Encapsulated Pinch Valve Layout for Low-Residual Fluid Handling
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Solution Overview
Problem
Current fluid management and valving systems in pharmaceutical and biological applications are complex, cumbersome, and prone to cross-contamination, with significant residual volume issues leading to increased costs and product loss due to the need for sterilization and cleaning-in-place processes.
Innovation Solution
An encapsulated valve system featuring a disposable conduit sandwiched between two housing portions with pinch valve actuators, reducing organizational complexity and residual volume by using a disposable, un-reinforced silicone tubing that eliminates the need for sterilization and cleaning-in-place processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional fluid management systems with multiple conduits and valves are used, then fluid transport functionality is achieved, but system complexity and organizational complexity increase significantly
Solution Approach 1:
The system is divided into modular encapsulated valve units, each containing integrated conduits and valve elements. These modules can be independently configured and connected to create different fluid management configurations, reducing overall system complexity while maintaining functionality.
Solution Approach 2:
The encapsulated valve design integrates multiple functions (conduit, valve body, actuator mounting) into a single universal module that can handle various fluid transport tasks. This multi-functional module replaces multiple separate components, simplifying the overall system architecture.
2Reliability
If sterilization and cleaning-in-place processes are implemented, then cross-contamination is prevented, but processing time and operational complexity increase
Solution Approach 1:
The encapsulated valve system is designed as a disposable component that is sterilized once during manufacturing and then used without requiring cleaning or re-sterilization. After use, the entire unit is discarded, eliminating time-consuming CIP processes while ensuring cross-contamination prevention through single-use design.
3Reliability
If reinforced silicone tubing is used, then leakage prevention is improved, but flexibility and cost are worsened
Solution Approach 1:
The reinforcement elements are integrated directly into the silicone tubing manufacturing process, combining the flexibility of silicone with the leakage prevention of reinforcement in a single unified component. This eliminates the need for separate reinforcement layers or complex assembly while maintaining both flexibility and reliability.
4Volume of stationary object
If large residual volume in conduits is accepted, then system size is reduced, but product loss and cost increase significantly
Solution Approach 1:
The design extracts and eliminates unnecessary conduit volume by using direct, optimized fluid paths within the encapsulated valve structure. By removing redundant tubing and minimizing conduit dimensions while maintaining functional requirements, the system reduces residual volume and associated product loss.
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 encapsulated valve system simplifies fluid management, reduces residual volume, and decreases costs by eliminating the need for sterilization and cleaning-in-place processes, while maintaining high pressure ratings and flexibility through the use of un-reinforced silicone tubing.
Implementation Method 1
A plurality of pinch valve actuators are mounted on one or both of the first housing portion and the second housing portion, the plurality of pinch valve actuators configured to pinch the disposable conduit at selective branch pathways
Data Source
AI summary
An encapsulated valve system includes a first housing portion having a first facing surface, the first facing surface comprising a plurality of branch pathways formed as a recess within the first facing surface. The valve system further includes a second housing portion having a second facing surface, the second facing surface comprising a plurality of branch pathways formed as a recess within the second facing surface. A disposable conduit is configured to be interposed between the first and second housing portions and disposed within the recess of the first facing surface and the recess of the second facing surface. The disposable conduit is thus sandwiched between the first and second facing surfaces. A plurality of pinch valve actuators are mounted on one or both of the first housing portion and the second housing portion, the plurality of pinch valve actuators configured to pinch the disposable conduit at selective branch pathways.