Sealed-Container Welding for Sterile Component Joining
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Solution Overview
Problem
Existing welding processes often require components to be manufactured in one location, shipped to another for sterilization and packaging, which complicates the manufacturing process and may expose components to contamination or hazards.
Innovation Solution
A welding process is performed within a sealed container, maintaining an isolated environment, using either ultrasonic or laser welding techniques, allowing sterilization and welding to occur at different locations, and enabling transportation of the welded components within the sealed container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are manufactured in one location and shipped to another for sterilization and packaging, then manufacturing specialization and efficiency are improved, but the risk of contamination and process complexity increase
Solution Approach 1:
The patent combines multiple previously separate operations (welding, sterilization, and packaging) into a single integrated process by performing welding inside a sealed sterilized container. This eliminates the need to ship components between locations for different operations, thereby maintaining manufacturing efficiency while eliminating contamination risks associated with multiple handling and shipping steps.
Solution Approach 2:
The container is sterilized before the components are inserted, and then sealed to maintain the sterile environment throughout the welding process. This preliminary sterilization action ensures that the components remain in a controlled, contamination-free environment from the start of the process through completion, eliminating the need for subsequent sterilization steps and associated shipping risks.
2Ease of manufacture
If welding is performed outside a sealed container, then the welding process is simpler and more accessible, but the risk of contamination and exposure to hazards increases
Solution Approach 1:
The sealed container serves as an intermediary environment that allows welding operations to be performed safely within a controlled space. The container walls act as a barrier that protects the external environment from welding hazards (such as sparks, fumes, and radiation) while still permitting the welding process to occur. This maintains ease of manufacture by using standard welding equipment while eliminating hazard exposure risks.
3Adaptability or versatility
If components are shipped between locations for different manufacturing steps, then specialized facilities can be used for each step, but transportation complexity and contamination risk increase
Solution Approach 1:
The patent merges multiple specialized operations (welding and sterilization/packaging) into a single location by performing welding inside the sterilized container. This eliminates the need for transportation between specialized facilities, thereby reducing transportation complexity while still allowing each operation to be performed with appropriate equipment and controls in one integrated setup.
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 maintains sterility and safety by ensuring welding occurs in a controlled environment, reducing contamination risks and enabling flexible, secure transportation of welded components.
Implementation Method 1
The welding device is an ultrasonic welder
Implementation Method 2
The welding device is a laser welder
Data Source
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.