Segmented Sanitary Fitting Eliminates Welding and Contaminant Entrapment
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Solution Overview
Problem
The bio-pharmaceutical industry faces challenges in maintaining a clean and sanitary connection for fluid handling equipment, particularly due to difficulties with threaded fittings that can trap contaminants and are hard to clean, and the complexities of welding sanitary fittings which require precise machining and can lead to errors and rework.
Innovation Solution
A threaded sanitary fitting that eliminates the need for welds by using a non-threaded tubular insert with a gasket and fastener construction, which is screwed into a socket and includes O-rings to prevent contaminant entry, allowing for easy assembly and inspection without the need for welding or additional machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If threaded fittings are used for connection, then assembly is simplified, but contaminants can be trapped in threads and grooves making cleaning difficult
Solution Approach 1:
The fitting is divided into separate components: a body portion with external threads and a cap portion with internal threads. The gasket groove is segmented into two separate grooves located on different surfaces, preventing contaminant entrapment while maintaining threaded connection functionality.
Solution Approach 2:
The problematic single deep gasket groove is extracted and replaced with two separate shallower grooves positioned on different surfaces of the fitting body. This extraction eliminates the contaminant-trapping geometry while preserving the sealing function.
2Object-affected harmful factors
If welded sanitary fittings are used, then cleanability is improved, but complex machining and welding procedures are required
Solution Approach 1:
The fitting is segmented into removable body and cap portions that can be disassembled for cleaning. This eliminates the need for welding while maintaining cleanability, as the split design allows access to all internal surfaces including the gasket groove areas.
Solution Approach 2:
The fitting transitions from a static welded structure to a dynamic removable structure. The body and cap can be separated and reassembled, providing the cleanability benefits of welded fittings without the manufacturing complexity of welding operations.
3Reliability
If welded fittings are used, then sanitary standards are met, but welding errors require scrapping or re-machining of housing
Solution Approach 1:
The fitting is designed as a segmented assembly of body and cap portions that can be independently inspected and replaced. If welding errors occur during manufacturing, the entire fitting can be replaced without affecting the housing, eliminating the need for costly re-machining or scrapping.
Solution Approach 2:
The fitting is designed as a replaceable component rather than a permanent welded attachment. If manufacturing defects occur, the entire fitting can be replaced as a unit, treating it as a disposable component that protects the expensive housing from damage during error correction.
4Ease of operation
If threaded fittings are used, then installation is simplified, but threads are exposed to contaminants
Solution Approach 1:
The threaded connection is segmented into external threads on the body and internal threads in the cap. The gasket groove is also segmented and positioned on the body surface away from the threaded interface, preventing contaminant exposure to threads while maintaining installation simplicity.
Solution Approach 2:
The cap acts as an intermediary component that protects the internal threads from contaminant exposure. The cap's internal threads are shielded within the cap structure, while the body's external threads remain exposed but are separated from the gasket groove by the cap's positioning.
Data Source
AI summary
A sanitary fitting for biopharmaceutical equipment includes an elongate tubular insert having a main tubular section, which is cylindrical and terminates at an annular flange or annulus which seats at a bottom of a socket in an equipment housing. The bottom face of the annulus includes a groove, which receives a gasket that is compressed between the annulus and bottom face of the socket to prevent entry of fluids into this space. A threaded section of the socket is spaced outwardly of the smooth surfaced fitting so as to receive a threaded nut within such space. A threaded nut is slid down the fitting and engaged with the socket threads wherein the nut drives the socket into and retains the fitting tightly within the socket.