Plasma Sterile Welding for Thermoset Elastomer Joints
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Solution Overview
Problem
Traditional welding apparatuses fail to effectively join thermoset elastomers, such as silicone elastomer, with other polymeric materials, and maintaining sterility at the connection is challenging.
Innovation Solution
A plasma welding apparatus that applies a plasma treatment to the end contact surfaces of profiles to activate the materials, followed by aligning and forcing them into contact within a sterile environment, using a mechanical motion module to form a sterile connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional high temperature welding methods are used, then thermoplastic materials can be joined effectively, but thermoset elastomers cannot be joined and sterility cannot be maintained
Solution Approach 1:
The patent changes the fundamental welding parameter from thermal energy to plasma energy. The plasma welding apparatus uses plasma treatment to activate the surfaces of thermoset elastomers, enabling them to bond without melting or high temperature exposure. This parameter change allows the same welding process to effectively join both thermoplastic and thermoset materials, resolving the material compatibility limitation.
Solution Approach 2:
The patent replaces the traditional thermal welding mechanism with a plasma-based chemical activation mechanism. Instead of using heat to melt and fuse materials, the system uses plasma to create reactive surface groups that enable bonding at lower temperatures. This substitution allows thermoset elastomers, which cannot be melted, to be joined effectively while maintaining sterility.
2Strength
If high temperature welding is applied to join polymeric materials, then strong connections can be formed, but sterility is compromised
Solution Approach 1:
The patent changes the energy parameter from high temperature thermal energy to controlled plasma energy. The plasma welding process operates at temperatures that activate surface chemistry for bonding without reaching levels that would compromise sterility or damage the polymeric materials. This enables strong connections to form while maintaining the sterile environment.
Solution Approach 2:
The patent introduces plasma as an intermediary substance that facilitates bonding without direct thermal contact. The plasma treatment creates reactive groups on the material surfaces that enable strong chemical bonds to form at lower temperatures, avoiding the need for high temperature exposure that would compromise sterility.
3Productivity
If conventional welding methods are used, then simple material joining is achieved, but complex material combinations including thermoset elastomers cannot be joined
Solution Approach 1:
The patent creates a universal welding system that can handle multiple material types through plasma treatment. The plasma welding apparatus is designed to effectively join thermoplastic materials, thermoset elastomers, and other polymeric materials using the same plasma-based mechanism, eliminating the need for different welding processes for different material categories.
Solution Approach 2:
The patent uses plasma energy as a universal activation method that works across different material types. By changing from material-specific thermal parameters to a universal plasma chemical activation parameter, the system achieves both high productivity and broad material versatility, including the previously problematic thermoset elastomers.
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 apparatus efficiently joins a wide range of materials, including thermoset elastomers, maintaining sterility and forming a strong, sterile connection with tensile strength comparable to the unmodified materials.
Implementation Method 1
applying a plasma treatment to end contact surfaces of a first profile and a second profile
Implementation Method 2
applying a plasma treatment to end contact surfaces of a first profile and a second profile, preferably in a sterile environment
Data Source
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AI summary
Systems and methods are disclosed that include generating a plasma treatment and applying the plasma treatment to end contact surfaces of a first profile and a second profile in a sterile environment, manipulating at least one of the first profile and the second profile to force contact between the end contact surface of the first profile and the end contact surface of the second profile to permanently connect, join, or weld the end contact surfaces of the first profile and the second profile together, thereby forming a sterile connection between the first profile and a second profile.