Sealed-Container Welding for Sterile Component Isolation
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Solution Overview
Problem
Current methods for welding sterile or hazardous components often require separate locations for manufacturing, sterilization, and packaging, which can be inefficient and expose the components to non-sterile or hazardous environments during transportation.
Innovation Solution
A welding process that involves inserting work pieces into a sealed container, which is then placed into a welding device, allowing for either ultrasonic or laser welding to be performed within the container, maintaining an isolated environment and enabling sterilization and welding to occur at different locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If components are manufactured in one location and shipped to another for sterilization and packaging, then manufacturing specialization can be achieved, but components are exposed to non-sterile environments during transportation
Solution Approach 1:
The patent combines sterilization, packaging, and welding operations into a single integrated process that occurs within a sealed container. The container serves multiple functions: it maintains sterile isolation, enables welding through laser or ultrasonic energy transmission, and protects components during transportation. This merging eliminates the need to ship components between separate manufacturing and sterilization locations.
2Ease of operation
If welding is performed outside a sealed container, then welding equipment can access work pieces directly, but the isolated sterile environment is compromised
Solution Approach 1:
The sealed container acts as an intermediary medium that transmits welding energy (laser or ultrasonic) from the welding device to the work pieces while maintaining sterile isolation. The container material is selected to be transparent or transmissive to the welding energy, allowing the welding process to occur through the container wall without compromising the sterile environment inside.
3Ease of manufacture
If multiple separate locations are used for sterilization and welding, then each process can be optimized independently, but process time and transportation requirements increase
Solution Approach 1:
The patent merges sterilization, packaging, and welding into a single integrated process performed within the sealed container. The container is sealed in a sterile environment, and welding is then performed through the container wall without breaking the sterile seal. This eliminates transportation time and allows both sterilization and welding to be optimized within the same isolated system.
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 approach ensures that welding can be performed in a controlled, sterile, or hazardous environment without exposing the components to external contamination, improving efficiency and safety by maintaining the integrity of the sealed container throughout the process.
Implementation Method 1
performing one of an ultrasonic or a laser weld on the at least one work piece
Implementation Method 2
performing one of an ultrasonic or a laser weld on the at least one work piece
Data Source
Figure 1~2
Figure 3
Figure 4A
AI summary
A welding process includes inserting two work pieces inside a sealable container. Placing the container with the two work pieces inside into a welding device and welding the two members together while inside the container.