However, benefits, advantages, solutions to problems, and any features that may make any benefit, advantage, or solution contemplated or more significant are not considered to be critical, required, or essential features of any or all claims.

[0202] After reading this specification, those skilled in the art will appreciate that certain features described herein for clarity in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features described for brevity in the context of a single embodiment may also be provided separately or in any subcombination. In addition, references to values ​​expressed as ranges include each and every value within that range.

Claims

1. A plasma welding device, comprising: An operating room, which contains a sterile environment, the operating room includes a ventilation system, the ventilation system provides two-way ventilation with the operating room, thereby maintaining the sterile environment; a plasma generator having a plurality of plasma heads, wherein at least one plasma head is disposed in the operating chamber and is adjacent to an end contact surface of a first profile in the operating chamber and an end contact surface of a second profile in the operating chamber, wherein the first profile and the second profile each have one or more inner cavities that can convey a fluid, wherein the plasma head is configured to apply a plasma treatment to the end contact surfaces of the first profile and the second profile to join the first profile and the second profile in the sterile environment, and at least one of the plurality of plasma heads is configured to sterilize the internal environment of the operating chamber; wherein at least one of the first profile and the second profile is formed of a thermosetting elastomer, wherein the thermosetting elastomer comprises a silicone elastomer, a diene elastomer, butyl rubber, natural rubber, polyurethane rubber, ethylene propylene diene rubber, isoprene rubber, nitrile rubber, styrene butadiene rubber, a blend, or a combination thereof; and A mechanical motion module configured to axially align the end contact surfaces of the first profile and the second profile, wherein the mechanical motion module is capable of rotational movement, and the mechanical motion module is configured to manipulate the one or more internal cavities of the first profile and the second profile before plasma welding so that the first profile and the second profile remain open or closed during plasma treatment and / or joining of the first profile and the second profile, wherein the operating chamber forms a substantially sealed environment, and wherein the operating chamber confines the plasma treatment within the substantially sealed environment. 2 . The plasma welding apparatus according to claim 1 , wherein the first profile and the second profile are formed of a thermoplastic elastomer, a thermosetting elastomer, or a combination thereof.

3. The plasma welding apparatus of claim 2, wherein the thermoplastic elastomer comprises polystyrene, polyester, silicone copolymer, silicone thermoplastic vulcanizate, copolyester, polyamide, fluoropolymer, polyolefin, polyether-ester copolymer, thermoplastic polyurethane, polyetheramide block copolymer, polyamide copolymer, styrene block copolymer, polycarbonate, thermoplastic vulcanizate, ionomer, polyoxymethylene (POM), acrylonitrile-butadiene-styrene (ABS), acetal, acrylic, polyvinyl chloride (PVC), blends, or combinations thereof, and wherein the thermosetting elastomer comprises silicone elastomer, diene elastomer, butyl rubber, natural rubber, polyurethane rubber, ethylene propylene diene rubber, isoprene rubber, nitrile rubber, styrene-butadiene rubber, blends, or combinations thereof.

4. The plasma welding apparatus of claim 1, wherein the operating chamber is prevented from being opened or removed during application of the plasma treatment.

5. The plasma welding apparatus according to claim 1, wherein the plasma generator comprises a gas supply source and an electric power supply source.

6. The plasma welding apparatus of claim 5, wherein the gas supply source comprises an atmospheric air supply source, a compressor, a compressed gas cylinder, an internal gas line, an internal compressed gas line, a fan, a turbine, or a combination thereof, and wherein the gas supply source provides a gas flow comprising an inert gas, an oxygen-containing gas, a nitrogen-containing gas, a fluorine-containing gas, or a combination thereof. 7 . The plasma welding equipment according to claim 6 , wherein the inert gas comprises argon, neon, helium or any combination thereof.

8. The plasma welding apparatus according to claim 6, wherein the oxygen-containing gas comprises atmospheric air, pure oxygen, ethanol, water vapor, or a combination thereof, wherein the nitrogen-containing gas comprises atmospheric air, pure nitrogen, ammonia, or a combination thereof, and wherein the fluorine-containing gas comprises sulfur hexafluoride (SF6), trifluoromethane (CHF3), tetrafluoromethane (CF4), octafluorocyclobutane (C4F8), or a combination thereof.

9. The plasma welding apparatus of claim 6, wherein the power supply ionizes a gas flow from the gas supply to produce the plasma process. 10 . The plasma welding apparatus according to claim 1 , wherein the plasma treatment activates materials at the end contact surfaces of the first and second profiles.

11. The plasma welding device according to claim 1, further comprising: A cutting device is disposed in the operating room and is configured to cut the first profile and the second profile.

12. The plasma welding device according to claim 1, further comprising: A control system is configured to automatically stop the plasma process when an out-of-specification condition exists.

Images