Fluid Distribution Junction Assembly for Sterile Conduit Joining
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Solution Overview
Problem
Current fluid distribution junctions and assembly methods are inefficient, time-consuming, and prone to errors, particularly in connecting flexible conduits to junctions, which can lead to contamination and increased costs.
Innovation Solution
The use of pre-assembled fluid distribution junctions with flexible conduits, where the conduits are sandwiched between two shells and bonded using sonic welding, creating a secure and sterile assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly of flexible conduits to junctions is used, then assembly flexibility is maintained, but assembly time increases and contamination risk increases
Solution Approach 1:
The flexible conduits are pre-assembled to the junctions in a controlled manufacturing environment before sterilization. This preliminary assembly allows the entire assembly to be autoclaved as one unit, eliminating the need for post-sterilization assembly and thereby preventing contamination while maintaining productivity.
Solution Approach 2:
The assembly process merges conduit connection with the sterilization cycle. By combining these operations into a single integrated process where conduits are attached before autoclaving, the system eliminates separate assembly steps that would increase contamination risk and assembly time.
2Loss of time
If pre-assembled junctions with conduits are used, then assembly time is reduced, but manufacturing complexity increases
Solution Approach 1:
The junctions are pre-assembled with conduits attached in a controlled manufacturing setting, transferring complexity from the end-use assembly to the manufacturing process. This allows complex connections to be made once during production rather than repeatedly during application, reducing assembly time while consolidating manufacturing complexity.
3Reliability
If conventional joining methods are used, then manufacturing simplicity is maintained, but connection reliability decreases
Solution Approach 1:
The thermoplastic components undergo phase transition during autoclaving, where heat softens the materials to enable bonding between conduits and junctions. This phase transition creates reliable thermal bonds that are stronger and more dependable than mechanical connections, while the process integrates seamlessly with the existing sterilization cycle.
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 method reduces assembly time, minimizes contamination risk, and lowers costs by providing a rapid, reliable, and sterile connection of conduits to junctions, enhancing the efficiency of fluid distribution systems.
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 are disclosed apparatus including 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.