Rotary Aseptic Coupler With Integrated Valve Sealing
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Solution Overview
Problem
Existing aseptic coupling systems for fluid lines in bioprocessing and blood handling systems are complex and often result in excessive fluid leakage when disconnected, leading to potential biological contamination, necessitating additional clamping devices to prevent exposure.
Innovation Solution
A rotary coupling device with a first and second connector housing, each with a rotary valve segment that rotates to align or block fluid conduits, ensuring aseptic connection and disconnection while maintaining sterility by forming a tight seal, allowing components to be separated without exposing inner openings to the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional aseptic coupling systems are used, then fluid connection between components is achieved, but excessive fluid leakage occurs during disconnection leading to potential biological contamination
Solution Approach 1:
The rotary valve is rotated to the closed position before disconnecting the coupling, preliminarily blocking the fluid pathway and preventing fluid leakage during the disconnection process. This preliminary action ensures that no fluid can escape into the environment when the coupling is separated.
Solution Approach 2:
The valve mechanism is extracted and integrated directly into the coupling device, allowing independent control of fluid flow separate from the connection/disconnection action. This enables the valve to be closed before disconnection, eliminating the fluid leakage problem inherent in conventional couplings.
2Device complexity
If conventional aseptic coupling systems are used, then fluid connection is achieved, but additional clamping devices are required to prevent fluid exposure
Solution Approach 1:
The valve mechanism is merged with the coupling device, integrating flow control and connection/disconnection functions into a single unified device. This eliminates the need for separate clamping devices while maintaining sterility, as the integrated valve can be closed before disconnection.
Solution Approach 2:
The coupling device is designed with multi-functionality, incorporating both the connection/disconnection function and the flow control function through the integrated rotary valve. This universal design eliminates the need for additional specialized components like clamping devices.
3Ease of operation
If the rotary valve is rotated to align fluid conduits for connection, then fluid pathway is established, but the valve must be precisely positioned to maintain seal
Solution Approach 1:
The valve segments and connector housings feature asymmetric designs with complementary shapes that guide the rotary valve to its correct positioned. The asymmetric geometry ensures proper alignment during rotation while maintaining reliable sealing, reducing the need for high manufacturing precision.
Solution Approach 2:
The valve segments and connector surfaces incorporate curved and cylindrical geometries that facilitate smooth rotation and self-alignment. The curved surfaces guide the valve into the correct position during rotation, reducing sensitivity to manufacturing tolerances and improving ease of operation.
Data Source
Figure 1~2
Figure 2A
Figure 3~4
AI summary
A coupler for aseptically coupling and controlling fluid communication between at least two components. The coupler includes a first connector housing with an inner concave surface. A first connector extends from the top of the first connector housing and is adapted to connect to a first component. A first connector conduit extends through the first connector and into the first connector housing so as to define a fluid passageway to an inner opening on the inner surface of the first connector housing. A rotary valve is located within an inner cavity of the first connector housing and includes at least two rotary valve segments. The rotary valve segments are configured to rotate within the cavity. At least one of the rotary valve segments includes a fluid conduit extending through the at least one rotary valve segment.