Integrated Pinching and Heating for Thermoplastic Hose Welding
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Solution Overview
Problem
The existing welding and metering devices for thermoplastic hoses require separate steps and additional equipment for welding, leading to increased costs and hygienic risks, especially in the medical and biotech industries where aseptic conditions are crucial.
Innovation Solution
A welding device with a movable pinching jaw actuated by a controllable bidirectional actuator and a heating device integrated with the metering device, allowing for adjustable pinching pressure and temperature control to weld the hoses directly during the metering process, eliminating the need for separate welding steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate welding equipment and steps are used to weld thermoplastic hoses, then welding function is achieved, but device complexity and cost increase
Solution Approach 1:
The patent combines the welding device with the metering device by integrating a heating device into the pinching device. The pinching device that already exists in the metering device is enhanced with heating capability, allowing both metering and welding functions to be performed by a single integrated system, thereby reducing device complexity and eliminating the need for separate welding equipment.
Solution Approach 2:
The pinching device is transformed into a multi-functional component that can perform both metering control (by adjusting pinching pressure) and welding (by applying heat). This universal device replaces what were previously two separate functions requiring separate equipment, simplifying the overall system while maintaining both capabilities.
2Ease of manufacture
If separate welding steps are performed after metering, then welding is achieved, but processing time and productivity are reduced
Solution Approach 1:
The welding operation is merged with the metering operation into a single integrated process. The heating device is activated during or immediately after the metering process, allowing the hose to be welded in place without requiring removal or transfer to separate welding equipment, thereby eliminating additional processing time and improving productivity.
Solution Approach 2:
The heating device is integrated into the pinching device structure, allowing welding preparation and execution to occur in advance or during the metering process itself, rather than as a subsequent separate step. This preliminary integration of the welding function into the existing metering workflow eliminates idle time between operations.
3Ease of manufacture
If separate welding equipment is used, then welding function is provided, but hygienic risks increase in aseptic environments
Solution Approach 1:
By merging the welding function into the existing metering device that operates within the aseptic environment, the welding process occurs in the same controlled hygienic zone without requiring external equipment entry. This eliminates potential contamination risks associated with introducing separate welding equipment into or near the sterile field.
Solution Approach 2:
The integrated heating device serves as an intermediary that enables welding through thermal energy rather than mechanical contact or external energy sources that might compromise sterility. This intermediary approach allows welding to occur within the sealed, controlled environment without exposing the hose to external contaminants.
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 solution enables efficient and hygienically safer welding of thermoplastic hoses, reducing costs and hygienic risks by integrating the welding process into the metering operation, ensuring the hoses are permanently sealed and sterilized without additional equipment or steps.
Implementation Method 1
the pinching device has a heating device, which is coupled to a control unit and is configured to heat the hose pinched between the pinching jaws
Implementation Method 2
a volumetric flow rate of the medium can be controlled by controlling a pinching pressure that is exerted on the connecting hose by the pinch valve at a pinching point
Implementation Method 3
The pinching pressure that is constant during the entire process is so high that it completely closes the free lumen of the hose at the pinching point
Data Source
AI summary
A welding device for the sealing welding of thermopolastic hoses (184), includes a clamping device (12) with at least two clamping jaws (122, 124), of which at least one is movable and between which a hose (184) which is to be welded can be clamped, wherein the clamping device (12) has a heating devices (38; 40; 64) which is coupled to a control unit (30) and is configured to heat the hose clamped between the clamping jaws (122, 124). The invention is distinguished in that the at least one movable clamping jaw (122) is actuable with a controllable, bidirectional actuator (32, 34; 42-52; 54, 56, 58) which is coupled to the control unit (30) in such a manner that the clamping pressure acting on the hose (184) can be adjusted independently of the heating device.