Fluid flow conduits and apparatus and methods for making and joining fluid conduits

• US 9,199,070 B2
• Filed: 12/12/2012
• Issued: 12/01/2015
• Est. Priority Date: 12/21/2011
• Status: Active Grant

• Current Assignee: Fenwal Incorporated (Fresenius SE & Co. KGaA)
• Original Assignee: Fenwal Incorporated (Fresenius SE & Co. KGaA)
• Inventors: Wegener, Christopher, Min, Kyungyoon, Brierton, Mark, Kusters, Benjamin, Madsen, James, Cork, William H.
• Primary Examiner(s): Crispino, Richard
• Assistant Examiner(s): Bradford, Elizabeth
• Application Number:
  US14/110,010
• Publication Number:
  US 20140034230A1
• Time in Patent Office: 1,084 Days
• Field of Search: 156/273.9, 156/256, 156/296, 156/304.2, 156/304.6, 156/308.4
• US Class Current: 1/1
• CPC Class Codes: A61M 39/14 for connecting tubes having sealed ends needle sets A61M5/162; having valves closing automatically on disconnection of line A61M39/26
• CPC Class Codes: A61M 39/143 both tube ends being sealed by meltable membranes pierced after connection by use of heat, e.g. using radiant energy
• CPC Class Codes: B29C 65/022 Particular heating or welding methods not otherwise provided for
• CPC Class Codes: B29C 65/2015 being a single welding mirror comprising several separate heating surfaces in different planes, e.g. said heating surfaces having different temperatures
• CPC Class Codes: B29C 65/203 being several single mirrors, e.g. not mounted on the same tool
• CPC Class Codes: B29C 65/30 Electrical means B29C65/38 takes precedence
• CPC Class Codes: B29C 65/32 Induction
• CPC Class Codes: B29C 65/3444 being a ribbon, band or strip
• CPC Class Codes: B29C 65/3456 being a layer of a multilayer part to be joined, e.g. for joining plastic-metal laminates
• CPC Class Codes: B29C 65/36 heated by induction
• CPC Class Codes: B29C 65/3644 being a ribbon, band or strip
• CPC Class Codes: B29C 65/3656 being a layer of a multilayer part to be joined, e.g. for joining plastic-metal laminates
• CPC Class Codes: B29C 65/4855 characterised by their physical properties, e.g. being electrically-conductive
• CPC Class Codes: B29C 65/5021 being multi-layered
• CPC Class Codes: B29C 65/5057 positioned between the surfaces to be joined B29C65/5035 takes precedence
• CPC Class Codes: B29C 65/58 Snap connection
• CPC Class Codes: B29C 65/72 by combined operations or combined techniques, e.g. welding and stitching
• CPC Class Codes: B29C 65/7841 Holding or clamping means for handling purposes clamping means for the purpose of applying pressure on the parts to be joined, in the area to be joined B29C66/81; work holders in general B25B; devices for holding or positioning work for welding metal B23K37/04
• CPC Class Codes: B29C 66/0342 Cooling, e.g. transporting through welding and cooling zone
• CPC Class Codes: B29C 66/1142 Single butt to butt joints
• CPC Class Codes: B29C 66/3494 : while keeping the welding zone under pressure
• CPC Class Codes: B29C 66/5221 : for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other
• CPC Class Codes: B29C 66/5223 : for forming corner connections or elbows, e.g. for making V-shaped pieces
• CPC Class Codes: B29C 66/52298 : said socket being composed by several elements
• CPC Class Codes: B29C 66/5346 : said single elements being substantially flat
• CPC Class Codes: B29C 66/5414 : said substantially flat extra element being rigid, e.g. a plate B29C66/5416 takes precedence
• CPC Class Codes: B29C 66/543 : joining more than two hollow-preforms to form said hollow articles
• CPC Class Codes: B29C 66/71 : characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/72321 : consisting of metals or their alloys
• CPC Class Codes: B29C 66/73115 : Melting point
• CPC Class Codes: B29C 66/73141 : Electrical conductivity
• CPC Class Codes: B29C 66/857 : Medical tube welding machines
• CPC Class Codes: B29C 66/91231 : of the joining tool
• CPC Class Codes: B29C 66/91421 : of the joining tools
• CPC Class Codes: B29C 66/91651 : by controlling or regulating the heat generated by Joule heating or induction heating
• CPC Class Codes: B29C 66/919 : characterised by specific temperature, heat or thermal flux values or ranges specific electrical resistance values B29C66/81262
• CPC Class Codes: B29C 66/91933 : higher than said fusion temperature
• CPC Class Codes: B29C 66/949 : characterised by specific time values or ranges
• CPC Class Codes: B29C 66/954 : by measuring or controlling the thickness of the parts to be joined
• CPC Class Codes: B29K 2023/12 : PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/06 : PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2067/003 : PET, i.e. poylethylene terephthalate

Abstract

Fluid flow conduits (14a, 14b) and apparatus (40) and methods for joining the conduits (14a, 14b), preferably in a sterile manner, are disclosed. Each conduit (14, 14b) has a polymeric open end that is sealed by a sealing member (26a, 26b) that may include a heating element (28). The polymeric end material is melted, the sealing members (26a, 26b) are moved to expose the melted open ends of the conduits (14a, 14b) and the ends are brought together to form a fused or welded connection (12) between the conduits (14a, 14b).

Claims

1. A method of joining first and second fluid flow circuits to form a fluid flow circuit assembly, each fluid flow circuit including a fluid flow conduit with a lumen and an open end terminating in a polymeric material and a sealing member attached to the flow conduit and sealing the open end thereof, and at least one of the sealing members including at least one single-use heating element as a pre-assembled composite part of the sealing member prior to joining;

(a) melting the polymeric material of the open ends by heating the at least one heating element;

(b) relatively separating the sealing members and the respective open ends to which they are sealed to expose the open ends; and

(c) bringing the exposed open ends together while melted to form a junction between the fluid flow circuits that allows fluid flow therebetween.

2. The method of claim 1 wherein each of the sealing members comprises a panel attached to the open polymeric end of the respective conduit and at least one of the panels comprises a metallic layer defining the heating element, the method including:

positioning the polymeric ends of the conduits generally in axial alignment and with the respective panels in face to face contact,

heating the metallic layer sufficiently to melt the polymeric material of the open end of each conduit,

separating the sealing members and the open ends by laterally separating the panels from between the polymeric ends while the polymer is melted while applying an axial compressive force to the conduits so as to substantially simultaneously bring the open ends together as the panels are separated from between the conduits; and

cooling the molten ends while maintaining the axial compressive force to form a junction between the fluid conduits that allows fluid flow therebetween.

3. The method of claim 2 in which the conduits are held generally laterally stationary during heating and the panels are moved laterally from between the conduits.

4. The method of claim 2 in which the metallic layer is electrically conductive and heated by an inductive electrical power source operating at a selected electrical frequency and the metallic layer has a thickness not substantially greater than the skin depth for such metal at such frequency.

5. The method of claim 2 in which the fluid flow circuits are pre-sterilized, and the panels and the open ends are separated relative to one another and the melted ends are compressed together while maintaining the sterility of the fluid flow circuits.

6. The method of claim of 2 in which the metallic layer comprises a material that exhibits an antimicrobial property.

7. The method of claim 2 in which the metallic layer is heated to at least sterilizing temperature for a time sufficient to sterilize the sealing members before moving the panels relative to the open ends.

8. The method of claim 2 in which the polymeric material has a melt temperature of about 230°

C. or greater.

9. The method of claim 2 in which each of the first and a second fluid flow circuits comprises a panel having a plurality of layers including a polymer layer and a metallic layer defining the heating element.

10. The method of claim 2 in which at least one of the fluid flow circuits comprises a panel having a plurality of layers including two polymer layers and a metallic layer defining the heating element located between the polymer layers.

11. The method of claim 2 wherein the panel has a thickness of less than about 0.5 mm.

12. The method of claim 1 including sterilizing each of the first and second fluid flow circuit prior to steps (a)-(c).

13. The method of claim 1 wherein the at least one heating element is heated to a sufficient temperature for a time sufficient to sterilize the sealing members.

14. The method of claim 1 wherein the at least one heating element is heated to at least about 230°

C.

15. The method of claim 1 wherein the at least one heating element is electrically conductive and is heated by induction.

16. The method of claim 1 wherein at least one of the sealing members comprises a metallic film defining the at least one heating element.

17. The method of claim 1 wherein at least one of the sealing members is heated by an inductive electrical power source operating at an electrical frequency of “

f” and

the at least one member includes a metallic film having a thickness not substantially greater than the skin depth for such metal at such frequency.

18. The method of claim 1 wherein at least the surface of the sealing member that is exposed to the interior of the fluid conduit comprises a material having antimicrobial properties.

19. The method of claim 1 wherein the fluid flow circuits are pre-sterilized and the sealing members and open ends are relatively separated and the melted ends are compressed together while maintaining sterility of the fluid flow circuits.

20. The method of claim 1 wherein the open end and sealing member of each fluid flow circuit are carried by a housing configured for connection to the housing of the other fluid flow circuit.

21. The method of claim 1 wherein each of the sealing members comprises a film including a metallic layer attached to the open polymeric end of the respective conduit, the method including:

positioning the circuits with the open polymeric ends of the conduits generally in alignment and with the respective films in face to face contact,

heating the metallic layer sufficiently to melt the polymeric material of the open end of each conduit and sterilize the sealing members,

separating the films from the respective open ends by laterally withdrawing the films substantially simultaneously from between the molten polymeric ends while pressing the open ends of the conduits together; and

cooling the open ends while maintaining the pressure, forming a junction between the fluid conduits.

22. A method of joining first and second fluid flow conduits, each having a lumen and an open end terminating in a polymeric material and a sealing member attached to the flow conduit and sealing the open end thereof, and each of the sealing members including at least one single-use heating element as a pre-assembled composite part of the sealing member prior to joining, the method including:

(a) placing the sealing members in face to face contact;

(b) melting the polymeric material of the open ends by heating the at least one heating elements of each sealing member;

(c) separating the sealing members from the respective open ends by withdrawing the sealing members from between the respective open ends of the conduits while pressing the open ends of the conduits toward each other to bring the exposed open ends together while melted to form a junction between the fluid flow conduits that allows fluid flow therebetween.

23. The method of claim 22 wherein each of the sealing members comprises a panel attached to the open polymeric end of the respective conduit and each of the sealing members comprises a panel having a plurality of layers including a polymer layer and a metallic layer defining the at least one heating element, the open polymeric end of the respective conduit being sealingly attached to the polymer layer, the method including:

positioning the polymeric ends of the conduits generally in axial alignment and with the respective panels in face to face contact,

heating the metallic layers sufficiently to melt the polymeric material of the open end of each conduit,

laterally separating the panels from between the polymeric ends while the polymer is melted to expose the open ends and while applying an axial compressive force to the conduits so as to substantially simultaneously bring the exposed open ends together as the panels are separated from between them; and

cooling the melted ends while maintaining the axial compressive force to form a junction between the fluid conduits that allows fluid flow therebetween.

24. The method of claim 23 in which the heating element is heated by an inductive electrical power source operating at a selected electrical frequency and the heating element has a thickness not substantially greater than the skin depth for such metal at such frequency.

25. The method of claim 22 in which the conduits are pre-sterilized, and the melted ends are joined while maintaining the sterility of the conduits.

26. The method of claim of 22 in which the sealing member comprises a material that exhibits an antimicrobial property.

27. The method of claim 22 in which the heating element is heated to at least sterilizing temperature for a time sufficient to sterilize the sealing members before separating them relative to the open ends.

28. The method of claim 22 wherein each sealing member includes a panel having a thickness of less than about 0.5 mm.