Aseptic Fluid Coupling Membranes for Sterile Single-Use Connections
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Solution Overview
Problem
Existing fluid coupling devices for bioprocessing and blood handling systems often require sterile connections, which can be challenging to maintain without contamination, especially in non-sterile environments.
Innovation Solution
The development of aseptic fluid coupling devices with removable membrane strips that protect the interior from contamination before use, and a method of attaching membranes using a membrane bonding tool that minimizes tension stress, ensuring secure and sterile connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid coupling devices are used without protective membranes, then the coupling process is simpler and faster, but the interior of the coupling device becomes contaminated during connection
Solution Approach 1:
A protective membrane is pre-installed over the interior cavity and seal member of the coupling device before use. This preliminary protective action prevents contamination during the coupling process, allowing the device to maintain sterility without requiring complex sterile handling procedures or environments.
Solution Approach 2:
The protective membrane acts as an intermediary barrier between the sterile interior of the coupling device and the non-sterile external environment. This intermediate layer allows connection to occur without direct exposure of critical surfaces to contaminants, resolving the contradiction between simplicity and sterility maintenance.
2Reliability
If membrane strips are attached directly to the coupling device surface without deflection, then the bonding process is simpler, but tension stress causes premature detachment
Solution Approach 1:
The bonding tool includes a protruding portion that deflects the membrane into the interior cavity along the z-axis (depth dimension) before heating. This dimensional change allows the membrane to be bonded in a relaxed state without tension stress, preventing premature detachment while maintaining attachment security.
Solution Approach 2:
The bonding process replaces simple surface contact with a three-step mechanical sequence: deflection into the cavity, compression against the seal member, and thermal bonding. This substituted mechanical approach eliminates tension stress while ensuring secure attachment.
3Strength
If the membrane is bonded with high compression force, then the bond strength is higher, but the membrane detaches from the seal member
Solution Approach 1:
The membrane is nested within the interior cavity during bonding, with the cavity walls and seal member providing containment. This nested configuration allows compression bonding to occur without the membrane being pushed outward, preventing detachment while achieving strong adhesion to the intended surface.
Solution Approach 2:
The interior cavity serves as a cushioning chamber that absorbs and distributes compression forces during bonding. This beforehand cushioning prevents excessive force from pushing the membrane off the seal member, allowing strong bonding to occur without compromising retention.
4Ease of manufacture
If gendered couplings (male/female) are used, then the connection geometry is simpler, but inventory management becomes more complex
Solution Approach 1:
The coupling device is designed with universal, genderless features that allow it to connect with any other coupling of the same type regardless of orientation or specific geometry variations. This universal design simplifies inventory management by requiring only one type of coupling component while maintaining ease of manufacture through standardized features.
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 aseptic fluid coupling devices provide a secure, single-use connection that maintains sterility, reducing the need for sterile rooms and allowing for efficient and cost-effective operations, while also simplifying inventory and usage with genderless couplings.
Implementation Method 1
The heating ring may apply heat to the membrane to create the bond.
Implementation Method 2
after deflecting the membrane, compressing the membrane between the heating ring and the surface to create a bond between the membrane and the surface
Data Source
AI summary
Aseptic fluid coupling devices can be used for fluid systems and manufacturing processes that require sterilized fluid flow pathways. For example, aseptic fluid coupling devices that include removable membrane strips that protect the interior of the aseptic fluid coupling devices from contamination prior to use can be used in such contexts. Methods for attaching removable membranes to the aseptic fluid coupling devices can include heat sealing using a protruding die that reduces the resultant tension of the removable membranes.