Aseptic Connector Seals That Isolate Wetted Surfaces

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Solution Overview

Problem

Current aseptic coupling systems require multiple steps for connection and disconnection, have a large footprint, use metal or mechanisms that can damage or contaminate cells/media, and pose contamination risks due to exposed wetted sealing surfaces.

Innovation Solution

An aseptic coupling system with axially movable valve seal elements that keep wetted surfaces sealed off from the external environment in the uncoupled condition and ensure non-wetted surfaces are sealed off from the fluid flow path in the coupled condition, using elastomeric materials and spring-biased mechanisms to maintain sterility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If traditional aseptic coupling arrangements are used, then connection and disconnection can be achieved, but multiple steps are required and the footprint is large

Engineering Contradiction:

Improveconnection and disconnection operationVSAvoidnumber of steps and footprint

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent combines multiple functions (valve sealing, flow control, and connection sealing) into a single integrated connector body. The first connector integrates a valve seal, flow element, and sealing surfaces, while the second connector integrates a valve element, plunger seal, and corresponding sealing surfaces. This merging eliminates the need for separate sealing mechanisms and reduces the number of connection steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connector design provides multi-functionality where the same structural components serve multiple purposes. The valve seal and valve element not only control flow but also provide sealing surfaces. The flow element defines both the flow passage and works with the valve element to provide flow control. This universality reduces the overall device complexity and footprint.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If metal or mechanisms are used in the fluid path, then structural strength is provided, but cell or media damage and contamination can occur

Engineering Contradiction:

Improveconnector structural strengthVSAvoidcell or media damage and contamination

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The patent changes the material parameter from metal to elastomeric materials for all components in contact with the fluid path. The valve seal, valve element, plunger seal, and flow element are all made of elastomeric materials that provide sufficient structural strength while being non-reactive and non-damaging to cells and media. This parameter change eliminates the harmful effects of metal while maintaining necessary mechanical properties.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional sealing mechanisms are used, then connection sealing is achieved, but wetted sealing surfaces are exposed to the external environment creating contamination risk

Engineering Contradiction:

Improvesealing effectivenessVSAvoidcontamination risk from exposed wetted surfaces

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the sealing function from traditional exposed gaskets or O-rings and integrates it into the valve seal and valve element assembly. The valve seal is positioned such that it seals against the valve element, creating a sealed fluid path that is isolated from the external environment. The wetted surfaces of the valve seal and plunger seal are contained within the connector body, preventing exposure to contaminants.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The valve seal and valve element act as intermediary sealed barriers between the internal fluid path and the external environment. When the valve element is in the closed position, it creates a seal with the valve seal, and the flow element with its defined passage provides an additional sealed pathway. These intermediary elements ensure that wetted surfaces remain isolated from potential contamination sources.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The system provides aseptic coupling with reduced contamination risk, simplified connection/disconnection, and maintains sterility by isolating potentially contaminated surfaces from the fluid path, while using non-metal components to prevent damage.

Implementation Method 1

spring-biased mechanisms to maintain sterility

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12460759B2Aseptic coupling system with seal isolating connectors

Publication Date: 2025.11.04 NORDSON CORP

AI summary

An aseptic coupling system includes a first and second connectors having inboard mating portions, outboard terminal connections, first and second valve seals, and first and second valve elements. When the first and second connectors are joined in a coupled condition, the first and second valve elements are each moved from a shutoff position in sealing engagement with the first and second valve seals to a flow position separated from the first and second valve seals to permit flow therebetween, thereby defining a flow path between the outboard terminal connections. In the coupled condition, non-wetted surfaces of the first valve seal are sealed off from the flow path by sealing engagement with a flow passage defining annular wall of the second connector, and non-wetted surfaces of the second valve seal are sealed off from the flow path by scaling engagement with a flow passage defining annular wall of the first connector.