Fluid Manifold Channel Layout to Eliminate Dead Zones
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Solution Overview
Problem
Fluid manifolds used in biopharmaceutical manufacturing often experience reduced performance due to inefficient fluid transport, leading to stagnant 'dead zones' near plugged pinholes, which impede the flow of media.
Innovation Solution
A fluid manifold design featuring a primary channel that is coterminous with a distal flow channel, where the distal support is integrated and forms an elbow bend without dead zones, enhancing fluid communication and flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a support pin is used to suspend the mandrel above the mold, then the mandrel can be properly positioned, but a pinhole is created that causes dead zones and reduced fluid flow
Solution Approach 1:
The invention removes the support pin from the system entirely. Instead of using a pin that creates a harmful pinhole, the mandrel is positioned using the mold structure itself (mandrel rest and positioning features integrated into the mold halves). This extracts the harmful element while preserving the positioning function.
Solution Approach 2:
The invention converts the potential harm of needing support (which creates pinholes) into a benefit by using the mold structure to provide support. The mold halves incorporate features like mandrel rests and positioning surfaces that support the mandrel without creating dead zones, turning a structural requirement into a flow-friendly design.
2Ease of manufacture
If the primary channel ends before the distal flow channel, then manufacturing is simpler, but dead zones are created causing stagnant fluid
Solution Approach 1:
The invention ensures continuous fluid flow action by making the primary channel coterminous with the distal flow channel. The primary channel extends all the way to the distal end where it seamlessly connects to the distal flow channel, eliminating any interruption or dead zone. This continuous geometry ensures fluid constantly moves through the entire channel length.
3Strength
If multiple manufacturing steps are used to plug pinholes, then structural integrity is maintained, but production time and complexity increase
Solution Approach 1:
The invention performs preliminary action by designing the mold and mandrel positioning system to prevent pinhole creation in the first place. The mandrel is positioned using integrated mold features before polymer injection, so no pinholes need to be plugged afterward. This preliminary positioning eliminates the need for subsequent plugging operations.
Solution Approach 2:
The invention merges the mandrel positioning function with the mold structure itself. The mandrel rest, positioning surfaces, and support features are integrated into the mold halves, combining multiple functions (support, positioning, and flow channel formation) into a single manufacturing step, eliminating separate plugging operations.
Data Source
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AI summary
A method of making a fluid manifold may include the use of a mold, a mandrel, and a distal support. A fluid manifold may include a primary channel, a plurality of secondary channels, and a distal channel, and the primary channel may be coterminous with the distal channel.