ILC Dover Film Welding System

James HarmonTommy Lupinski

Katherine NitzDan Vennard

ILC Dover BackgroundILC Dover Background

ILC offers containment solutions for processing active pharmaceutical products Effective and safe systems get products to

market faster

Containment products include DoverPac ® Continuous Liner DoverPac ® SF

Pharm / Biopharm Products

Current Sealing TechniquesCurrent Sealing Techniques Twist-tie-tape and cut

Crimping

Thermal welding Senior Design focus

Current Thermal WelderCurrent Thermal Welder

$100,000

Why the high cost?Why the high cost? Film welder needs to be “explosion-proof” due to its

surroundings Design must meet several requirements for

approval Electrical requirements are main hurdle

Regulatory agencies involved NFPA

Class 1, Class 2, Division 1 Articles 496, 497

ATEX Ensuring the machine is explosion-proof is very

expensive!

Project ObjectiveProject Objective To design a film welder that can successfully seal

plastic layers together in an explosive environment without using electricity Eliminate electrical system approval hurdles Reduce cost

Produce an engineering model of the film welder Model must meet all performance specifications

possible Concentration on non-electrical aspect

Project ScopeProject Scope

Customer SpecificationsCustomer Specifications

Sealing temperature goal

130°C (266°F)

Sealing pressure goal 20psi ± 5psiCost per use $3Exterior temperature 50°C (120°F)Operators required 1Full sealing cycle time

2 minutes*

Sealing area 37” x 1.5” (23” Ø bag)

Metric Target Value

Be safe for the user Meet NFPA and ATEX regulations Use no electricity!

Constraints

*This target value was increased to around 5 minutes.

3-D Concept Design3-D Concept Design

Heating arm Pressure arm

Steps to Complete CycleSteps to Complete Cycle

Start

Flush with H2O

Remove sealed plastic

Add chemicals

Insert plastic

Apply pressure

Concept SubsystemsConcept Subsystems

Heating & Cooling System

Pressure System

Heat Generati

on System

Thermal Sealer Prototype

Heat Generation SystemHeat Generation SystemThe system requires… Ability to reach temperature of 130°C as

quickly as possible Safe chemical components

ConceptsConcepts

Heat Generation Concepts

Epoxy Resin

Hydrogen Peroxide (H2O2) Decomposition

HH22OO22 DecompositionDecomposition TestingTesting

Mixed H2O2 and MnO2 in… An open beaker

Maximum temperature was 90°C A pressurized copper pipe

Maximum temperature was 144°C

Temperature goal cannot be reached if not pressurized

Amount of MnO2 only affects speed of reaction, not the temperature the mixture can reach

Lessons Learned…Lessons Learned…

Heating & Cooling Heating & Cooling SystemSystem

The system requires… Efficient heat transfer (for heating and cooling) Insulation to ensure cool outer surface User-friendly chemical addition system Effective drainage

Heating & Cooling Concepts

Hollow Al chamber

Eliminated copper tube “middle man”

Increased heat transfer efficiency

Heating & Cooling System Heating & Cooling System AnalysisAnalysis

Internal pressure analysis Need pressure valve that releases

between 150psi and 200psi

Force analysis Found deflection of steel casing

Adjusted thickness to minimize it

Aluminum end-cap (green)

Aluminum channel (grey)

H2O2 / H20 input valve

Pressure relief valve

MnO2 input valve

Draining valve (on bottom)

Progressive AssemblyProgressive Assembly Step 1Step 1

Air valve

Silicone rubber insulation

(blue)

Bungs for welding (red)

Step 2Step 2

Step 3Step 3

Steel casing (grey)

Locking bar (teal)

Steel end-cap

(turquoise)

Fully Assembled ViewFully Assembled View

Pressure SystemPressure SystemThe system requires… Even pressure application along length Ability to impose a tear strip on plastic Withstanding pressure from inflated bladder

Pressure Concepts

Inflatable bladder

Lever & lock

Turn screw

Pressure System Pressure System AnalysisAnalysis

Force analysis Found deflection of steel backing

Adjusted thickness to minimize it

Found force on the locking pin Determined the required diameter needed

Pressure AssemblyPressure AssemblyStep 1Step 1

Interior guide blocks (red)

Steel backing

(turquoise)

Steel casing (blue)

Step 2Step 2

Pressure plate (green)

Exterior guide blocks (red)

Force pad

(blue)

Tear strip O-ring (pink)

Pressure bladder (grey)

Fully Assembled ViewFully Assembled View

Comprehensive Concept Comprehensive Concept DesignDesign

Put in REAL picture of it assembled!!!!!

START

Steps to Add ChemicalsSteps to Add Chemicals

Open MnO2 valve

Add 1g of MnO2

Open H2O2 valve

Add 250mL of H2O2

Close MnO2 valve

Close H2O2 valve

Film Welder in ActionFilm Welder in Action

Setup

Pressurize

Add chemicals

Flush system with water

Depressurize

Remove sealed plastic

Heating & cooling system Validate:

Time to seal Sealing temperature goal Sealing area Exterior temperature

Pressure system Validate:

Sealing pressure goal Even pressure distribution

Test entire prototype Validate:

One operator required

Cost per use

System ValidationSystem Validation

Heating Arm TestingHeating Arm Testing

Heating Arm Testing Isolated heating arm

Varied chemical amounts 150-250mL H2O2 0.5-1.0g MnO2

Varied chamber pressure 60-200psi

Varied MnO2 input valve location

Temperature Validation Results

0

20

40

60

80

100

120

140

0 2 4 6 8 10 12 14 16

TrialT

emp

erat

ure

(°C

)

Target Value

Testing Results

Trial 1-6: 150mL H2O2, 0.5g MnO2

Trial 7-15: 250mL H2O2, 1g MnO2

Results and ValidationResults and Validation Results

Temperature peak is very inconsistent Target value for temperature was not met

but plastic did seal Average time to seal was 2 minutes, 24

seconds

Validation– Time to seal 2 minutes, 24 seconds– Sealing temperature goal 127°C– Sealing area 14” x 1.5”– Exterior temperature 25°C

Pressure Arm TestingPressure Arm Testing Pressure Arm Testing Isolated pressure arm

Inflated bladder with air pump Used Pressurex® pressure sensing film

Trial 1

Trial 2

Results and ValidationResults and Validation Results

Very even pressure distribution across length Across o-ring, pressure was about 75psi Elsewhere, pressure was less than 28psi

Tear strip was imposed

Validation– Sealing pressure goal < 28psi– Even pressure distribution Yes

Target vs. Actual ValuesTarget vs. Actual Values

Sealing temperature goal

130°C (266°F)

127°C (°F)

Sealing pressure goal 20psi ± 5psi < 28psi

Cost per use $3 ≈ $4

Exterior temperature 50°C (120°F) 25°C (77°F)

Operators required 1 1

Full sealing cycle time

5 minutes ≈ 5 minutes

Sealing area 37” x 1.5” 14” x 1.5”

Metric Target Value

Actual Value

BudgetBudget

Component CostHeating arm $393

Pressure arm

$225

Testing $348

Total cost $966

Handoff to ILCHandoff to ILC

Sealing can be accomplished using non-electrical means Hydrogen peroxide decomposition is one

successful method Purchase a more accurate pressure

relief valve Further work needs to be done in order

to transfer product to industry Patent potential after further investigation

and testing

AcknowledgmentsAcknowledgments

Sponsor• ILC Dover

– Dave Cadogan and Anshu Dixita

Advisor• Dr. Keefe

Technical Advisors• Dr. Wingrave (Chemistry Department)• Steve Beard (Machine Shop)• Dave Styer (Machine Shop)

• Heat transfer analysis– Found temperature of 133°C is required to

ensure full heat conduction through plastic

• Thermodynamics– Found 180mL of H2O2 is needed to get

reaction to 133°C

Heat Generation AnalysisHeat Generation Analysis

T1=133°C

T2=130°C Input heat

Pressure System BudgetSteel (backing, end-caps, arms) $190

Aluminum (U-channel) $33

Schraeder valve $2

O-ring $3

Force distribution pad $37

Total System Cost $265

*ILC has agreed to take care of making the inflatable bladder.

Heating/Cooling System Budget

Aluminum (end-caps, chamber) $25

Steel (casing, locking bar) $55

Insulation $75

Plumbing (pipes, valves, hoses, etc.) $140

Total System Cost $295

*ILC has agreed to take care of all welding needs.