Fluid Distribution Junction Assembly Using Sonic-Welded Conduits
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Solution Overview
Problem
Current fluid distribution junctions for chemical and biological reactors are inefficient to assemble, prone to errors, and time-consuming, especially when connecting flexible conduits to junctions, which can lead to contamination and worker injuries.
Innovation Solution
A method involving pre-assembling flexible conduits with fluid connectors using sonic welding, where two shells sandwich the conduit-subassembly, and ultrasonic energy is applied to bond the components, ensuring a secure and sterile connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly of flexible conduits to junctions is used, then ease of operation is maintained, but assembly time increases and contamination risk increases
Solution Approach 1:
The patent applies preliminary action by pre-assembling the flexible conduits to the junction bodies in a controlled manufacturing environment before final installation. The conduits are pre-attached to the junction bodies using adhesive or ultrasonic welding, creating pre-assembled units that are then ready for quick installation at the destination, thereby reducing on-site assembly time and contamination risk
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated processes such as ultrasonic welding or adhesive bonding machinery. This substitution eliminates the need for manual connection of flexible conduits to junctions, significantly reducing assembly time and minimizing the risk of contamination from human handling
2Ease of operation
If manual connection of conduits is used, then flexibility in assembly is maintained, but worker safety deteriorates due to potential injuries
Solution Approach 1:
The patent applies preliminary action by pre-assembling the flexible conduits to the junction bodies in a controlled manufacturing environment before final installation. The conduits are pre-attached to the junction bodies using adhesive or ultrasonic welding, creating pre-assembled units that are then ready for quick installation at the destination, thereby reducing on-site assembly time and contamination risk
Solution Approach 2:
The patent replaces manual mechanical assembly operations with automated processes such as ultrasonic welding or adhesive bonding machinery. This substitution eliminates the need for manual connection of flexible conduits to junctions, significantly reducing assembly time and minimizing the risk of contamination from human handling
3Productivity
If traditional linear manifold assembly is used, then system simplicity is maintained, but fluid distribution efficiency deteriorates due to pressure equalization delays
Solution Approach 1:
The patent applies segmentation by dividing the fluid distribution system into multiple independent vertical junction bodies, each with its own plenum chamber and conduit connections. This segmentation allows each junction to independently distribute fluid to its connected receptacles without waiting for pressure equalization across the entire linear manifold, thereby improving fluid distribution speed and efficiency
Solution Approach 2:
The patent transitions from a horizontal linear manifold arrangement to a vertical three-dimensional configuration with multiple stacked junction bodies. This dimensional change allows fluid to be distributed vertically to multiple receptacles simultaneously from a single source, eliminating the sequential pressure equalization delays inherent in linear horizontal arrangements
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 method significantly reduces assembly time, minimizes contamination risk, and prevents worker injuries by providing a rapid, reliable, and cost-effective fluid distribution system.
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
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
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.