Anesthetic Agent Containers With FSW-Healed Brazing Surfaces

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Solution Overview

Problem

Existing methods for manufacturing containers and manifolds for anesthesia machines using cast metal are limited by surface porosity, which prevents reliable oven brazing, leading to leaks and increased costs due to the need for extensive machining and higher-cost fabrication techniques.

Innovation Solution

The use of friction stir welding to process the mating surfaces of cast metal parts, eliminating porosity and enabling reliable oven brazing, allowing for cost-effective production of gas and liquid containers with complex passageways.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cast metal parts are used for manufacturing containers, then manufacturing cost is reduced and design flexibility is improved, but surface porosity prevents reliable oven brazing leading to leaks

Engineering Contradiction:

Improvemanufacturing cost and design flexibilityVSAvoidbrazing reliability and leak-free performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The friction stir welding process is applied to the mating surfaces of cast parts before brazing to pre-heal the porosity. This preliminary action eliminates the harmful porosity that would otherwise prevent reliable brazing, allowing cast parts to be used while maintaining brazing reliability and preventing leaks.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If cast metal parts with porosity are directly brazed, then manufacturing process is simplified, but brazing fails due to porosity causing leaks

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidbrazing success and leak-free performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

Friction stir welding is performed as a preliminary step before brazing to heal the porosity in the mating surfaces. This additional step eliminates porosity that would cause brazing failure, enabling reliable leak-free brazing of cast parts while maintaining overall process simplicity.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If porosity in cast mating surfaces is not treated, then manufacturing time is reduced, but oven brazing cannot be performed reliably requiring extensive machining

Engineering Contradiction:

Improvemanufacturing cycle timeVSAvoidsurface quality for brazing

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The friction stir welding process replaces the need for extensive mechanical machining to remove porosity. Instead of mechanically removing large amounts of material to achieve pore-free surfaces, the FSW process heals porosity in place, significantly reducing manufacturing cycle time while achieving the required surface quality for reliable brazing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If traditional machining is used to remove porosity, then brazing reliability is improved, but manufacturing cost and time increase significantly

Engineering Contradiction:

Improvebrazing reliabilityVSAvoidmanufacturing cost and time

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Friction stir welding replaces traditional mechanical machining methods for porosity removal. The FSW process heals porosity through plastic deformation and material flow, achieving the same brazing reliability as extensive machining would provide, but with significantly reduced cost and manufacturing time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method allows for the reliable joining of cast metal parts using oven brazing, reducing costs and improving manufacturing flexibility while ensuring leak-tight reservoirs for anesthesia machines, enabling the production of complex designs without excessive machining.

Implementation Method 1

processing the mating surface of the first part via friction stir welding to reduce the pores defined therein

Methodology Applied

Scientific EffectFriction stir welding: Friction Welding

Implementation Method 2

brazing the first part and the second part together such that the first mating surface of the first part is in contact with the second mating surface of the second part

Methodology Applied

Scientific EffectBrazing: Brazing

Data Source

PatentUS11958126B2Containers for retaining anesthetic agent and manufacturing methods thereof

Publication Date: 2024.04.16 GE PRECISION HEALTHCARE LLC

AI summary

A method for making a container for retaining anesthetic agent. The method includes creating two or more parts each having a mating surface, where the container is formed when the mating surfaces of the two or more parts are coupled together, and where a first part of the two or more parts is formed of a material having pores defined within the mating surface thereof. The method further includes processing the mating surface of the first part via friction stir welding to reduce the pores defined therein. The method further includes coupling the two or more parts together such that the mating surfaces contact to create the container configured to retain the anesthetic agent therein.