Pre-Assembled Fluid Junction Shells for Clean Conduit Attachment
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Solution Overview
Problem
Current fluid distribution systems for chemical and biological reactors are inefficient and prone to errors during assembly, requiring time-consuming and labor-intensive connection of flexible conduits to junctions, which can lead to contamination and worker injuries.
Innovation Solution
A pre-assembled fluid distribution junction system using flexible conduits connected to a junction with outer shells that are bonded using sonic welding, reducing assembly time and minimizing the risk of contamination by pre-attaching conduits to junctions before assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flexible conduits are connected to junctions manually in current systems, then assembly can be performed with simple tools, but assembly time is excessive and error-prone
Solution Approach 1:
The patent applies preliminary action by pre-assembling the flexible conduits to the junction bodies before final system assembly. The conduits are pre-attached to the junctions in a controlled manufacturing environment, allowing for optimized assembly procedures and reducing on-site assembly time and potential errors.
2Reliability
If manual assembly of conduits to junctions is performed, then flexibility in assembly location is maintained, but contamination risk and worker injury risk increase
Solution Approach 1:
The patent applies preliminary action by performing conduit attachment in a controlled manufacturing environment before system deployment. This pre-assembly approach minimizes contamination risks by conducting the procedure in a clean, controlled setting rather than in field conditions, and reduces worker safety risks by using automated or assisted assembly processes.
3Strength
If conventional bonding methods are used for shells, then assembly is straightforward, but bonding strength and sealing reliability are insufficient
Solution Approach 1:
The patent applies mechanical vibration through ultrasonic welding to bond the shells to the junction bodies. The ultrasonic vibration generates frictional heat at the interface between the thermoplastic shell and junction body, melting the materials and creating a strong, sealed bond that ensures both structural strength and fluid-tight sealing reliability.
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 pre-assembled system significantly reduces assembly time, minimizes the risk of contamination, and prevents worker injuries by securely attaching flexible conduits to junctions, enhancing the efficiency and safety of fluid distribution processes.
Implementation Method 1
When the ultrasonic energy is applied by the horn, the bonding shells melt at their joint surfaces and secure the flexible conduits to the fluid connectors
Implementation Method 2
Energy directors or concentrators such as narrow features along the joint surfaces of one of the shells facilitates rapid melting and good and reliable coupling of the shells
Data Source
AI summary
There is disclosed fluid distribution junctions and methods of assembly therefor. Flexible conduits connect to the junctions, and a consumable subsystem of the junction, conduits and receptacle caps or other connectors may be pre-assembled for ease of use. A subassembly is formed by coupling a plurality of flexible tubular conduits to a plurality of fluid connectors of a fluid junction, the fluid junction having an inner fluid plenum chamber leading to the fluid connectors. Two shells are sandwiched on opposite sides of the subassembly, the shells having mating concave receiving surfaces that together conform around each of the fluid connectors and clamp the tubular conduits onto the circular beads. Juxtaposed joint surfaces on each pair of mating concave receiving surfaces are bonded together such as with sonic welding to make the fluid distribution junction assembly.