Aseptic Fluid Coupling Assembly for No-Spill Disconnection
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Solution Overview
Problem
Existing fluid coupling devices in bioprocessing systems face challenges in aseptic disconnection, leading to potential biological contamination and fluid spillage during disconnection, which requires sterile environments and can be costly and inefficient.
Innovation Solution
The development of single-use aseptic fluid coupling devices with a specific disconnection sequence that involves a removable sleeve, rotational and translational steps, and internal valves to irreversibly block fluid paths, preventing reconnection and minimizing spillage by ensuring mechanical sealing during disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid coupling devices are used for disconnection, then operational simplicity is maintained, but biological contamination and fluid spillage occur during disconnection
Solution Approach 1:
The coupling device is divided into two separate coupling halves (first coupling half and second coupling half) that can be disconnected from each other. Each coupling half contains its own fluid path and sealing mechanism, allowing independent sealing during disconnection. This segmentation enables aseptic disconnection by ensuring that each half can seal its fluid path independently, preventing contamination and spillage.
Solution Approach 2:
The sealing mechanism is activated before complete disconnection occurs. As the coupling halves separate, the sealing elements (such as seals or valves) automatically close the fluid paths in advance, preventing fluid leakage and contamination before the connection is fully broken. This preliminary sealing action ensures aseptic conditions are maintained throughout the disconnection process.
2Reliability
If sterile environments (sterile rooms) are used for disconnection, then contamination is prevented, but operational cost and complexity increase
Solution Approach 1:
The coupling device performs its own sealing and protection function during disconnection without requiring external sterile environment infrastructure. The built-in sealing mechanisms (seals, valves, or closing elements) automatically activate to prevent contamination, making the system self-sufficient for maintaining sterility. This eliminates the need for sterile rooms or specialized cleanroom facilities, improving operational efficiency and reducing costs.
3Reliability
If mechanical sealing is implemented during disconnection, then fluid spillage is prevented, but device complexity increases
Solution Approach 1:
The sealing function is merged with the existing coupling structure rather than being added as a separate complex subsystem. The sealing elements (such as elastomeric seals, O-rings, or valve components) are integrated into the coupling halves themselves, combining the connection and sealing functions in a unified structure. This integration minimizes additional complexity while ensuring reliable fluid path closure during disconnection.
4Reliability
If single-use design is implemented, then contamination risk is reduced, but device cost increases
Solution Approach 1:
The coupling device is designed as a single-use disposable component that can be discarded after one connection cycle. This eliminates the need for complex sterilization procedures between uses and ensures that no contamination risk remains after disposal. The coupling halves and their sealing mechanisms are designed to be inexpensive enough to justify single-use deployment, trading component reusability for guaranteed contamination prevention and simplified operational workflows.
Data Source
AI summary
Some fluid coupling devices described herein are configured for use in fluid systems for purposes of providing a single-use, aseptic disconnection functionality that substantially prevents fluid spillage when being disconnected. In some embodiments, the coupling portions cannot be functionally reconnected to each other after being disconnected from each other.