Cold-Welded Rupture Disk Sealing for Reusable Bioreactor Assemblies
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Solution Overview
Problem
In bioprocess systems, the need to replace elastomeric sealing members in rupture disk assemblies often requires replacing the entire assembly, leading to premature failure and increased maintenance costs, as the existing sealing members are not easily replaceable without substantial manipulation of the rupture disk.
Innovation Solution
A rupture disk assembly with a direct integral hermetic joint between the rupture membrane and the housing, formed by cold welding, eliminating the need for elastomeric sealing members and allowing for reuse of the assembly upon replacement of other sealing members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If elastomeric sealing members are used to seal the union of the rupture membrane and housing, then the assembly can be disassembled and reassembled, but the sealing members require periodic replacement and may lead to premature failure
Solution Approach 1:
The invention extracts and eliminates the elastomeric sealing member from the assembly, replacing it with a direct metal-to-metal seal between the rupture membrane and housing. This removes the component that requires periodic replacement while maintaining the ability to disassemble and reassemble the unit.
Solution Approach 2:
The invention changes the material interface from elastomer-to-metal to metal-to-metal, fundamentally altering the sealing mechanism. This parameter change eliminates the degradation issues associated with elastomeric materials while preserving operational flexibility.
2Reliability
If the entire rupture disk assembly is replaced when the elastomeric member fails, then seal integrity is maintained, but this leads to premature failure of serviceable components and increased costs
Solution Approach 1:
The invention segments the sealing function from the structural components by eliminating the elastomeric intermediary. The metal-to-metal seal allows the rupture membrane and housing to be independently serviced, enabling replacement of only the necessary component rather than the entire assembly.
Solution Approach 2:
The invention enables recovery and reuse of the rupture membrane and housing by eliminating the elastomeric sealing member that would otherwise require replacement of the entire assembly. The metal-to-metal seal allows these serviceable components to be retained and reused after maintenance.
3Ease of manufacture
If elastomeric sealing members are used, then initial sealing is achieved, but substantial manipulation is required for replacement which may cause premature failure of the rupture disk
Solution Approach 1:
The invention removes the elastomeric sealing member that creates maintenance complexity. The direct metal-to-metal seal eliminates the need for substantial manipulation during repair, allowing for simpler maintenance procedures that do not risk damaging the rupture disk.
4Duration of action of stationary object
If a direct integral hermetic joint is used between rupture membrane and housing, then replacement of sealing members is minimized and assembly lifespan is extended, but the initial assembly complexity increases
Solution Approach 1:
The invention merges the rupture membrane and housing into a direct integral assembly through cold welding, eliminating the separate elastomeric sealing component. While the initial joining process is more complex, the resulting unified structure eliminates ongoing maintenance needs and extends the assembly lifespan significantly.
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 solution minimizes the need for frequent replacement of rupture disk assemblies and reduces the risk of premature failure by providing a secure, metal-to-metal bond that maintains the seal between the rupture membrane and the housing, enabling efficient maintenance and extending the lifespan of the rupture disk.
Implementation Method 1
formed by cold welding, eliminating the need for elastomeric sealing members
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A rupture disk (10) includes a body (14) including an internal wall (32) extending from a first end of the body to a second end of the body. The internal wall defines an opening extending through the body. In some embodiments, the body further includes an internal flange (42) formed on the internal wall, and the internal flange has a stepped surface (44). A rupture membrane (40) is positioned within the body, and secured, for example, by cold welding. The rupture membrane may be secured to the stepped surface. The rupture membrane is positioned within the body such that the rupture membrane does not extend beyond the first end of the body. A process system including the rupture disk is also provided. A method of maintaining a process system that includes the rupture disk is also provided.