Anti-Run-Dry Membrane Welding for IV Drip Units
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Solution Overview
Problem
Current intravenous delivery systems face challenges in efficiently removing air bubbles, which can lead to serious patient injuries, and existing air filtering membranes pose manufacturing difficulties due to melting point disparities and increased complexity and cost.
Innovation Solution
An intravenous delivery system with an anti-run-dry membrane made of hydrophilic materials with specific pore sizes, secured using laser or ultrasonic welding techniques, allowing for effective air exclusion while accommodating melting point differences between membrane and seat materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air filtering membranes are used in intravenous delivery systems, then air bubble removal is improved, but manufacturing complexity and cost increase due to melting point disparities
Solution Approach 1:
The patent introduces a membrane support structure as an intermediary component between the membrane and the drip chamber. This support structure has a melting point compatible with both the membrane material and the drip chamber material, serving as a mediator that enables welding connections without the melting point disparity problem. The support structure is welded to the drip chamber using the first welding process, and the membrane is then attached to the support structure using a second welding process, with each welding process using parameters appropriate for the specific materials involved.
2Reliability
If air filtering membranes are used in intravenous delivery systems, then air bubble removal is improved, but manufacturing cost increases
Solution Approach 1:
The patent segments the membrane assembly into three separate components: the membrane itself, the membrane support structure, and the drip chamber. This segmentation allows each component to be manufactured independently using materials and processes optimized for that specific component, rather than requiring a single complex integrated structure. The support structure acts as a separate element that facilitates easier and more cost-effective manufacturing by bridging the melting point gap between the membrane and drip chamber materials.
3Strength
If traditional welding processes are used to attach membrane to drip chamber, then attachment strength is improved, but melting point differences cause manufacturing failures
Solution Approach 1:
The membrane support structure serves as a mediator in the welding process. It is welded to the drip chamber using a first welding process with parameters suitable for the drip chamber material, and the membrane is then welded to the support structure using a second welding process with parameters suitable for the membrane material. This intermediary approach allows each welding operation to use optimized parameters for the specific materials being joined, ensuring strong attachments while avoiding the problems caused by direct welding between materials with disparate melting points.
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 anti-run-dry membrane effectively prevents air from entering the tubing, reducing the risk of air embolism and simplifying the manufacturing process by ensuring secure attachment without melting point issues, thus enhancing system reliability and reducing manufacturing complexity and cost.
Implementation Method 1
The anti-run-dry membrane may be formed of a hydrophilic material, and may have a plurality of pores that permit the liquid to flow through the anti-run-dry membrane, while resisting passage of air through the anti-run-dry membrane
Implementation Method 2
The anti-run-dry membrane may be secured to a seat formed on an exterior wall of the drip unit through the use of a welding process, such as laser welding or ultrasonic welding
Implementation Method 3
The anti-run-dry membrane may be secured to a seat formed on an exterior wall of the drip unit through the use of a welding process, such as laser welding or ultrasonic welding
Data Source
Figure 1
Figure 2~3
Figure 4~6B
AI summary
An intravenous delivery system (100) may have a liquid source (102) containing a liquid (122), tubing (106), and an anti-run-dry membrane (136, 320, 420, 720) positioned such that the liquid (122), flowing form the liquid source (102) to the tubing (106), passes through the anti-run-dry membrane (136, 320, 420, 720). The anti-run-dry membrane (136, 320, 420, 720) may be positioned within an exterior wall (133, 310, 410, 710, 1110) of a drip unit (134, 300, 400, 700, 1100), and may have a weld surface (346, 446, 746) secured to a seat (334, 434, 734, 1134) of the exterior wall (133, 310, 410, 710, 1110) via application of compression to press the weld surface (346, 446, 746) against the seat (334, 434, 734, 1134), and application of coherent light (352) or vibration. In response to application of the coherent light (352) or vibration, localized melting may occur, causing the weld surface (346, 446, 746) to adhere to the seat (334, 434, 734, 1134). The anti-run-dry membrane (136, 320, 420, 720) may be modified to have a melting point close to that of the seat (334, 434, 734, 1134). Ultrasonic or laser welding may be applied in a manner that causes portions of the seat (334, 434, 734, 1134) to melt and flow into pores (138) of the weld surface (346, 446, 746).