Multi-branch static mixer

Abstract

Static mixer capable of mixing even when flow rates are low and / or intermittent. [Solution] The static mixer (100) comprises a static mixer housing having an inlet port (120), a channel (104) in fluid communication with the inlet port, a flow splitter for splitting the fluid into a first stream (106a) and a second stream (106b) within the channel, a second flow splitter for splitting the first stream (106a) into a third stream (110a) and a fourth stream (110b), a third flow splitter for splitting the second stream into a fifth stream (110c) and a sixth stream (110d), a first T-junction for recombining the third and fourth streams within channel (112a), a second T-junction for recombining the fifth and sixth streams within channel (112b), and a third T-junction for recombining the streams.

Description

[Technical Field]

[0001] Related Applications This application claims the benefit of EP priority application 19306541.4, filed November 29, 2019, which is incorporated by reference in its entirety.

[0002] The present disclosure relates to mixing of fluids, and more particularly to static mixers capable of mixing small amounts of fluid, and to embodiments of mixers and mixing methods. [Background technology]

[0003] In the bioprocessing industry, biological fluids are mixed in solution. Homogeneous mixing is a particular goal. Processes include cell culture and other bioprocesses, such as the production of desired products, such as virus inactivation for use in plant and animal cells. However, the use of high shear rates, i.e., turbulence, can damage components of biological fluids, such as cells, viruses, capsids, and monoclonal antibodies. Therefore, static mixers are used. However, mixing small amounts of fluids and / or solids with static mixers can be difficult. Furthermore, achieving uniform mixing of small amounts of fluids and / or solids is particularly challenging, especially when the flow rate is low and / or intermittent.

[0004] A low flow rate occurs when the volume of fluids being mixed is very small and drips into the system. Fluids (or solids) may be injected as "droplets." The dominant fluid, i.e., the dominant volume of fluid, flowing at a faster rate, only encounters the recessive fluid intermittently or periodically; in other words, "packs" of the dominant fluid flow without any contact with the recessive fluid. Uniform mixing of the dominant and recessive fluids can only occur through a very long-term diffusion process. In this context, the term "long-term" can refer to mixing over a long duration and / or within a long physical conduit or mixing system, which is undesirable. Summary of the Invention [Problem to be solved by the invention]

[0005] Static mixers generally consist of a baffle with a fixed position within a conduit or pipe. The baffle is a spiral or grid element within the conduit or pipe. The conduit is typically part of a closed system through which fluids flow. Such mixers are inefficient for laminar flow and cannot mix fluids with non-continuous flow rates. [Means for solving the problem]

[0006] A novel static mixer that can rapidly and thoroughly mix two or more fluids despite significant differences in flow rates, and a novel static mixer that can efficiently mix two or more fluids during low flow rates and / or intermittent flow, represents an advance in the art.

[0007] The static mixer includes a static mixer housing having an inlet port capable of receiving a plurality of fluids, a channel in fluid communication with the inlet port, at least one channel, a plurality of flow splitters within the at least one channel for splitting the fluid flow, and a plurality of T-junctions for recombining and mixing the fluid flows. The static mixer comprises a static mixer housing having an inlet port for receiving a fluid, a channel in fluid communication with the inlet port, raised ribs along the periphery of the channel, a flow splitter for splitting the fluid into a first stream and a second stream within the channel, a second flow splitter for splitting the first stream into a third stream and a fourth stream within the channel, a third flow splitter for splitting the second stream into a fifth stream and a sixth stream within the channel, a first T-junction for recombining and mixing the third and fourth streams within the channel, a second T-junction for recombining and mixing the fifth and sixth streams within the channel, and a third T-junction for recombining and mixing the streams; and a plastic film sealed to the raised ribs to form a static mixer capable of mixing fluids.

[0008] In some embodiments according to the present disclosure, the static mixers disclosed herein mix two or more fluids, one or more of which are optionally introduced intermittently or continuously dropwise into the fluid stream.

[0009] In some embodiments according to the present disclosure, the static mixers disclosed herein mix acids, bases, and / or buffers with biological products or biological fluids. In some embodiments, the static mixers disclosed herein are used for low pH virus activation bioprocesses. In this context, low pH refers to a pH between 5.0 and 6.0. In some embodiments, low pH refers to a pH between 3.0 and 7.0.

[0010] In some embodiments, the static mixers described herein are capable of efficiently mixing two or more fluids. In some embodiments, the fluid flow of at least one fluid is discontinuous, intermittent, and / or "trickle" into the second fluid, and the flow of either or both fluids is low, intermittent, and / or laminar.

[0011] In some embodiments, the static mixers described herein are capable of efficiently mixing two or more fluids at significantly different flow rates for purposes of in-line viral inactivation processes, as known to those skilled in the art.

[0012] These and other provisions will become apparent from the following description, claims, and drawings. Various advantages, aspects, novel and inventive features of the present disclosure, as well as details of exemplary embodiments thereof, will become more fully understood from the following description and drawings. Accordingly, how the features disclosed herein can be understood in detail, and a more particular description of the embodiments of the present disclosure briefly summarized above, can be had by reference to the accompanying drawings. It should be noted, however, that the accompanying drawings illustrate only typical embodiments of the present disclosure and should not be considered as limiting its scope, as the described embodiments may allow for other equally effective static mixers. It should also be understood that elements and features of one embodiment may be found in other embodiments without further recitation, and that, where possible, the same reference numerals have been used to indicate equivalent elements common to the figures. As used herein, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which these embodiments pertain. Additionally, as used herein, the following terms are ascribed to the following definitions, unless the context indicates otherwise. [Brief explanation of the drawings]

[0013] [Figure 1] 1 illustrates a top view of a static mixer housing according to an embodiment of the present disclosure. [Figure 2A] 2 illustrates a perspective top view of a cross section taken along line 2-2 of the static mixer housing of FIG. 1 in accordance with an embodiment of the present disclosure. [Figure 2B] 2 illustrates a perspective top view of a cross section taken along line 2-2 of the static mixer housing of FIG. 1 in accordance with an embodiment of the present disclosure. [Figure 2C] 2 illustrates a perspective top view of a cross section taken along line 2-2 of the static mixer housing of FIG. 1 in accordance with an embodiment of the present disclosure. [Figure 2D] 2 illustrates a perspective top view of a cross section taken along line 2-2 of the static mixer housing of FIG. 1 in accordance with an embodiment of the present disclosure. [Figure 3A] 2 shows a perspective view of the top of the static mixer housing of FIG. 1, a film for coupling to the static mixer housing, and an exploded view of a back view of the static mixer housing 100 according to an embodiment of the present disclosure. [Figure 3B] 2 shows a perspective view of the top of the static mixer housing of FIG. 1, a film for coupling to the static mixer housing, and an exploded view of a back view of the static mixer housing 100 according to an embodiment of the present disclosure. [Figure 4] 4 illustrates a dual system including two static mixers of FIG. 3 connected in series, according to some embodiments of the present disclosure. [Figure 5] 1 illustrates a second static mixer housing according to some embodiments of the present disclosure. [Figure 6] 10 illustrates a third static mixer housing having seven T-junctions according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0014] FIG. 1 illustrates a top view of a static mixer housing 100 according to an embodiment of the present disclosure. FIG. 1 illustrates a primary inlet channel 102 disposed in the static mixer housing 100, with a fluid flow F entering the static mixer housing 100. It should be understood that a port, such as a barbed port, may be connected to the inlet channel 102. In some embodiments, the barbed port further comprises a Y-connector or a T-connector for connecting with the inlet channel 102, either of which may have attached tubing for supplying two different fluid components to be mixed. In some aspects, the barbed port has a single port connected to tubing for supplying a fluid, the fluid containing two or more fluid components for subsequent mixing. After receiving the fluid flow from the inlet 102, the primary inlet channel 102 branches at a branch 104. As illustrated, the branch 104 is a Y-branch, with the branch forming an acute angle. It is contemplated that the branch 104 may be a different style, such as a T-branch. The fluid flow is then split into two secondary channels 106a, 106b. As shown, each of the secondary channels forms a 45° angle with the primary channel 104; however, angles such as 10°, 20°, 30°, 60°, 70°, etc. are also considered within the scope of the present disclosure. Nevertheless, other angles are also considered within the scope of the present technology. Secondary channel 106a then splits into tertiary channels 108a and 108b, also shown as a Y-junction. As noted above, any acute angle is contemplated herein. Tertiary channels 108a and 108b then form a near-perpendicular angle at points 110a and 110b, which then recombine to create a mixing action. While not intending to be bound by theory, it is believed that the fluids in 110a and 110b mix more efficiently than at other junctions because they terminate at T-junction 112a.

[0015] Similar to secondary channel 106a, secondary channel 106b splits into tertiary channels 108c and 108d, again shown as a Y-junction. Tertiary channels 108c and 108d then form near-perpendicular angles at points 110c and 110d, before reuniting and creating a mixing action at T-junction 112b. Two terminal channels 114a and 114b, respectively, following T-junctions 112a and 112b then join at T-junction 116, creating additional mixing. The fluids inside static mixer 100 can then exit thoroughly mixed through outlet port 120.

[0016] As shown, the sizes or inner diameters of the channels 104, 106a, 106b, 108a, 108b, 108c, 108d, 110a, 110b, 110c, 110d, 112a, 112b, 114a, 114b, and 116 are substantially similar, however, this does not have to be the case, as explained below.

[0017] Figure 2 shows a top perspective view 200 of a cross section taken along line 2-2 of the static mixer housing of Figure 1 in accordance with an embodiment of the present disclosure. Figure 2A shows a perspective view in which the geometry of the channel 104 includes a semicircular shape 202a taken along line 2A-2A. Figure 2B shows a perspective view in which the geometry of the channel 104 includes a trapezoidal shape 202b taken along line 2B-2B. Figure 2C shows a perspective view in which the geometry of the channel 104 includes a rectangular shape 202c taken along line 2C-2C. Figure 2D shows a perspective view in which the geometry of the channel 104 includes a chevron shape 202d taken along line 2D-2D. It should be understood that, for example, two similar static mixer housings 100, each having a semicircular channel 104, each having a trapezoidal channel 104, each having a rectangular channel 104, or each having an angled channel 104, may be welded or glued together to form a static mixer.

[0018] FIG. 3A shows an exploded view of a plastic sheet 302 and a top perspective view of the static mixer housing 100 of FIG. 1. The plastic sheet 302 may be made of almost any polymeric material that can be sterilized with heat, gamma radiation, alcohol, etc., such as polyethylene, silicone, nylon, polyethylene terephthalate, biaxially oriented polyethylene terephthalate, biaxially oriented polypropylene, polyethersulfone, copolymers and blends thereof, and other suitable materials. The plastic sheet 302 may be die-cut, laser-cut, or formed into a shape that generally corresponds to the perimeter of the static mixer housing 100. The plastic sheet 302 is bonded to the static mixer housing 100 via heat and pressure, adhesives, and other bonding methods known to those skilled in the art. As shown, the static mixer housing 100 has a large inlet port 306 for the primary biological fluid and a small inlet port 304 for delivering a small amount of fluid, such as a buffer solution, to the primary biological fluid. A medium-sized outlet port 320 is also shown. The outlet port 320 may have a smaller inner diameter than the larger inlet port 306 to provide back pressure, increase fluid residence time, and limit the amount of turbulence inside the static mixer. In practice, any size outlet port 320 may be used, regardless of the size of the channel. It should be further understood that any and all inlet ports 304, 306 may be the same size as any outlet port 320.

[0019] Raised ribs 308 are shown around all perimeters of channels 104, 106, 108, 110, 112, and 114 for heat staking or bonding to plastic sheet 302. The raised ribs 308 fuse with plastic sheet 302 during the heat bonding operation. Static mixer housing 100 may be manufactured from any suitable plastic material. For example, static mixer housing 100 may be made from high-density polyethylene (HDPE), acrylonitrile-butadiene-styrene (ABS), nylon 6, nylon 66, nylon 46, polyethersulfone, and other sterilizable polymers commonly used in the bioprocessing industry. Static mixer housing 100 can be manufactured using, for example, an injection molding process. Static mixer housing 100 may also be manufactured by milling channels into a plastic sheet or by using laser and / or other ablation methods. It should be understood that some embodiments of any static mixer housing described herein may include ribs 308, and some embodiments may not have ribs 308. In some embodiments, two static mixer housings may be bonded together to form the static mixer. Such embodiments may not include raised ribs 308. Figure 3B shows a rear view of the static mixer housing 100 shown in Figure 3A.

[0020] FIG. 4 illustrates a dual system 400 including two static mixers 100 of FIG. 3 connected in series, according to some embodiments of the present disclosure. A first static mixer 100′ is connected to a second static mixer 100″ at connection M′, which may be a tubular connector 150. Fluids are introduced into the static mixer 100′ at ports 1 and 2. Port 1 can have fluid delivered to the inlet port 120 in a state of low-order fluid flow. Port 2 can have fluid delivered to the inlet port 120 in a state of relatively high-order fluid flow. The two fluids are then mixed within the static mixer 100′, as described above. The mixed two fluids then exit the outlet port 120. The fluids are then further mixed in the static mixer 100″ and exit the outlet port 120 at point F. Although two static mixers 100' and 100'' are shown, it should be understood that any practical number of static mixers 100 may be connected in series and / or parallel (not shown). It should also be understood that connector 150 may further include an inlet for adding an additional fluid. The additional fluid may be one of the two fluids added at port 1 and port 2, or may be a third fluid.

[0021] FIG. 5 illustrates a second static mixer housing 300 according to some embodiments of the present disclosure. The second static mixer housing 300 is similar to the static mixer 100 described above. The second static mixer housing 300 may include optional features. For example, the second static mixer housing 300 may include a radial inflection 326 adjacent to the inlet channel 302. The radial inflection 326 can promote mixing. The second static mixer housing 300 may further include a concave protrusion 328. As shown, the protrusions 328 are at points 310a and 310b where they rejoin to create a mixing action at the T-junction 312a. The second static mixer housing 300 may further include a convex protrusion 330. As shown, convex protrusions 330 are at the points 310c, 310d where they rejoin, creating a mixing action at T-junction 312b. It should be further understood that radial inflection 326, concave protrusion 328, and / or convex protrusion 330 may be present (or omitted) from any Y-split or T-junction.

[0022] Also, the channel sizes, i.e., inner diameters or dimensions 304, 306a, 306b, 308a, 308b, 308c, 308d, 310a, 310b, 310c, 310d, 312a, 312b, 314a, 314b, 316, vary within the static mixer housing 300. For example, the cross-sectional area of ​​channels 308a, 308b is larger than that of channel 306a. In some embodiments, the cross-sectional area of ​​channels 308a, 308b is smaller than that of channel 306a. As noted above, the second static mixer housing 300 may have a plastic film applied to it to form a static mixer, or any two similar static mixers 300 may be glued together.

[0023] FIG. 6 illustrates a third static mixer housing 500 having seven T-junctions 535a, 535b, 535c, 535d, 545a, 545b, and 555 according to an embodiment of the present disclosure. In practice, any suitable number of splitters and junctions may be used. The third static mixer housing 500 operates similarly to the static mixers and systems described above. A fluid containing two or more components for mixing enters the third static mixer housing 500 at point F via port 120. The fluid flow is then split into two secondary streams 510a and 510b at a Y-split 505. Stream 510a is then split into tertiary streams 515a and 515b at a Y-split. Tertiary stream 515a is then split into quaternary streams 525a and 525b at another Y-split. Quaternary streams 525a and 525b are then recombined at T-junction 535a, and mixing occurs as described above. Stream 535b from stream 515b (which has undergone the same separation and recombination as stream 515a) is then recombined at T-junction 545a. Stream 510b is split and recombined similarly to stream 510a to produce a mixed stream at T-junction 545b. Streams 545a and 545b are then recombined as they are combined at T-junction 555. One stream then exits port 120 at point E. In total, one stream entering third static mixer housing 500 was split into eight separate streams and recombined into one mixed stream. It should be understood that the third static mixer housing 500 can include any or all of the features described above with respect to mixers 100, 100′, 100″, and 300. The static mixer housing 500 can have ribs 308, radial inflections 326, concave protrusions 328, convex protrusions 330, plastic film 302, or two static mixer housings 500 mated to form a static mixer. This also applies to any dimensional differences described in FIG. 5.Additionally, static mixer housings 500 may be arranged in series or parallel to form a mixing system.

[0024] All ranges of the formulae recited herein are inclusive and may include or exclude endpoints. Optionally included ranges are derived from integer values ​​therebetween (or including one original endpoint) and are in the recited order of magnitude or the next smaller order of magnitude. For example, if the lower end of the range is 0.2, optional included endpoints can be 0.3, 0.4, 1.1, 1.2, etc., as well as 1, 2, 3, etc.; if the upper end of the range is 8, optional included endpoints can be 7, 6, etc., as well as 7.9, 7.8, etc. Boundaries on one side, such as 3 or more, similarly include consistent boundaries (or ranges) beginning at the recited order or the next lower integer value. For example, 3 or more includes 4 or 3.1 or more.

[0025] Throughout this specification, references to "one embodiment," "a particular embodiment," "one or more embodiments," "some embodiments," or "an embodiment" indicate that a feature, structure, material, or characteristic described in connection with an embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of phrases such as "in one or more embodiments," "in a particular embodiment," "in one embodiment," "in some embodiments," or "in an embodiment" throughout this specification are not necessarily referring to the same embodiment. Nevertheless, it should be understood that any feature described herein can be incorporated into any embodiment disclosed herein.

[0026] The patent applications and patents and other non-patent publications cited herein are incorporated by reference in their entirety, throughout the entirety of the portion cited, to the same extent as if each individual publication or reference was specifically and individually indicated to be incorporated by reference herein as if fully set forth. Any patent application to which this application claims priority is also incorporated by reference herein in the manner described above for publications and references.

Claims

1. A static mixer comprising a static mixer housing and a plastic film, The static mixer housing is an inlet port for receiving a fluid; a channel in fluid communication with the inlet port; a raised rib along the periphery of the channel; a flow splitter for splitting the fluid into a first stream and a second stream within the channel; a second flow splitter for splitting the first stream into a third stream and a fourth stream within the channel; and a third flow splitter for splitting the second stream into a fifth stream and a sixth stream within the channel; a first T-junction for recombining and mixing the third and fourth streams within the channel; a second T-junction for recombining and mixing the fifth and sixth streams within the channel; a third T-junction for recombining and mixing the streams; Equipped with A static mixer, wherein the plastic film is sealed to the raised ribs to form a static mixer capable of mixing fluids.

2. 10. The static mixer of claim 1, wherein the channel comprises one of a semicircular shape, a trapezoidal shape, a rectangular shape, or a chevron shape.

3. 10. The static mixer of claim 1, wherein the static mixer housing is formed from one of high density polyethylene (HDPE), acrylonitrile-butadiene-styrene (ABS), nylon 6, nylon 66, nylon 46, or polyethersulfone.

4. The static mixer of claim 1 further comprising an additional T-junction.

5. The static mixer of claim 4 further comprising an additional flow splitter.

6. The static mixer according to any one of claims 1 to 5, wherein the flow splitter is a Y-splitter.

7. 7. The static mixer according to claim 1, wherein the plastic film is made of a polyethylene material.

8. The static mixer of any one of claims 1 to 7, further comprising a port having at least two inlet ports.

9. The static mixer of any one of claims 1 to 8, wherein the flow splitter further comprises a concave protrusion, a convex protrusion, or a radial inflection.

10. A static mixer according to any preceding claim, wherein the channel has a constant internal dimension.

11. A static mixer according to any preceding claim, wherein the channel has internal dimensions that are not uniform in size.

12. A static mixer system comprising one or more static mixers connected in series.

13. A static mixer system comprising one or more static mixers connected in parallel.

14. A static mixer comprising a static mixer housing, The static mixer housing is an inlet port for receiving a fluid; a channel in fluid communication with the inlet port; a flow splitter for splitting the fluid into a first stream and a second stream within the channel; a first T-junction for recombining and mixing the first and second streams within the channel; A static mixer comprising:

15. 15. The static mixer of claim 14, wherein the channel comprises one of a semicircular shape, a trapezoidal shape, a rectangular shape, or a chevron shape.

16. 15. The static mixer of claim 14, wherein the static mixer housing is formed from one of high density polyethylene (HDPE), acrylonitrile-butadiene-styrene (ABS), nylon 6, nylon 66, nylon 46, or polyethersulfone.

17. 15. The static mixer of claim 14, further comprising an additional T-junction.

18. 15. The static mixer of claim 14, further comprising an additional flow splitter.

19. The static mixer according to any one of claims 14 to 18, wherein the flow splitter is a Y-splitter.

20. The static mixer according to any one of claims 14 to 19, wherein the first T-junction is located outside the static mixer.

21. A static mixer according to any one of claims 14 to 20, further comprising a raised rib along the periphery of the channel.

22. 22. The static mixer of claim 21, further comprising a plastic film, the plastic film sealed to the raised ribs to form a static mixer capable of mixing fluids.

23. A static mixer according to any one of claims 14 to 22, wherein two fluids are introduced into the static mixer.

24. A static mixer according to any one of claims 14 to 23, wherein at least one of the two fluids is in a discontinuous flow state.

25. A static mixer comprising a static mixer housing, The static mixer housing is an inlet port for receiving at least two fluids, at least one of the fluids being introduced intermittently; a channel in fluid communication with the inlet port; a flow splitter for splitting the fluid into a first stream and a second stream within the channel; a first T-junction for recombining and mixing the first and second streams within the channel; An outlet port; A static mixer comprising:

26. 26. The static mixer of claim 25, further comprising a plurality of flow splitters.

27. 26. The static mixer of claim 25, further comprising a plurality of T-junctions.

28. 26. The static mixer of claim 25, wherein the inlet port includes two inlets.

29. 26. The static mixer of claim 25, wherein the inlet port includes two inlets of different inner diameters.

Images