Fluid distribution joint and assembly method

Abstract

A fluid distribution joint and a method for assembling the same are disclosed. Flexible conduits are connected to the joint, and the consumable subsystems, conduits, and receptacle caps or other connectors of the joint may be pre-assembled for ease of use. A subassembly is formed by coupling a plurality of flexible tubular conduits to a plurality of fluid connectors of the fluid joint, and the fluid joint has an internal fluid plenum chamber connected to the fluid connectors. Two shells are sandwiched on either side of the subassembly, and the shells fit integrally around each fluid connector and have mating recessed receiving surfaces that clamp the tubular conduits onto circular beads. The joint surfaces juxtaposed on each pair of mating recessed receiving surfaces are joined to each other by means of ultrasonic welding or the like to produce a fluid distribution joint assembly.

Description

Technical Field

[0001] (Notice Regarding Copyrights and Trade Dress) Part of the disclosure of this patent document contains material that is subject to copyright protection. This patent document may present and / or describe matter that is, or may be, the owner's trade dress. The owner of the copyrights and trade dress has no objection to the reproduction in whole by any one of the patent disclosures as it appears in the patent file or records of the United States Patent and Trademark Office, but otherwise retains all copyrights and trade dress rights.

[0002] (Field)

[0003] This disclosure relates to fluid distribution joints and methods of assembling the same, and more particularly to methods of pre-assembling a joint with a tubular conduit.

Background Art

[0004] (Description of Related Art)

[0005] In the processing of fluids in chemical reactors and bioreactors, valuable fluid products are often produced, which need to be distributed into various containers for further processing, delivery to customers, or sampling. Current joints for the distribution of fluids from one location to one or more other locations are inefficient to assemble.

[0006] Current systems utilize a linear manifold led from a fluid source, to which cross joints and tee joints are connected at the fluid source. The fluid enters at one end of the manifold and flows linearly along the header of the manifold across each cross or T-shaped branch. As the liquid flows in this way, it follows the path of least resistance, and most of the branches (droplets) receive the liquid until the hydraulic pressure rises to the equal pressure point because they are smaller in diameter than the manifold header. Furthermore, assembling a large-scale fluid distribution system having conduits to various destinations takes time and is prone to errors.

[0007] Fluid distribution joints and assembly methods are needed for distributing fluids between various locations. [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] This application discloses a fluid distribution joint and assembly method for distributing fluid between various locations. Flexible conduits are connected to the joint, and the consumable subsystems of the joint, conduits, and receptacle caps or other connectors may be pre-assembled for ease of use. A subassembly is formed by coupling a plurality of flexible tubular conduits to a plurality of fluid connectors of the fluid joint, and the fluid joint has an internal fluid plenum chamber connected to the fluid connectors. Two shells are sandwiched on either side of the subassembly, and the shells have mating recessed receiving surfaces that fit together around each of the fluid connectors and clamp the tubular conduits onto circular beads. The juxtaposed joining surfaces on each pair of mating recessed receiving surfaces are joined to each other by means of ultrasonic welding or the like to produce a fluid distribution joint assembly.

[0009] This application discloses a method for forming pre-assembled fluid joints and flexible conduits. One joint, having a flexible tubular conduit pressed against a fluid connector, is sandwiched between two coupling shells. The sandwiched stack is then positioned between a base and an ultrasonic vibrating horn. When ultrasonic energy is applied by the horn, the coupling shells melt at their joint surfaces, fixing the flexible conduit to the fluid connector. An energy director or concentrator, such as a narrow feature along one of the joint surfaces of the shells, facilitates rapid melting of the shells and a good, secure bond.

[0010] One fluid distribution system utilizing an improved joint has a distribution manifold with a single inlet and multiple outlets arranged around a circumferential circumference. The outlets may be directed to different receptacles, each having its own aeration filter, or each receptacle may be connected to return to the distribution manifold for common aeration. This system is particularly useful for distributing fluid products from a chemical or biological reactor while ensuring an integrally closed system. [Brief explanation of the drawing]

[0011] [Figure 1] This is a schematic diagram of a sampling receptacle having several flexible conduits extending from its cap, one of which connects to a conventional four-way joint having an additional flexible conduit connected to all three outlets.

[0012] [Figure 2] This is an elevation view of a conventional four-way joint, showing the barbs for connecting to a flexible conduit.

[0013] [Figure 3] This is an exploded perspective view of the four-way joint assembly of this application in a process of being integrated with a flexible conduit.

[0014] [Figure 4] This is an exploded elevation view of a four-way jointed assembly integrated with a flexible conduit in the process of pressing and joining the components together.

[0015] [Figure 5] A single flexible conduit is connected via a conventional barbed T-shaped joint.

[0016] [Figure 6] This is an exploded perspective view of the T-shaped joint of the present application.

[0017] [Figure 7]It is an assembly perspective view of the T-shaped joint in FIG. 6, which is integrated with three flexible conduits.

[0018] [Figure 8] It is a prior art barb-equipped Y-shaped joint to which one flexible conduit is connected.

[0019] [Figure 9] It is an exploded perspective view of the Y-shaped joint of the present application.

[0020] [Figure 10] It is an assembled perspective view of the Y-shaped joint in FIG. 9, which is integrated with three flexible conduits.

[0021] [Figure 11] It is a perspective view of an alternative fluid distribution system for quickly filling eight smaller receptacles all supported by a support stand from a single supply source.

[0022] [Figure 12] It is an enlarged perspective view of an alternative fluid distribution and venting manifold assembly in which an inlet conduit and an outlet conduit are connected for a fluid distribution system. [Figure 13] It shows a fluid distribution and venting manifold assembly with the inlet conduit and the outlet conduit removed.

[0023] [Figure 14] It is an exploded perspective view of a fluid distribution and venting manifold assembly, including a shell that sandwiches together a fluid distribution and venting manifold along with inlet and outlet connectors.

[0024] [Figure 14A] It is an enlarged view of one of the shells, showing a raised joint surface that mates with the joint surface of an adjacent shell. [Figure 14B] It is an enlarged view of one of the shells, showing a raised joint surface that mates with the joint surface of an adjacent shell.

[0025] [Figure 15] This is an exploded elevation view of the fluid distribution and ventilation manifold assembly.

[0026] [Figure 16A] These are elevation views of the fluid distribution and ventilation manifold assembly at slightly different rotational positions. [Figure 16B] These are elevation views of the fluid distribution and ventilation manifold assembly at slightly different rotational positions.

[0027] [Figure 17A] Figure 16A is an axial cross-sectional view along the cutting line, passing through the fluid distribution and ventilation manifold assembly. [Figure 17B] Figure 16B is an axial cross-sectional view along the cutting line, passing through the fluid distribution and ventilation manifold assembly.

[0028] [Figure 18A] Figure 15 is a bottom view of the fluid distribution manifold portion of the assembly. [Figure 18B] Figure 18A is a radial cross-sectional view taken along the cutting line through the fluid distribution manifold.

[0029] [Figure 19A] Figure 14 is a perspective view of the fluid distribution manifold assembly during an intermediate step in the integration with the flexible conduit. [Figure 19B] Figure 14 is a perspective view of the ventilation distribution manifold assembly during an intermediate step in the integration with the flexible conduit.

[0030] [Figure 20] This is an exploded elevation view of a fluid distribution and ventilation manifold assembly integrated with a flexible conduit during the process of pressing and joining the components together.

[0031] [Figure 21]This is a perspective view of a deliverable / consumable sterile fluid distribution subsystem for mounting on a receptacle that allows for fluid filling from a single source.

[0032] [Figure 22] Figure 13 is an exploded view of a typical ultrasonic coupling stack for joining pails to form a fluid distribution and ventilation manifold assembly.

[0033] [Figure 23] Figure 22 is an exploded perspective view of the base and nesting cavity for receiving the stacked fluid distribution and ventilation manifold assembly.

[0034] [Figure 24] This is an exploded perspective view of a reduced linear joint, with two connecting shells positioned on either side to connect the joint to a flexible tube. [Figure 24A] This is a magnified view of one of the shells, showing the ultrasonic concentrator rib.

[0035] [Figure 25] This is an exploded perspective view of an elbow joint, where two connecting shells are positioned on either side to connect the joint to a flexible tube. [Figure 25A] This is a magnified view of one of the shells, showing the ultrasonic concentrator rib.

[0036] [Figure 26] This is an exploded perspective view of a reduced elbow joint, with two connecting shells positioned on either side to connect the joint to a flexible tube. [Figure 26A] This is a magnified view of one of the shells, showing the ultrasonic concentrator rib.

[0037] [Figure 27] This is an exploded perspective view of a reduced T-shaped joint, with two connecting shells positioned on either side to connect the joint to a flexible tube. [Figure 27A] This is a magnified view of one of the shells, showing the ultrasonic concentrator rib.

[0038] [Figure 28] This is an exploded perspective view of a reduced cross-shaped joint, with two connecting shells positioned on either side to connect the joint to a flexible tube. [Figure 28A] This is a magnified view of one of the shells, showing the ultrasonic concentrator rib.

[0039] [Figure 29] The exploded perspective view of the reduced Y-shaped joint shows two connecting shells on either side to connect the joint to the flexible tube. [Figure 29A] This is a magnified view of one of the shells, showing the ultrasonic concentrator rib.

[0040] [Figure 30] Figure 24 is a scaled-down linear joint and exploded elevation end view of the shell assembly.

[0041] [Figure 31A] This is a magnified view of one edge of the shell, showing the ultrasonic concentrator ribs from the end. [Figure 31B] This is a magnified view of the other edge of the shell, which has a flat contact surface.

[0042] [Figure 32] Figures 31A and 31B are schematic diagrams of the melting patterns that are estimated to occur when the two shells are joined together using ultrasonic energy.

[0043] [Figure 33] This is a schematic diagram of an alternative configuration for an ultrasonic concentrator between two edges that are joined together. [Figure 34] This is a schematic diagram of an alternative configuration for an ultrasonic concentrator between two edges that are joined together. [Figure 35]This is a schematic diagram of an alternative configuration for an ultrasonic concentrator between two edges that are joined together. [Figure 36] This is a schematic diagram of an alternative configuration for an ultrasonic concentrator between two edges that are joined together. [Modes for carrying out the invention]

[0044] Referring here to Figure 1, an exemplary fluid distribution system 20 for collecting fluid from a supply source and distributing the fluid to another location is shown. It should be understood that the illustrated system 20 is merely an example, and the concepts disclosed herein can be modified for different systems.

[0045] The system 20 comprises a flask or receptacle 22 having a cap 24 and several flexible conduits connected thereto. An inlet conduit 26 supplies fluid from a source (not shown) into the hollow receptacle 22. A second conduit 28 is connected to the cap 24 and may include a vent filter 30. This can then safely vent any gases that may accumulate in the receptacle 22. The fluid distribution system 20 is particularly useful for dividing a fluid flow from a larger container into smaller individual receptacles 22, such as the flask shown in the figure. For example, a third conduit 32 extends from the cap 24 to a conventional four-way joint 34, shown separately in Figure 2. The four-way joint 34 distributes the fluid removed from the receptacle 22 to different destinations via three flexible conduits 36.

[0046] The conduit 32 leading from the receptacle 22 and three additional flexible conduits 36 are attached to barbed fittings 38 provided by a joint 34. Four-way joints 34, etc., are standard components of conventional fluid distribution systems. In the illustrated example, the barbed fittings 38 include a short, rigid tube 40 with frustoconical outward-facing beads 42 (often called barbs or barbed beads) that widen toward a central housing 44 where a plenum chamber is located that joins the inner lumens of all four fittings. The joint 34 is typically molded from a rigid plastic such as polypropylene, and the flexible conduits 32, 36 are made of thermoplastic elastomer (TPE), silicone, etc., which can be pressed against each fitting 38. The inner diameters of the conduits 32, 36 are approximately the same as the diameter of the rigid tube 40 so that the conduits bend and slide over the tapered inclined section provided to the central housing 44 by the outward-facing beads 42. The sharp step on the inner end of the outward-facing bead 42 prevents the removal of the conduits 32 and 36. The single barb provided by the outward-facing bead 42 can be replaced with a series of such beads in an alternative joint configuration.

[0047] The configuration of attaching flexible conduits 32, 36 to a four-way joint 34 is extremely common in the fields of chemical and biological processing, and is typically performed when setting up a particular process. Often, this same setup is replicated many times for a single process, and the task of connecting all the flexible conduits to all the joints can be time-consuming and therefore costly. Furthermore, pressing the conduits 32, 36 into the barbed fittings 38 can require considerable force, which over time can cause injuries to workers, such as carpal tunnel syndrome. Finally, the need to assemble all the separate conduits into such barbed fittings can sometimes lead to contamination in very delicate chemical or biological processing. A better system is needed for connecting flexible conduits to such joints.

[0048] As one solution, Figure 3 is an exploded perspective view of the four-way joint assembly 50 of this application in the process of being integrated with a flexible conduit 52. The joint assembly 50 comprises three components, namely an inner four-way joint 54 and two outer covers or shells 56. The four-way joint 54 is constructed very similarly to the prior art four-way joint 34 illustrated and described above, and has a central housing 60, from which four tubular fittings 62 extend outward in a cruciate pattern. As previously stated, the central housing 60 defines a central plenum chamber that communicates evenly with the lumen 64 of each of the tubular fittings 62. Rather than frustoconical beads, each of the fittings 62 has a circular bead 66 that protrudes outward with a somewhat semicircular cross-section. As shown, assembling the four-way joint 54 and the two outer shells 56 provides sufficient friction to hold the flexible conduit 52 in place on the fittings 62. As mentioned above, the joint 54 is typically molded from a rigid plastic such as polypropylene, and the flexible conduit 52 is made of a thermoplastic elastomer (TPE), silicone, etc., that can be pressed against each fitting 62. The outer shell 56 is also molded from a rigid plastic such as polypropylene.

[0049] Figure 3 shows two of the flexible conduits 52 mounted on the associated tubular fittings 62, with the third fitting in the process of receiving the flexible conduit and the fourth fitting without the conduit. This represents the steps in putting the joint assembly 50 together. This sequence includes first pre-assembling the flexible conduits 52 onto the tubular fittings 62 of the joint 54, and then sandwiching the subassemblies with outer shells 56. Each of the outer shells 56 has a cross pattern of inwardly concave walls that fit tightly around the conduits 52 and the subassemblies of the joint 54. More specifically, each of the four legs of the outer shell 56 has a concave semi-cylindrical inner wall portion 70 with semicircular inner ribs 72 provided radially outward thereof. The diameter of the semi-cylindrical inner wall portion 70 preferably matches the outer diameter of the flexible conduit 52. When the two shells 56 are closed around the conduit 52 and the subassembly of the joint 54, the inner wall portion 70 compresses the flexible conduit 52 against the circular beads 66 of the tubular fitting 62. Furthermore, the semicircular inner ribs 72 compress the flexible conduit 52 inward. This combination of compression from the outer shell 56 effectively holds the flexible conduit 52 in place.

[0050] Figure 3 shows that each of the shells 56 has a flat joint surface 74 that coincides with the joint surface of the other shell. The joint surfaces 74 extend along the edge of the concave inner wall portion 70 and are therefore arranged in a cross pattern. By juxtaposing these joint surfaces 74 of both shells 56, it becomes possible to join them to each other. The joining can be done in a variety of ways, including adhesive, fusion welding or electrofusion welding, and ultrasonic welding. In this application, we envision an assembly process that utilizes ultrasonic welding to avoid the use of chemical adhesives.

[0051] Figure 4 is an exploded elevation view of a four-way joint 54 integrated with a flexible conduit 52 in the process of pressing and joining the frame or shell 56 together. The components of the four-way joint assembly 50 are stacked as shown. Opposing presses 80 are used to compress the stacked assembly of components together, applying pressure and vibration or heat / electric current to fuse the contacting components. The opposing presses 80 have a press surface that fits tightly with the stacked shell 56, such as having a cross-shaped pattern of recesses 82. The preferred method for fusion is ultrasonic welding, but thermal welding or electric thermal welding may be used as an alternative or incidental method.

[0052] Ultrasonic welding, also known as sonic welding, is a technique used to join thermoplastic materials together and is widely used in various industries, including automotive, electronics, medical, and packaging. This process utilizes high-frequency mechanical vibrations to generate frictional heat at the interface of plastic parts, melting and fusing the plastic parts together.

[0053] Ultrasonic welding first involves preparing the plastic parts to be joined, ensuring their surfaces are clean and free of contaminants. Any protective coatings, films, or adhesives are removed from the joining area. The plastic parts are positioned between opposing presses 80 designed to hold them securely during the welding process. The two presses 80 consist of a fixed anvil and a movable horn (also called an ultrasonic stack) that applies ultrasonic vibrations to the parts. The opposing presses 80 apply constant pressure to ensure that the surfaces of the plastic parts (i.e., the joint) contact each other and properly interlock, in this case the juxtaposed joining surfaces 74 of the stacked outer shells 56 interlock, as shown in Figure 3. The amount of pressure applied depends on the specific material and its thickness. To achieve faster heating, ultrasonic energy may be focused or concentrated over a smaller area using narrow physical sides or an ultrasonic energy director. For example, Figure 4 shows a thin rib 75 visible beneath the joining surface 74 of the upper shell of the stacked shells 56. These thin ribs 75 contact the collinear, flat bonding surface 74 on the lower shell of the stacked shells 56, directing the energy along the strands rather than to areas for faster heating and melting. Rigid plastics such as polypropylene used for the laminated shells 56 melt quickly and provide a solid bond. The specific configuration of such an ultrasonic energy director will be illustrated and described later.

[0054] The horn portion of the opposing press 80 transmits high-frequency ultrasonic vibrations (typically in the range of 20 kHz to 70 kHz) to the bonding interface between the plastic parts. The vibrations are generated by a transducer, which converts electrical energy into mechanical vibrations. As a result, the ultrasonic vibrations generate rapid back-and-forth motion at the bonding interface, accumulating frictional heat between the plastic surfaces. This localized heat softens the plastic material and causes it to melt at the contact point. Once the plastic material reaches its melting point, the pressure applied to the joint causes the molten material to flow and interdiffuse, forming molecular bonds between the parts. When the vibrations stop, the molten plastic solidifies again, forming a strong and durable bond.

[0055] After the ultrasonic vibrations stop, the joint is cooled. The cooling time depends on the specific plastic material and the size of the weld. Cooling can be accelerated by methods such as air cooling or water cooling. Once the joint has cooled and solidified, the welding process is considered complete. The welded parts can be inspected for any defects such as incomplete fusion, voids, or burrs. Depending on the specific application, additional trimming or post-welding may be required.

[0056] By utilizing the method shown in Figure 4, the conduit 52 can be quickly pre-assembled with the four-way joint 54 for subsequent connection, for example, within the fluid distribution system 20 in Figure 1. If a given chemical or biological process is known to require a specific number of joints attached to the flexible conduit, these joints can be obtained pre-assembled from the manufacturer and simply plugged into the specific process configuration. This pre-assembly has the significant advantage of arriving sterile in sterile packaging, eliminating the need for individual connections to the conduit joints, which could be a source of contamination. Furthermore, the pre-assembled conduit 52 and four-way joint 54 can be further joined with manufacturer components such as the cap 24 of the receptacle 22, further facilitating assembly in the laboratory or process facility. Saving time, cost, and potentially hazardous repetitive assembly steps represents a significant advantage.

[0057] Another such configuration is shown in Figure 5, where a conventional barbed T-joint 90 is shown connected to a flexible conduit 92. Here again, the barbed T-joint 90 has a truncated conical bead or barb 94 on which the flexible conduit 92 is pressed. Thus, each barbed T-joint 90 requires three separate steps to attach the conduit 92, which can cause contamination and is time-consuming and therefore costly.

[0058] Figure 6 is an exploded perspective view of an equivalent T-joint assembly 100 of the present application, which comprises an inner T-joint 102 sandwiched between two outer covers or shells 104. The T-joint 102 has three legs or fittings having barbs or beads 106, as described above with respect to the four-way joint 54. Similarly, the outer shells 104 have concave inner surfaces 108 that fit together along a planar joint surface 110. The flexible conduit 112 is first integrated with the inner T-joint 102, and then, as shown in Figure 7, its subassembly is sandwiched between 22 outer shells 104 that are joined together. Again, sonic welding is the preferred joining method.

[0059] In Figure 8, a conventional barbed Y-joint 120 is connected to a flexible conduit 122. Here again, the barbed Y-joint 120 has truncated conical beads or barbs 124 onto which the flexible conduit 122 is pressed. Therefore, each barbed Y-joint 120 requires three separate steps to attach the conduit 122, which can cause contamination, is time-consuming, and is therefore costly.

[0060] Figure 9 is an exploded perspective view of an equivalent Y-joint assembly 130 of the present application, which comprises an inner Y-joint 132 sandwiched between two outer covers or shells 134. The Y-joint 132 has three legs or fittings having barbs or beads 136, as described above with respect to the four-way joint 54. Similarly, the outer shells 134 have concave inner surfaces 138 that fit together along a planar joint surface 140. The flexible conduit 142 is first integrated with the inner T-joint 132, and then, as shown in Figure 10, its subassembly is sandwiched between two outer shells 134 that are joined together. Again, sonic welding is the preferred joining method.

[0061] Figure 11 is a perspective view of a more complex alternative fluid distribution system 220 for rapidly filling eight receptacles 222, all supported by support stands 224, from a single source. The alternative fluid distribution system 220 includes a lower inlet 226 connected to a fluid distribution and aeration manifold assembly 228, which separates the inlet fluid flow and delivers it to eight individual receptacles 222, all supported by support stands 224. Although not shown, the source of the inlet flow may include a larger container, such as a bioreactor vessel or other such chemical processing equipment. The fluid distribution system 220 is particularly useful for dividing the fluid flow from such a larger container to smaller individual receptacles 222, such as the illustrated flasks. Its lower inlet 226, located on the underside of the manifold assembly 228, connects to a larger inlet pipe 230.

[0062] The fluid distribution and ventilation manifold assembly 228 is shown in the enlarged perspective and elevation views of Figures 12 and 13. Specifically, Figure 12 shows an enlarged perspective view of the manifold assembly 228 with eight fluid outlet and inlet tubes or conduits 232, 234 connected thereto, and Figure 13 shows the manifold assembly with the conduits removed. The manifold assembly 228 comprises a compact cylindrical frame 236, a central inlet connector 238 projecting downward from the cylindrical frame 236, and a central outlet connector 240 projecting upward. The manifold assembly 228 includes a plurality of lower outlet fittings 242 connected to the outlet conduit 232, and a plurality of upper inlet fittings 244 connected to the inlet conduit 234. The fluid conduits 232 and 234 may be fused, bonded, or otherwise fixed to the outlet fitting 242 and the inlet fitting 244, which are recessed within the cylindrical manifold assembly 228 as described below.

[0063] As shown in the figure, there are eight outlet fittings 242 and outlet conduits 232 evenly distributed (in 45° increments) around the cylindrical manifold assembly 228. Similarly, eight inlet fittings 244 and inlet conduits 234 are shown evenly distributed (in 45° increments) around the cylindrical manifold assembly 228. As described below, the main internal channels within the manifold assembly 228 direct the fluid flowing in through the inlet connector 238 evenly outward through the outlet fittings 242 and fluid outlet conduits 232. When configured to provide a common vent, the secondary internal channels within the manifold assembly 228 direct the fluid flowing in through the inlet conduits 234 and inlet fittings 244 upward, evenly inward towards the central plenum and central outlet connector 240.

[0064] Referring here to the exploded view in Figure 14, the components of the fluid distribution and vent manifold assembly 228 can be better described. The substantially cylindrical frame 236 shown in Figure 13 is formed by three disc-shaped members connected to one another. That is, the upper shell 250a and the lower shell 250b sandwich the central shell 252. The shells 250, 252 contain and conceal a pair of fluid distribution joints or manifolds 254, 256. More specifically, as shown in the exploded elevation view in Figure 15, the lower fluid distribution manifold 254 is positioned between the lower shell 250b and the central shell 252, and the upper vent distribution manifold 256 is positioned between the upper shell 250a and the central shell 252. The fluid distribution manifold 254 has a radially oriented outlet fitting 242, and the vent distribution manifold 256 has a radially oriented inlet fitting 244. The radially projecting outlet and inlet fittings 242, 244 are recessed within the shells 250, 252 that axially sandwich the fluid distribution manifold 254 and the aeration distribution manifold 256, defining the compact cylindrical shape of the outer shell. Each manifold 254, 256 has at least four outlet fittings 242 and inlet fittings 244, but preferably eight as shown in the figure.

[0065] The terms “joint” and “manifold” are used herein to refer to a single-part component having several fluid inlet and outlet connectors or fittings for distributing a fluid between multiple locations, such as manifolds 254, 256. “Fluid” in this sense means liquid or gas. The term “joint” has traditionally been used to describe T-joints, Y-joints, and four-way joints (and others not mentioned) having intersecting internal channels within the joint, while “manifold” is more precise when discussing a component having one channel or port opening to an internal plenum chamber communicating with two or more other ports. In this sense, a manifold is a more complex subset of a joint, and the term “joint” encompasses both devices.

[0066] The fluid distribution manifold 254 and the vent distribution manifold 256 are preferably identical, being only inverted relative to each other, and are therefore described together with similar elements bearing the same reference numerals. As shown in Figure 14 as well as in Figures 18A and 18B, the fluid distribution manifold 254 has a cylindrical outer wall 260 from which an outlet fitting 242 projects radially outward. A radially oriented, rigid plenum floor 262 extends across the manifold 254 within the cylindrical outer wall 260 and is stepped either above or axially downward of the cylindrical outer wall 260. The remaining features of the fluid distribution manifold 254 are also seen in the top view of the vent distribution manifold 256 in Figure 14, since the two manifolds are identical.

[0067] The cylindrical outer wall 260 encloses a smaller inner circular wall 264, with a radially oriented inner partition wall 266 extending between them. The inner circular wall 264 extends axially until it is intercepted by a stepped cylindrical plenum chamber wall 268, through which several radial passages 270 open to a central plenum chamber 272. The radial passages 270 extend outward through the inlet fitting 244 (or outlet fitting 242 of the fluid distribution manifold 254) of the vent distribution manifold 256. Figures 16A and 16B are elevation views of the fluid distribution and vent manifold assembly 228 at slightly different rotational positions. As previously mentioned, the various components shown in Figure 15 are incorporated into a small cylindrical frame 236 with the inlet connector 238 protruding downward and the outlet connector 240 protruding upward from there. The circular array of outlet fittings 242 is seen below the circular array of inlet fittings 244.

[0068] Figures 17A and 17B are axial cross-sectional views through the fluid distribution and ventilation manifold assembly 228, cut along the respective cutting lines of Figures 16A and 16B. The slight difference in rotational orientation between Figures 16A and 16B allows us to see the fluids and gases flowing through the manifold assembly 228. The inlet connector 238 and outlet connector 240 both have stepped ends, which engage with the respective manifolds 254 and 256 and open into the respective central plenum chambers 272. That is, the innermost ends of each connector 238 and 240 fit tightly into the circular wall 264 and abut against the stepped cylindrical plenum chamber wall 268. The outward flanges of each connector 238 and 240 contact the outer surfaces of the respective shells 250a and 250b, as is best seen in Figures 13 and 16A / 16B. Thus, the fluid or gas flows directly into or from the plenum chamber 272 through the connectors 238 and 240.

[0069] Firstly, Figure 16A is a cross-sectional view through one of the radial passages 270 within the fluid distribution manifold 254. The fluid introduced into the inlet connector 238 moves upward into the central plenum chamber 272 and is then evenly distributed outward through the radial passages 270, as shown in Figure 17A. Figures 11 and 12 show the subsequent connection of the outlet conduit 232 to the outlet fitting 242, finally leading to a fluid container or receptacle 222 held on a stand 224. Each receptacle 222 has a closure or cap 222a with an opening through which the outlet conduit 232 communicates. The cap 222a has a second opening through which the inlet conduit 234 communicates. The inlet conduit 234 extends upward and connects to the inlet fitting 244 of the manifold assembly 228.

[0070] Therefore, Figure 16B is a cross-sectional view through one of the radial passages 270 in the vent distribution manifold 256. When filled with liquid, the gas discharged from the receptacle 222 is vented upward through the conduit 234 and the inlet fitting 244 into the radial passage 270 in the vent distribution manifold 256, as shown in Figure 17B. The gas flows inward into the central plenum chamber 272, from there upward and exits through the outlet connector 240. Although not shown in Figure 11, one or more common vent filters may be attached to the outlet connector 240, as shown by 60 in Figures 1 and 2.

[0071] The fluid distribution and ventilation manifold assembly 228 in the alternative system 220 exemplifies advantageous assembly techniques that significantly reduce assembly time and cost. Fluid distribution systems used to transport fluid in bulk from a single source to multiple separate containers must necessarily utilize flexible tubing such as conduits 232, 234. Such conduits are typically connected to hose barbs at each end in the end-user processing facility, with or without couplings or hose clamps to prevent leaks. When assembling such a fluid distribution system, the time required to make each of these connections is considerable, further increasing assembly costs. In addition, errors can occur in the laboratory when connecting numerous conduits to receptacles.

[0072] The fluid distribution and ventilation manifold assembly 228 can be assembled in a much shorter time than previous systems, and the margin for error is also greatly reduced. Generally, the assembly method involves pre-attaching the flexible tubing to the manifold components in the manufacturing facility, and then joining the manifold components and the flexible tubing together using shells and fusion. In contrast to connecting the tubing between the manifold assembly and the vessel afterward, the tubing can be attached to the manifold components more quickly, thus accelerating the entire process.

[0073] To illustrate an exemplary assembly method, the perspective views of the fluid distribution manifold 254 and the vent distribution manifold 256 in Figures 19A and 19B are referenced. First, the flexible outlet conduits 232 are attached to each of the outlet fittings 242 of the fluid distribution manifold 254. Simultaneously or subsequently, the flexible inlet conduits 234 are attached to each of the inlet fittings 244 extending outward from the vent distribution manifold 256. In the illustrated embodiment, each of the fittings 242, 244 is configured similarly to a hose barb, but may have only one instead of a series of circular beads. Each circular bead is designed to be slightly larger than the inner diameter of the associated flexible conduit so that the conduit can be pressed into the fitting and tightly fitted.

[0074] Next, the various components of the manifold assembly 228 are stacked as shown in Figure 20. A counter press 280 is used to compress this stacked assembly of components together, applying pressure and vibration or heat / current to fuse the contacting components. Again, the counter press 280 has a press surface that closely fits with the stacked shells 250a, 250b. The preferred method for fusion is ultrasonic welding, but adhesives or thermal welding or electric thermal welding may be used as alternative or incidental methods.

[0075] Ultrasonic welding first involves preparing the plastic parts to be joined, ensuring their surfaces are clean and free of contaminants. Any protective coatings, films, or adhesives are removed from the joining area. The plastic parts are positioned between opposing presses 280 designed to hold them securely during the welding process. The two presses 280 consist of a fixed anvil and a movable horn (also called an ultrasonic stack) that applies ultrasonic vibrations to the parts. The opposing presses 280 apply constant pressure to ensure that the surfaces of the plastic parts (i.e., the joint) contact each other and properly interlock, in this case the surfaces of the laminated shells 250a, 250b interlock, as shown in Figures 13 and 16A / 16B. The amount of pressure applied depends on the specific material and its thickness. The remainder of the process may be as described above with respect to Figure 4.

[0076] It should be noted that the various components of the manifold assembly 228 are shaped to nest within each other, and when joined together, they form a compact cylindrical body 236 as seen in Figure 13. For example, referring to Figure 14, the upper shell 250a and lower shell 250b have flat outer surfaces, but define multiple radially oriented channels or grooves 290 on their inner surfaces. These grooves 290 fit around the respective protruding fittings 242, 246 within the manifolds 254, 256. Similarly, the central shell 252 has a circular array of radially oriented channels or grooves 292 on both sides, which also accept the protruding fittings 242, 246. Figure 13 shows the resulting assembly 228, with the fittings 242, 244 remaining within the cylindrical outer boundary. This serves to protect the integrity of fittings 242, 244 from damage, but more importantly, it clamps the inner ends of the flexible conduits 232, 234 around the fittings. That is, the curvature of the radial grooves 290, 292 matches or is slightly smaller than the outer diameter of the conduits 232, 234, and thus compresses the conduits around the circular beads on each of the fittings 242, 246. This ensures a good fluid-tight fit between the conduits and fittings, similar to hose clamps. Furthermore, the compression provided by sandwiching the conduits between grooves 290 and 292 ensures that the conduits do not loosen from their respective fittings.

[0077] When the upper shell 250a, the lower shell 250b, and the central shell 252 sandwich the manifolds 254 and 256 between them, the shells contact each other along the pi-shaped raised segments 294 between them, joining the assembly. The pi-shaped raised segments 294 are in contact with radially oriented grooves 290 and 292 and have outer edges on the outer circumference of each of the shells 250a, 250b, and 252.

[0078] As best shown in Figures 14A and 14B, each of the shells 250a, 250b, and 252 has a joint surface 296 along a raised segment 294 that coincides with and contacts the joint surface of the adjacent shell. That is, the upper shell 250a has a joint surface 296 on its lower surface, the lower shell 250b has a joint surface 296 on its upper surface, and the central shell 252 has joint surfaces 296 on both its upper and lower surfaces. The joint surfaces 296 extend along the raised edges of the segment 294. By juxtaposing these joint surfaces 296 on the shells 250a, 250b, and 252, it becomes possible to join them to one another. As described herein, joining can be carried out in a variety of ways, including adhesives, fusion welding or electrofusion welding, and ultrasonic welding. In this application, an assembly process utilizing ultrasonic welding to avoid the use of chemical adhesives is envisioned.

[0079] Referring again to Figures 14A and 14B, one of each pair of contacting raised segments 294 contacts a collinear, flat joint surface 296 on the second segment of the pair, directing the energy along the strand rather than to areas for faster heating and melting. The narrow rib 298 in the illustrated embodiment has a triangular cross-section, but other shapes may be used, as will be detailed below.

[0080] Figure 21 is a perspective view of a deliverable / consumable sterile fluid distribution subsystem 220a for mounting to a receptacle, which allows it to be filled with fluid from a single source. Subsystem 220a forms part of the larger fluid distribution system 220 shown in Figure 11. Subsystem 220a can be assembled quickly and efficiently in a manufacturing facility as described above and can be packaged in a sterile form in the laboratory for immediate integration into the larger system 220.

[0081] The fluid distribution subsystem 220a comprises a manifold assembly 228 having an inlet connector 238 and an outlet connector 240, as described above. The fluid outlet conduit 232 and the fluid inlet conduit 234 are pre-assembled with the manifold assembly 228, as described above. Finally, the conduits 232 and 234 are connected to the receptacle cap 222a. By producing and shipping subsystem 220a in this form within sterile packaging, the end user only needs to connect the remaining elements of the entire system 220, such as screwing the sterile receptacle 222 onto the cap 222a, attaching the fluid source to the inlet connector 238, and the common vent to the outlet connector 240. These final assembly steps take only a few minutes and are almost foolproof in that they ensure the correct connections are made, after which the end user can begin filling the receptacle with fluid. Once the processing connection within the receptacle 222 is complete, the conduits 232 and 234 to each are closed using clamps or flow control valves 110 and 112, etc., as shown in Figure 5, and may then be cut to separate the closed receptacle 222 from the larger filling system. The subsystem 220a is a consumable product that is relatively inexpensive to manufacture and can therefore be discarded after use.

[0082] Figure 22 is an exploded view of a typical ultrasonic coupling stack for joining pails to form the fluid distribution and ventilation manifold assembly of Figure 13. The coupling stack begins with an ultrasonic vibrating horn 300 located above the upper nesting block 302. The ultrasonic vibrating horn 300 is typically formed from stainless steel or titanium or other similar metal. The stack of the upper shell 250a and lower shells 250a, 250b and the intermediate shell 252 remains the same as described above, with the manifolds 254, 256 and flexible tubing interposed between them. The central inlet connector 238 and central outlet connector 240, as seen in Figure 20, may also be housed in the assembly and coupled to it, but are not shown for brevity. The stack components are supported on the lower nesting block 304, which rests on a stable base 306, such as a table.

[0083] Figure 23 is an exploded perspective view of the base 306 and the lower nest block 304 on it, showing a nest cavity 308 for receiving the stacked fluid distribution and ventilation manifold assembly. The lower bonding shell 250b is viewed in an upward orientation to see the contour on its lower surface 312, which rests on the floor 310 of the nest cavity 308. The nest cavity further includes a plurality of raised blocks 314, which fit into a similarly sized cavity 316 on the bottom surface of the lower bonding shell 250b. The nest cavity 308 may be machined from the lower nest block 304, which may be formed from aluminum, stainless steel, or the like.

[0084] Although not shown, the lower surface of the upper nesting block 302 has a similar shape to the upper surface of the upper coupling shell 250a, as shown in Figure 14. The tight fitting or “nested” contact between the nesting blocks 302, 304 and the coupling shells 250a, 250b ensures excellent contact between them, and as a result, the ultrasonic energy directed upward from the horn 300 through the stack is absorbed mainly at the contact surfaces between the manifold assembly pails, preventing accidental vibrations or energy losses between the pails and the flanking coupling equipment. In other words, the stacked assembly shown in Figure 22 creates an extremely stable stack of manifold assembly components and is therefore less prone to vibration at the contact surfaces between the shells 250a, 250b, 252.

[0085] Figure 24 is an exploded perspective view of assembly 400 of a reduced linear joint 402, with two connecting shells 404, 406 positioned on either side for connecting the joint to a flexible tube (not shown) in the manner described above. The reduced linear joint 402 has a smaller fitting 408 at one end and a larger fitting 410 at the other end. The connecting shells 404, 406 have concave receiving surfaces that fit integrally around each fluid fitting, clamping the tubular conduit onto a circular bead and juxtaposed joining surfaces in contact with each other. Thus, the inner contours of the shells 404, 406 on both sides reflect the fittings 408, 410 of different sizes, and flexible tubes of different sizes will be joined to these fittings. Figure 24A is an enlarged view of the shell 404, showing an ultrasonic concentrator rib 412 extending along its joining surface. Each of the concentrator ribs 412 has a triangular cross-section, and as a result, it contacts the flat edge on the other shell 406 along a line rather than across a surface. This directs the ultrasonic energy along the vertices of the concentrator ribs 412, providing faster melting.

[0086] Figure 25 is an exploded perspective view of an assembly 420 of two coupling shells 422, 424 flanking a standard elbow joint 426 for connecting a joint to a flexible tube (not shown) in the manner described above. The elbow joint 426 has two equally sized fittings 428, 430 at both ends. The coupling shells 422, 424 have concave receiving surfaces that fit integrally around each of the fluid fittings 428, 430, clamping the tubular conduit onto a circular bead and juxtaposed coupling surfaces in contact with each other. Figure 25A is a magnified view of a shell 422, showing ultrasonic concentrator ribs 432 extending along its coupling surface. Each of the concentrator ribs 432 has a triangular cross-section, and as a result, contacts the flat edge on the other shell 424 along a line rather than across a surface. This directs the ultrasonic energy along the vertices of the concentrator ribs 432, providing faster melting.

[0087] Figure 26 is an exploded perspective view of an assembly 440 of two coupling shells 442, 444 flanking a retractable elbow joint 446 positioned on either side, for connecting the joint to a flexible tube (not shown) in the manner described above. The retractable elbow joint 446 has a smaller fitting 448 opposite a larger fitting 450 at the other end. Thus, the inner contours of the side shells 442, 444 reflect the fittings 448, 450 of different sizes, and flexible tubes of different sizes are joined to the fittings. The coupling shells 442, 444 have concave receiving surfaces that fit integrally around each of the fluid fittings 448, 450, clamping the tubular conduit on circular beads and juxtaposed joining surfaces in contact with each other. Figure 26A is an enlarged view of shell 442, showing an ultrasonic concentrator rib 452 extending along its joining surface. Each of the concentrator ribs 452 has a triangular cross-section, and as a result, it contacts the flat edge on the other shell 444 along a line rather than across a surface. Here again, this directs the ultrasonic energy along the vertices of the concentrator ribs 452, providing a faster melting.

[0088] Figure 27 is an exploded perspective view of an assembly 460 of two coupling shells 462, 464 flanking a reduced T-shaped joint 466 for connecting the joint to a flexible tube (not shown) in the manner described above. The reduced T-shaped joint 466 has a larger fitting 468 positioned perpendicular to two collinear, smaller fittings 470 at both ends. The coupling shells 462, 464 have concave receiving surfaces that fit integrally around each of the fluid fittings 468, 470, clamping the tubular conduit onto circular beads and juxtaposed joining surfaces in contact with each other. As described above, the inner contours of the flunking shells 462, 464 thus reflect the fittings 468, 470 of different sizes, and flexible tubes of different sizes are joined to the fittings. Figure 27A is an enlarged view of the shell 462, showing an ultrasonic concentrator rib 472 extending along its joining surface. Each of the concentrator ribs 472 has a triangular cross-section, and as a result, it contacts the flat edge on the other shell 464 along a line rather than across a surface. This directs the ultrasonic energy along the vertices of the concentrator ribs 472, providing faster melting.

[0089] Figure 28 is an exploded perspective view of an assembly 480 of two coupling shells 482, 484 flanking a reduced cruciate joint 486 for connecting a joint to a flexible tube (not shown) in the manner described above. The reduced cruciate joint 486 has a pair of collinear, larger fittings 488 positioned perpendicular to two collinear, smaller fittings 490 on opposing ends. The coupling shells 482, 484 have concave receiving surfaces that fit integrally around each of the fluid fittings 488, 490, clamping the tubular conduit on circular beads and juxtaposed joining surfaces in contact with each other. As described above, the inner contours of the side shells 482, 484 reflect the fittings 488, 490 of different sizes, and flexible tubes of different sizes will be joined to the fittings. Figure 28A is an enlarged view of shell 482, showing an ultrasonic concentrator rib 492 extending along its joining surface. Each of the concentrator ribs 492 has a triangular cross-section, and as a result, the ultrasonic energy is directed along the vertices of the concentrator ribs 492 by contacting the flat edge on the other shell 484 along a line rather than across a surface, providing faster melting.

[0090] Figure 29 is an exploded perspective view of an assembly 500 of two coupling shells 502, 504 flanking a reduced Y-shaped joint 506 for connecting the joint to a flexible tube (not shown) in the manner described above. The reduced Y-shaped joint 506 has a larger fitting 508 extending along an axis that bisects two smaller angled fittings 510 on opposite ends of the joint. The coupling shells 502, 504 have concave receiving surfaces that fit integrally around each of the fluid fittings 508, 510, clamping the tubular conduit onto circular beads and juxtaposed joining surfaces in contact with each other. The inner contours of the side shells 502, 504 reflect the fittings 508, 510 of different sizes, and flexible tubes of different sizes are joined to the fittings. Figure 29A is an enlarged view of shell 502, showing an ultrasonic concentrator rib 512 extending along its joining surface. Each of the concentrator ribs 512 has a triangular cross-section, and as a result, it contacts the flat edge on the other shell 504 along a line rather than across a surface. This directs the ultrasonic energy along the vertices of the concentrator ribs 512, providing faster melting.

[0091] Figure 30 is an exploded elevation end view of the assembly of the reduced linear joint 406 and side shells 402, 404 of Figure 24. The concentrator rib 412 is shown on the joint surface of the upper shell 402, and the lower shell 404 has a flat joint surface. These are shown in enlargement in Figures 31A and 31B. Finally, Figure 32 is a schematic diagram of the melting pattern that is presumed to occur when the two shells 402, 404 are joined to each other using ultrasonic energy. That is, the apex of the concentrator rib 412 is in contact with the flat edge 414, and therefore the ultrasonic energy between the two pails is all focused to the apex. The concentrator rib 412 then melts very quickly and spreads between the two contact edges, as schematically shown by pointillism.

[0092] Figures 33–36 are schematic diagrams of alternative ultrasonic concentrator configurations between two edges to be joined. It should be understood that these diagrams are not the only possible configurations of the concentrator, energy, or director. An energy director is either a specific angle intersecting a flat surface, or a small protrusion rising from a flat surface. When ultrasonic resonance is concentrated on the part, this small point or line melts instantaneously, creating a cascading effect across both surfaces being joined. Without an energy director, the likelihood of obtaining a good, repeatable weld is reduced. Triangular cross-sections are excellent for concentrating energy along a line, but curved shapes narrowing towards the generatrix, or other narrowing shapes as described below, are also conceivable.

[0093] In a first example of an alternative energy director, Figure 33a shows the contact edges of a pair of shells 520, 522. The lower shell 522 has a triangular projection 524 that acts as an energy director, fitting into a rectangular cavity 526 within the upper shell 520. When the two shells are joined together, ultrasonic vibrations cause the triangular projection 524 to heat up first and thus rapidly melt and spread between the contact surfaces, as schematically shown by pointillism.

[0094] Figure 34 shows the edges where a pair of shells 530 and 532 come into contact together. The lower shell 532 features a substantially rectangular projection 533 with an upper corner that fits into the triangular cavity 534 of the upper shell 530. Thus, the corner of the rectangular projection 533 contacts the size of the triangular cavity 534 and melts first. The estimated area of ​​molten material is schematically shown in stippling.

[0095] Figure 35 shows the upper shelf 540 in the lower shell 542 having a different energy director configuration. The upper shell 540 has a rectangular cavity defining a corner 544. The lower shell 542 has a trapezoidal projection 546, the upper corner of which contacts the corner 544 of the rectangular cavity on the upper shell 540, and thus the ultrasonic energy is concentrated along these contact lines. Here again, the estimated molten region is schematically shown in stippling.

[0096] Finally, Figure 36 shows an asymmetrical arrangement in which the edge of the upper shell 550 aligns with the edge of the lower shell 552. The upper shell 550 has a substantially triangular projection 554 extending downward on one side that fits into the rectangular step 556 of the lower shell 552. Thus, the vertices of the triangular projection 554 are initially heated, melted, and joined together. The estimated regions are schematically shown in pointillism.

[0097] In this specification, terms such as top, bottom, left, and right are used, but the fluid manifold may be used in various positions, including upside down. Therefore, some descriptive terms are used in a relative sense and not in an absolute sense.

[0098] Throughout this specification, the embodiments and examples presented should be considered illustrative and not limiting to the apparatus and procedures disclosed or claimed. While many of the examples presented herein involve specific combinations of method actions or system elements, it should be understood that such actions and elements may be combined in other ways to achieve the same objective. Actions, elements, and features discussed in relation to one embodiment are not intended to be excluded from similar roles in other embodiments.

[0099] As used herein, “plural” means two or more. As used herein, “set” of items may include one or more such items. In a claim, the use of ordinal terms such as “first,” “second,” “third,” etc., to modify an element of a claim does not, by itself, imply that an element of one claim has priority, significance, or order over an element of another claim, or that the actions of the method are performed in a temporal order, but is merely used as a label to distinguish an element of a claim having a certain name from other elements having the same name, thereby distinguishing those elements of the claim.

Claims

1. A method for fabricating a fluid joint assembly, A step of forming a subassembly by connecting a plurality of flexible tubular conduits to a plurality of fluid fittings of a fluid joint, wherein the fluid joint has an inner fluid plenum chamber connected to the fluid fittings, and each fluid fitting has an outer circular bead having a diameter larger than the inner diameter of the associated tubular conduit, A step of sandwiching two flunking shells on either side of the subassembly, wherein the shells have a mating recessed receiving surface that fits integrally around each of the fluid fittings, and clamps the tubular conduit onto the circular bead and the adjacent joint surfaces that are in contact with each other, To fabricate the fluid distribution joint assembly, the steps include joining together the juxtaposed joint surfaces on each pair of mating recessed receiving surfaces, Methods that include...

2. The method according to claim 1, wherein the joining step includes applying pressure and ultrasonic vibration to the sandwiched shell and the subassembly.

3. The method according to claim 2, wherein each of the flunking shells has a bonding surface that contacts each other when the shells are sandwiched on both sides of the subassembly and pressed against each other, and the bonding surface on the first of the flunking shells has an energy concentrator along it.

4. The method according to claim 3, wherein the energy concentrator on the joint surface of the first flunking shell is a projection having a triangular cross-section.

5. The method according to claim 3, wherein the energy concentrator on the joint surface of the first flunking shell is a projection having a rectangular cross-section.

6. The method according to claim 2, wherein the steps of applying pressure and ultrasonic vibration include positioning the sandwiched shell and the subassembly on a base and pressing the ultrasonic horn downward onto the upper block of the sandwiched shell and the subassembly.

7. The method according to claim 6, wherein both the base and the block have nesting cavities that fit the lower surface of the lower shell and the upper surface of the upper shell, respectively.

8. The method according to claim 1, wherein the fluid joint comprises a first manifold having a central plenum chamber and at least four radially outward-directed fluid fittings that are in fluid communication with the plenum chamber.

9. The method according to claim 8, further comprising a second manifold having a central plenum chamber and at least four radially outward-facing fluid fittings in fluid communication with the plenum chamber, wherein the fluid distribution joint assembly comprises, stacked from top to bottom, an upper shell of the shell, the first manifold, a central shell of the shell, the second manifold, and a lower shell of the shell.

10. The method according to claim 9, wherein a pair of tubular conduits extend from the first manifold and the second manifold, each terminating at and connected to a port in a receptacle closure, such that one of the pair of conduits can supply fluid to the receptacle and the other of the pair of conduits can discharge gas from the receptacle.

11. The method according to claim 9, wherein the fluid distribution coupling assembly further includes a first central fluid connector coupled to the upper surface of the first manifold and a second central fluid connector coupled to the lower surface of the second manifold.

12. The method according to claim 9, wherein the coupling step comprises applying pressure and ultrasonic vibration to the sandwiched shell and the subassembly, each of the shells having a bonding surface that contacts each other when the shells are sandwiched around the first manifold and the second manifold and pressed against each other, and the bonding surface on the first shell of each pair of adjacent shells has an energy concentrator along it.

13. The method according to claim 1, wherein the fluid joint is selected from the group consisting of a straight joint, an elbow joint, a T-shaped joint, a Y-shaped joint, and a cross-shaped joint.

14. The method according to claim 13, wherein the joint for the reduced joint has fluid fittings of different sizes.

15. The method according to claim 13, wherein the circular beads are selected from the group consisting of round beads and barbed beads.

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