Profile End Welding With Ionized Gas for Sterile Elastomer Joints

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Solution Overview

Problem

Existing technologies face challenges in effectively welding thermoset elastomeric materials, particularly when connecting two different profiles or materials, such as silicone elastomers, which cannot be melted and welded using conventional high-temperature methods, while also maintaining sterility.

Innovation Solution

The use of an ionized gas treatment to coincidentally weld the ends of two thermoset elastomer profiles, providing a sterile connection by exciting the molecular level of the materials and forming a strong, sterile weld without the need for external adhesives or heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional high-temperature welding methods are used, then thermoplastic materials can be welded effectively, but thermoset elastomeric materials cannot be welded because they cannot be melted

Engineering Contradiction:

ImproveweldabilityVSAvoidmaterial compatibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent changes the welding parameter from thermal energy (heat) to chemical energy (ionized gas/plasma). The ionized gas treatment activates the thermoset elastomer surfaces chemically, enabling bonding without melting, thus making thermoset materials weldable while maintaining their inherent properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal field (heat-based welding) with a chemical field (ionized gas treatment). This substitution allows thermoset elastomers to be joined without undergoing phase change, overcoming the limitation of conventional thermal welding methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If welding processes are used to connect two profiles, then a strong connection is achieved, but sterility is compromised during the welding process

Engineering Contradiction:

Improveweld strengthVSAvoidsterility maintenance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent merges the welding process with the sterilization process into a single ionized gas treatment step. The ionized gas simultaneously creates the weld bond and sterilizes the connection interface, achieving both strong connection and sterility maintenance without requiring separate processes.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ionized gas acts as an intermediary that performs dual functions: it activates the polymer surfaces for bonding while simultaneously sterilizing the materials. This intermediary enables both welding and sterilization without direct contact that would compromise sterility.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If different polymeric materials are welded, then material versatility is improved, but welding effectiveness deteriorates due to material incompatibility

Engineering Contradiction:

Improvematerial compatibilityVSAvoidwelding effectiveness

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent changes the bonding mechanism from thermal fusion (material-specific) to chemical activation (material-universal). The ionized gas treatment creates reactive sites on different polymeric materials that can form bonds across material types, enabling effective welding of dissimilar materials.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The ionized gas treatment provides a universal bonding mechanism that works across different polymeric materials including thermoset elastomers, thermoplastics, and rubbers. This multi-functional approach enables welding of diverse materials with a single process, achieving both versatility and effectiveness.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 ionized gas treatment effectively forms a sterile weld that withstands seal integrity pressure tests of up to 137.90 kPa (20 psi) for 30 minutes under both dry and wet conditions, maintaining sterility and providing a strong, reliable connection.

Implementation Method 1

the first end and the second end are coincidently welded via an ionized gas treatment to form a sterile coincident weld

Methodology Applied

Scientific EffectIonized gas treatment: Plasma

Implementation Method 2

providing a sterile connection between a treated surface of the first profile and a treated surface of the second profile

Methodology Applied

Scientific EffectIonized gas sterilization: Plasma

Data Source

PatentEP3993991B1Profile connection

Publication Date: 2025.05.21 SAINT GOBAIN PERFORMANCE PLASTICS CORP

Figure 1A~1B

AI summary

A connection including a first profile having a first end and a first lumen, the first profile including a first polymeric material and a second profile having a second end and a second lumen, the second profile including a second polymeric material, a metal, or combination thereof, wherein the first end and the second end are coincidently welded via an ionized gas treatment.