Pre-Assembled Fluid Junctions for Sterile Conduit Connection
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Solution Overview
Problem
Current fluid distribution systems are inefficient and time-consuming to assemble, prone to errors, and can introduce contamination during the connection of flexible conduits to junctions in chemical and biological processing.
Innovation Solution
The use of pre-assembled fluid distribution junctions with flexible conduits, where the conduits are secured by sandwiching them between two shells and bonded using sonic welding, eliminating the need for separate assembly and reducing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If linear manifolds with cross and tee junctions are used for fluid distribution, then fluid can be distributed to multiple receptacles, but the assembly process becomes time-consuming and error-prone
Solution Approach 1:
The patent combines multiple junction connections into a single integrated assembly operation. The pre-assembled junction with multiple pre-attached conduits allows all fluid distribution connections to be made in one step rather than requiring sequential assembly of individual junctions, thereby reducing assembly time while maintaining the ability to distribute fluid to multiple receptacles
Solution Approach 2:
The conduits are pre-assembled and pre-positioned on the junction before final installation. This preliminary assembly of conduits to the junction creates a ready-to-install unit that reduces on-site assembly time and minimizes errors during installation, while still providing the necessary adaptability for fluid distribution to multiple destinations
2Adaptability or versatility
If flexible conduits are connected to junctions during assembly, then fluid distribution flexibility is achieved, but contamination risk increases
Solution Approach 1:
The flexible conduits are pre-connected to the junction in a controlled manufacturing environment where sterile conditions can be maintained. This preliminary assembly allows the conduits to be attached to the junction before final installation at the use site, reducing the number of assembly steps performed in potentially contaminated environments and minimizing contamination risk while preserving connection flexibility
Solution Approach 2:
The pre-assembled junction with integrated conduits can be designed as a disposable sterile unit. After use, the entire assembly is discarded rather than disassembled and cleaned, ensuring that no contamination risk remains from repeated assembly/disassembly cycles. This approach maintains conduit flexibility during the product's service life while eliminating long-term contamination concerns
3Adaptability or versatility
If multiple separate junctions are assembled to distribute fluid, then fluid can reach various destinations, but assembly complexity increases
Solution Approach 1:
The patent merges multiple junction functions into a single integrated junction body with multiple pre-attached conduits. Instead of assembling separate junctions and conduits individually, the design combines all connection points and fluid distribution pathways into one unified component that can be installed as a single unit, reducing assembly complexity while maintaining the ability to reach various fluid destinations
4Ease of operation
If conventional assembly methods are used for fluid junctions, then flexibility in conduit connection is achieved, but assembly efficiency decreases
Solution Approach 1:
The conduits are pre-positioned and pre-connected to the junction in the correct orientations and positions during manufacturing. This preliminary action eliminates the need for complex alignment and connection operations during final assembly, making the installation process simpler and more efficient while maintaining the flexibility needed for proper conduit connection
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 method significantly reduces assembly time, minimizes errors, and ensures a sterile environment by providing a pre-assembled, easily integrated fluid distribution system that is cost-effective and reduces the risk of contamination.
Implementation Method 1
When the ultrasonic energy is applied by the horn, the bonding shells melt at their joint surfaces and secure the flexible conduits to the fluid connectors
Implementation Method 2
Energy directors or concentrators such as narrow features along the joint surfaces of one of the shells facilitates rapid melting and good and reliable coupling of the shells
Data Source
AI summary
There are disclosed apparatus including fluid distribution junctions and methods of assembly therefor. Flexible conduits connect to the junctions, and a consumable subsystem of the junction, conduits and receptacle caps or other connectors may be pre-assembled for ease of use. A subassembly is formed by coupling a plurality of flexible tubular conduits to a plurality of fluid connectors of a fluid junction, the fluid junction having an inner fluid plenum chamber leading to the fluid connectors. Two shells are sandwiched on opposite sides of the subassembly, the shells having mating concave receiving surfaces that together conform around each of the fluid connectors and clamp the tubular conduits onto the circular beads. Juxtaposed joint surfaces on each pair of mating concave receiving surfaces are bonded together such as with sonic welding to make the fluid distribution junction assembly.