Universal modular pressure sensors and fittings therefor

Abstract

A system for monitoring pressure in a bioprocessing system includes a binder connector or industrial connector including a plurality of electrically conductive pins disposed therethrough. A sensor cap has an opening for receiving a distal portion of the binder connector. A sensor spacer has an upper end engageable with a surface of the sensor cap. The sensor spacer has an opening for receiving wire leads coupled to the electrically conductive pina. A sensor has a printed circuit board (PCB) disposed thereon. The PCB includes a plurality of wire solder points for electrically coupling to the wire leads. A sensor insert having a sealing portion receives the sensor therein. A sensor housing has a seat portion for receiving the sealing portion thereon and an upper flange portion for coupling to the sensor cap.

Description

UNIVERSAL MODULAR PRESSURE SENSORS AND FITTINGS THEREFORCross-Reference to Related Applications

[0001] This application is a non-provisional of pending U.S. Provisional Patent Application Serial No. 63 / 598,653, filed November 14, 2023, the entirety of which application is incorporated by reference herein.Background of the DisclosureField of the Disclosure

[0002] Embodiments of the disclosure relate generally to sensing systems, and more particularly to a modular sensor arrangement configured to be receivable in a variety of different sizes and types of fittings for fluids including liquids and gases.Discussion of Related Art

[0003] Filtration is typically performed to separate, clarify, modify, and / or concentrate a fluid solution, mixture, or suspension. In the biotechnology, pharmaceutical, and medical industries, filtration is vital for the successful production, processing, and analysis of drugs, diagnostics, and chemicals as well as many other products. As examples, filtration may be used to sterilize fluids and to clarify a complex suspension into a filtered “clear” fraction and an unfiltered fraction. Similarly, constituents in a suspension may be concentrated by removing or “filtering out” the suspending medium. Further, with appropriate selection of filter material, filter pore size and / or other filter variables, many other specialized uses have been developed. Theseuses may involve selective isolation of constituents from various sources, including cultures of microorganisms, blood, as well as other fluids that may be solutions, mixtures, or suspensions.

[0004] Biologies manufacturing processes have advanced through substantial process intensification. Eukaryotic and microbial cell cultures to produce recombinant proteins, virus-like particles (VLP), gene therapy particles, and vaccines all now include cell growth techniques that can achieve 107cells / ml or higher. At these cell densities, it becomes critical to efficiently remove metabolic waste products and refresh the culture with additional nutrients. This is achieved in some bioreactor systems, referred to as “perfusion systems,” by alternating tangential flow hollow fiber filtration (ATF). In these systems, a hollow fiber filter is placed in fluid communication with the bioreactor and fluid flows through the filter are driven by an alternating pump, such as an alternating diaphragm pump. The system may be controlled by a controller, which may operate the pump based on a preprogrammed sequence or in response to a signal from one or more sensors.

[0005] More generally, it may be useful or desirable to use sensors in ATF and / or other biological processing systems to monitor and / or control processes therewithin. Sensors that may be useful include pressure sensors, temperature sensors, pH sensors, O2 partial pressure sensors (O2P), and frequency impedance-based biomass sensors. However, despite the desirability of incorporation of sensors into these systems, there remains a need for a simple sensor arrangement that can be used with a variety of piping / tubing systems sizes, connection schemes, and the like.Summary of the Invention

[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

[0007] The present disclosure provides apparatuses and methods that integrate sensors into bioprocessing systems and, advantageously, do not require significant reengineering of these systems. In one aspect, the disclosure relates to a sensor / fitting arrangement in which a sensor assembly is inserted into an aperture in a fluid process fitting. The aperture is of a size and configuration that receives the sensor assembly and places a sensor of the sensor assembly in contact with a fluid passing thorough the fluid process fitting. In some embodiments the aperture is of a size and configuration that receives the sensor assembly and places a sensor of the sensor assembly in contact with pressurized air / gas applications with pressures under 100 psi through the use of pneumatic fittings.

[0008] The sensor is directly exposed to the fluid in the fitting, and thus has the ability to measure, for example, positive pressure or vacuum pressure of the fluid in the fitting. In some embodiments, the sensor of the sensor assembly is pre-calibrated to a narrow pressure range in order to maximize accuracy of the readings. For example, the sensor used in the sensor assembly can be pre-calibrated to one of three ranges, including, but not limited to, -14.7 to +15.0 psi, 0.0 to +30.0 psi, and 0.0 to +60 psi. Of course, thenumber and breadth of these ranges is no critical, and any of a variety of ranges can be used.

[0009] The sensor assembly can include a smart scaling adjustment in which the calibrated pressure range is automatically detected by the sensing system, and scaling is automatically adjusted by connecting the sensor assembly to a signal converting device associated with the sensing system.

[0010] The sensor assembly can be used with any of a variety of fittings. In some embodiments the fitting is a tee connector having fluid path connections of 1 / 8- inch, %-inch, 3 / 8-inch, ’A-inch, %-inch, 1-inch, or 1.5-inch, though these sizes are not limiting. The fittings can be configured to be coupled to fluid system tubing via hose barb, luer, TC, and the like.

[0011] The sensor assembly and fitting are made from materials configured to be sterilizable using gamma sterilization, and / or autoclave sterilization.

[0012] In some embodiments the proposed pressure measuring device is a complete system which contains a sensor with a variety of connection points allowing integration to larger bioprocessing systems, and a pressure signal conversion module. The system enables visualization of instantaneous pressure values, providing the ability to trend and save trended data. Pressure sensors are designed for steam-in-place, gamma sterilization and autoclaving. Universal pressure sensor(s) can read absolute vacuum to 100 psi pressure (with signal scaling narrowing the pressure range as needed). Assembly is fully integral, which sustains claimed pressure values and sterility. Sensor integrity is compression based in that the component stack is permanently snapped in place. Onesystem can measure and trend simultaneously four pressure sensor values. Sensors are pre-calibrated, ready for use. Sensor accuracy can be increased by a built-in calibration method.

[0013] A system is disclosed for monitoring pressure in a bioprocessing system.The pressure monitoring system can include a connector including a plurality of electrically conductive pins disposed therethrough, a sensor cap having an opening for receiving a distal portion of the connector, a sensor spacer having an upper end engageable with a surface of the sensor cap, a sensor having a printed circuit board (PCB) disposed thereon, the PCB including a plurality of wire solder points for electrically coupling to the plurality of electrically conductive pins, a sensor insert for receiving the sensor therein, the sensor insert having a sealing portion, and a sensor housing having a seat portion for receiving the sealing portion thereon, and an upper flange portion for coupling to the sensor cap.

[0014] The system can also include a connector nut for thread able engaging threads disposed on the distal portion of the connector, and for fixing the connector to the sensor cap. The system can further include an o-ring disposed between the sensor cap and an upper surface of the sensor housing.

[0015] The sensor cap can include a plurality of resilient arms, each of said resilient arms having a barb at a distal end thereof for retaining the upper flange portion of the sensor housing when the sensor cap is snapped into engagement with the sensor housing. The upper flange portion of the sensor housing can have a plurality of openings for receiving the plurality of resilient arms and barbs therethrough. The sensor housingcan include an opening in a wall of the sensor housing for exposing the sensor to an interior portion of the sensor housing.

[0016] In some embodiments the sensor includes a gel portion for sealing a sensing element of the sensor therein, the gel portion configured to prevent fluid disposed within the housing from contacting the sensing element.

[0017] In some embodiments the connector includes a shorted connection between a selected two of said electrically conductive pins. The shorted connection between the selected two of said electrically conductive pins can be associated with a reading range of said sensor. The connector can be color-coded to correspond with a predetermined sensing range of said sensor.

[0018] The system can also include a monitoring and measuring system in electrical communication with at least some of the electrically conductive pins for receiving a signal from the sensor. In some embodiments the sensing system includes a processor executing instructions for recognizing the shorted connection and automatically adjusting the sensing system to recognize a predetermined pressure sensing range associated with the shorted connection.

[0019] In some embodiments the plurality of wire solder points electrically couple to the plurality of electrically conductive pins via a plurality of wires. In other embodiments the plurality of wire solder points electrically couple to the plurality of electrically conductive pins via a flexible circuit board. The sensor spacer may have a recess in a side wall thereof for receiving a central portion of the flexible circuit board.

[0020] Additional aspects and embodiments will be evident to skilled artisans in view of the disclosure that follows.Brief Description of the Drawings

[0021] The accompanying drawings illustrate preferred embodiments of the disclosed method so far devised for the practical application of the principles thereof, and in which:

[0022] FIG. 1 is an exploded view of an example embodiment of the disclosed sensor fitting system.

[0023] FIG. 2 is a cross-section view of the sensor fitting system of FIG. 1, in the assembled configuration.

[0024] FIG. 3 is an isometric view of an example sensor assembly for use with the sensor fitting system of FIG. 1.

[0025] FIGS. 4A - 4C are isometric views of sensor fitting systems of FIG. 1 provided in different color-coded sensing ranges.

[0026] FIGS. 5A and 5B are schematic views of wiring arrangements for a pressure sensor for use in the system of FIG. 1.

[0027] FIGS. 6A-6F are isometric, top, and side views of the sensor fitting system of FIG. 1, at various levels of assembly.

[0028] FIGS. 7A-7D show side, plan, cross-section, and isometric views of a sensor housing insert of the system of FIG. 1.

[0029] FIGS. 8A-8D show side, plan, cross-section, and isometric views of a sensor spacer of the system of FIG. 1.

[0030] FIGS. 9A-9D show side, plan, cross-section, and isometric views of a sensor cap of the system of FIG. 1.

[0031] FIG. 10 shows an exploded view of an example embodiment of the disclosed sensor fitting system.

[0032] FIG. 11 shows is a cross-section view of the sensor fitting system of FIG. 10, in the assembled configuration.

[0033] FIG. 12 shows is an isometric view of an example sensor assembly for use with the sensor fitting system of FIG. 10.

[0034] FIGS. 13A-13F show are top, and isometric views of the sensor fitting system of FIG. 10, at various levels of assembly.

[0035] FIGS. 14A-14D show side, plan, cross-section, and isometric views of a sensor housing employing a luer base fitting for use with the systems of FIGS. 1 and 10.

[0036] FIGS. 15A-15D show side, plan, cross-section, and isometric views of a sensor housing employing a 1-inch hose barb fitting for use with the systems of FIGS. 1 and 10.

[0037] FIGS. 16A-16D show side, plan, cross-section, and isometric views of a sensor housing employing a 1 / 2-inch hose barb fitting for use with the systems of FIGS.1 and 10.

[0038] FIGS. 17A-17D show side, plan, cross-section, and isometric views of a sensor housing employing a % - inch hose barb fitting for use with the systems of FIGS. 1 and 10.

[0039] FIGS. 18A-18D show side, plan, cross-section, and isometric views of a sensor housing employing a 1 / 8-inch hose barb fitting for use with the systems of FIGS. 1 and 10.

[0040] FIGS. 19A-19D show side, plan, cross-section, and isometric of a sensor housing employing a 1-1 / 2-inch TC fitting for use with the systems of FIGS. 1 and 10.

[0041] FIGS. 20A-20D show side, plan, cross-section, and isometric views of a sensor housing employing a 1-1 / 2-inch hose barb fitting for use with the systems of FIGS. 1 and 10

[0042] FIGS. 21A-21D show side, plan, cross-section, and isometric views of a sensor housing employing a %-inch hose barb fitting for use with the systems of FIGS. 1 and 10.

[0043] FIGS. 22A-22D show side, plan, cross-section, and isometric views of a sensor housing employing a %-inch TC fitting for use with the systems of FIGS. 1 and 10.

[0044] FIGS. 23A-23D show side, plan, cross-section, and isometric views of a sensor housing employing a 3 / 8-inch hose barb fitting for use with the systems of FIGS.1 and 10.

[0045] FIG. 24 is a schematic view of a measurement and monitoring system including the system of FIG. 1.

[0046] It should be understood that the drawings are not necessarily to scale and that the disclosed embodiments are often illustrated diagrammatically and in partial views. In certain instances, details which are not necessary for an understanding of the disclosed methods and devices, or which render other details difficult to perceive may have been omitted.Description of Embodiments

[0047] FIGS. 1 and 2 illustrates an example sensor assembly 1 in the context of an example sensor housing 2 which in the illustrated non-limiting example embodiment is a T-fitting with TC connection ends. The sensor assembly 1 includes a binder connector 4 or any appropriate type of industrial connector, a plurality of wire leads 6 (which in some embodiments can be replaced with a flexible printed circuit board), a connector washer 8, a sensor cap 10, a connector nut 12, an elastomeric o-ring 14, a sensor spacer 16, a sensor 18 having a printed circuit board (PCB) 20 wire solder points 20 disposed on a top surface thereof, and a sensor insert 22. The sensor assembly 1 can be assembled and coupled to the sensor housing 2 by snapping the sensor cap 10 into engagement with an upper flange 24 of the sensor housing 2.

[0048] FIG. 2 shows the assembled stack-up of elements that comprise the sensor assembly 1. As can be seen, the sensor 18 is pressed into engagement with a surface of the sensor housing 2 directly adjacent an opening 26 through the wall 28 of the sensor housing, thus directly exposing the sensor to the fluid flowing through or disposed withinthe sensor housing. The sensor 18 is seated in a first recess 30 in the sensor insert 22, while the sensor spacer 16 is seated in a second recess 32 in the sensor insert. The sensor spacer 16 engages an upper surface of the PCB and presses the sensor 18 into engagement with the sensor insert 22. In some embodiments the sensor insert 22 is made from an elastomer (e.g., silicone) so that it acts as a gasket, sealing against a conical seat portion 34 of the sensor housing 2 to prevent leakage of process fluid through the sensor assembly 1.

[0049] The sensor cap 10 can include a plurality of resilient arms 36 sized and configured to be received through corresponding openings 38 in the upper flange 4 of the sensor housing 2. Barbs 41 disposed on the distal ends of each of the plurality of resilient fingers 36 engage an undersurface of the upper flange 4, thus preventing removal of the sensor assembly 1 from the sensor housing once the two are engaged.

[0050] The sensor spacer 16 can be configured to build up the height of the sensor assembly stack so that the binder connector 4 is accessible at a common height above the sensor cap regardless of the size and type of sensor housing 2 is employed. As will be appreciated, an upper end of the binder connector 4 can include a plurality of pins 40 for electrically and physically coupling to a measurement and monitoring system (see FIG.19.)

[0051] A distal end 42 of the binder connector 4 passes through an opening 44 in the sensor cap 10 and is secured thereto via the connector nut 12. The wire leads 6 (or pins) of the binder connector 4 fit through the sensor spacer 16 and are connected (e.g., soldered) to the PCB 20 coupled to the top of the sensor 18.

[0052] The o-ring 14 is disposed within the sensor cap 10 and seals between an underside surface of the sensor cap 10 and the upper flange 24 of the sensor housing 2 to prevent leakage of process fluid past the upper flange.

[0053] The receiving portion (the upper T) of the sensor housing 2 and the stack up of elements of the sensor assembly 1 are the same between the different versions and sizes of the fittings, thus enabling a single sensor assembly 1 design to be used across a variety of sensor housing types and sizes (see, e.g., FIGS. 14-23). The sensor housing 2 is, in some embodiments, made from polysulfone or other material suitable for autoclaving.

[0054] As mentioned, the above arrangement places the sensor 18 in direct contact with process fluid (e.g., liquid, air or other gas) flowing through the sensor housing 2, thus allowing the sensor to accurately measure pressure in the fluid including vacuum pressure.

[0055] FIG. 3 is an isometric view of an example sensor assembly for use with the sensor fitting system of FIG. 1. The sensor assembly includes a sensor 18 surrounded by a support wall 19 that is mounted on top of the PCB 20. The support wall 19 in the illustrated embodiment is generally cylindrical, though other shapes are contemplated, surrounding the sensor 18. An interior portion of the support wall 19 is filled with a gel 21, which in one non-limiting embodiment is a silicone gel. The gel 21 covers and encapsulates the sensor 18 to protect the sensor while allowing it to sense the pressure in the fluid passing through or within the sensor housing 2.

[0056] FIGS. 4A-4C show three different sensor assembly 1 and sensor housing 2 combinations, in which the sensor in each of the figures is calibrated to different pressure range. Each of the binder connectors of the three sensor assemblies bears a different color, each of which represents a different standardizes pressure sensing range. For example, the blue binder connector (FIG. 4A) can indicate that the associated sensor has been calibrated to sense fluid pressures of from -14.7 to +15.0 psi, the white binder connector (FIG. 4B) can indicate that the associated sensor has been calibrated to sense fluid pressures of from 0.0 to +30.0 psi, and the red binder connector (FIG. 4C) can indicate that the associated sensor has been calibrated to sense fluid pressures of from 0.0 to +60 psi. This color-coding scheme can enable a user to quickly and easily identify the sensor assembly 1 and sensor housing 2 having a desired pressure sensing range.

[0057] FIGS. 5A and 5B show how the binder connector 4 of a sensor assembly 1 can be configured to enable a connected measuring and monitoring system (see FIG. 24) to recognize the calibrated range of the associated sensor 18 and to automatically adjust at least one sensing system setting accordingly. As mentioned, the sensor 18 of the sensor assembly 1 is calibrated to reduce the reading range to thereby maximize accuracy. Since only a limited / defined number of data points can be read across the entire range of the sensor, reducing the reading range maximizes the number of data points within that range. As shown in FIGS. 4A-4C, this calibration can, in some instances, be broken into three pressure ranges, each signified by a different color. It will be appreciated that the disclosure is not limited to three ranges, and thus the sensors can be calibrated to any desired range.

[0058] As shown in FIGS. 5A and 5B, pins on the binder connector can be shorted with a jumper, so that when the binder connector is coupled to a sensing system, the sensing system senses the two shorted pins and automatically recognizes which pressure sensing range the sensor has been calibrated to, and automatically sets the range within the sensing system. This eliminates the need for the user to manually adjust settings within the sensing system to accommodate the associated sensor assembly 1.

[0059] For example, as shown in FIG. 5B, a sensing range of from -14.7 to +15.0 psi can be associated with a first pin shorting (e.g., pin 8 shorted to pin 3), a sensing range of from 0 to +30 psi can be associated with a second pin shorting (e.g., pin 8 shorted to pin 4), and a sensing range of from 0 to +60 psi can be associated with a third pin shorting (e.g., pin 8 shorted to pin 7). It will be appreciated that these ranges are merely examples, and that other ranges can be used.

[0060] FIGS. 6A - 6F illustrate the assembly steps to obtain a sensor assembly 1 according to the disclosure. FIG. 6A shows the binder connector with wire leads 6. Pin 8 is shorted to pin 3, thus resulting in an example sensing range of from -14.7 to +15.0 psi. In FIG. 6B, the binder connector 4 is coupled to the sensor cap 10 and is secured thereto via connector nut 12, which engages threads on a portion of the binder connector that extends through the sensor cap. In FIG. 6C, the sensor spacer 16 is coupled to the binder connector 4 and the sensor cap 10 such that wire leads 6 extend through the sensor spacer. In FIG. 6D, the wire leads 6 are soldered to associated contacts on the PCB 20 which is coupled to the sensor 18. O-ring 14 is received within a recess in the sensor cap10. In FIG. 6E, the sensor subassembly 46 is positioned adjacent to the sensor housing 2,along with a sensor insert 22. FIG. 6F shows the sensor assembly 1 in the fully assembled condition.

[0061] FIGS. 7A-7D show the sensor insert 22 in greater detail. As mentioned, the sensor insert 22 functions to seal against the conical seat portion 34 of the sensor housing 2 and also to receive portions of the sensor 18, PCB 20, and sensor spacer 16. Thus, the sensor insert 22 has an upper cylindrical portion 48, a central conical portion 50, and a lower flat portion 52. The upper cylindrical portion 48 is sized to be received within a corresponding cylindrical portion 54 of the sensor housing 2 (see FIG. 2). The central conical portion 50 is sized and shaped to be received by the conical seat portion 34 of the sensor housing 2. The lower flat portion 52 engages a wall of the sensor housing 2. The lower flat portion 52 has an opening 56 that aligns with the opening 26 in the wall of the sensor housing 2 when the sensor insert 2 is engaged with the sensor housing 2.

[0062] The sensor insert 22 also includes a plurality of internal cylindrical recesses for receiving and aligning other components of the sensor assembly 1. For example, the first recess 30, which is located directly adjacent the opening 56, is sized and configured to receive the sensor 18 therein. The second recess 34, which is located within the upper cylindrical portion 48 of the sensor insert 22, is sized and configured to receive a portion of the sensor spacer 16. A third recess 58 is disposed between the first and second recesses 30, 34, and is sized to receive the PCB 20 therein.

[0063] As previously mentioned, the sensor insert 22 can be made from an elastomer, such as silicone, so that a fluid tight seal is provided between the adjoiningsurfaces, thus preventing process fluid from entering the upper portion of the sensor housing 2.

[0064] FIGS. 8A-8D show the sensor spacer 16 of FIG. 1 in greater detail. As mentioned, the sensor spacer is configured to ensure that a consistent stack up of the sensor assembly 1 is maintained. The sensor spacer 16 can be a cylindrical element with a predetermined height “H”, and a diameter “D” that enables a portion of the sensor spacer is received within the second recess 34 of the sensor insert 22. A plurality of web elements 60 form a cross shape within the sensor spacer 16 so that a plurality of axial openings 62 are provided through the sensor spacer. As can best be seen in FIG. 6C, these openings receive the wire leads 6 therethrough so that the binder connector 4 can be electrically coupled to the PCB 20. An upper rim portion 64 of the sensor spacer 16 is configured to engage a surface of the sensor cap 10 when the sensor cap is engaged with the upper flange 24 of the sensor cap.

[0065] FIGS. 9A-9D show the sensor cap 10 of FIG. 1 in greater detail. As mentioned, the sensor cap 10 includes a plurality of resilient arms 36 that are configured to snap onto the upper flange 24 of the sensor fitting 2. Barbs 41 disposed on the distal ends of each of the plurality of resilient arms 36 engage an undersurface of the upper flange 4, thus preventing removal of the sensor assembly 1 from the sensor housing once the two are engaged. The sensor cap and resilient arms are configured to prevent the sensor assembly 1 from being removed from the sensor housing 2 once the cap has been fully engaged with the upper flange.

[0066] FIGS. 10 and 11 illustrate an example sensor assembly 100 in the context of an example sensor housing 102 which in the illustrated non-limiting example embodiment is a T-fitting with TC connection ends. The sensor assembly 100 is substantially similar to the sensor assembly 1 of FIG. 1 except that the sensor assembly 100 includes a flexible circuit board 115 to couple the wires 106 of the binder connector 104 to the printed circuit board (PCB) 120 of the sensor 118.

[0067] As shown, the sensor assembly 100 includes a binder connector 104, a plurality of wire leads 106, a flexible circuit board 115, a connector washer 108, a sensor cap 110, an elastomeric o-ring 114, a sensor spacer 116, a sensor 118 having a printed circuit board (PCB) 120, and a sensor insert 122. The sensor assembly 100 can be assembled and coupled to the sensor housing 102 by snapping the sensor cap 110 into engagement with an upper flange 124 of the sensor housing 102. The flexible circuit board 115 can align with the connecting points on the binder connector side and the pressure sensor side. The binder connection side of the flexible circuit board 115 includes a pressure range identification as previously described, in which two connector pins are shorted to indicate a reading range of the sensor assembly. Three different flexible circuit boards 115 representing three different pressure ranges can be used used in the sensor assembly 100.

[0068] FIG. 11 shows the assembled stack-up of elements that comprise the sensor assembly 100. As can be seen, the sensor 118 is pressed into engagement with a surface of the sensor housing 102 directly adjacent an opening 126 through the wall 128 of the sensor housing, thus directly exposing the sensor to the fluid flowing through or disposed within the sensor housing. The sensor 118 is seated in the sensor insert 122, in amanner similar to that previously described in relation to the sensor 1 of FIG. 1. In some embodiments the sensor insert 122 is made from an elastomer (e.g., silicone) so that it acts as a gasket, sealing against the sensor housing 102 to prevent leakage of process fluid through the sensor assembly 100.

[0069] The sensor cap 110 can include a plurality of resilient arms 136 sized and configured to be received through corresponding openings 138 in the upper flange 140 of the sensor housing 102. Barbs 141 disposed on the distal ends of each of the plurality of resilient arms 136 engage an undersurface of the upper flange 140, thus preventing removal of the sensor assembly 100 from the sensor housing once the two are engaged.

[0070] The sensor spacer 116 can be configured to build up the height of the sensor assembly stack so that the binder connector 104 is accessible at a common height above the sensor cap regardless of the size and type of sensor housing 102 is employed. As will be appreciated, an upper end of the binder connector 104 can include a plurality of pins 144 for electrically and physically coupling to a measurement and monitoring system see FIG. 24.)

[0071] As can be seen, a distal end 142 of the binder connector 104 passes through an opening 144 in the sensor cap 110 and is secured thereto via the connector nut 112. The wire leads 106 of the binder connector 104 are coupled to a first end 115a of the flexible circuit board 115, while the second end 115b of the flexible circuit board are coupled to the PCB 120 of the sensor 118.

[0072] The o-ring 1 14 is disposed within the sensor cap 110 and seals between an underside surface of the sensor cap 110 and the upper flange 124 of the sensor housing 102 to prevent leakage of process fluid past the upper flange.

[0073] The receiving portion (the upper T) of the sensor housing 102 and the stack up of elements of the sensor assembly 100 are the same between the different versions and sizes of the fittings, thus enabling a single sensor assembly 100 design to be used across a variety of sensor housing types and sizes (see, e.g., FIGS. 14A-23D). The sensor housing 102 is, in some embodiments, made from polysulfone or other material suitable for autoclaving.

[0074] As mentioned, the above arrangement places the sensor 118 in direct contact with process fluid flowing through the sensor housing 102, thus allowing the sensor to accurately measure pressure in the fluid, including vacuum pressure.

[0075] FIG. 12 is an isometric view of an example sensor assembly for use with the sensor fitting system of FIG. 10. The sensor assembly includes a sensor 118 surrounded by a support wall 119 that is mounted on top of the PCB 120. The support wall 119 in the illustrated embodiment is generally cylindrical, though other shapes are contemplated, surrounding the sensor 118. An interior portion of the support wall 119 is filled with a gel 121, which in one non-limiting embodiment is a silicone gel. The gel 121 covers and encapsulates the sensor 118 to protect the sensor while allowing it to sense the pressure in the fluid passing through or within the sensor housing 102.

[0076] FIGS. 13A - 13F illustrate the assembly steps to obtain a sensor assembly100 according to the disclosure. FIGS. 13A and 13B show the binder connector 104 withpins 106 soldered to connections on the first end 115a of the flexible circuit board 1 15. FIGS. 13B and 13C show the PCB 120 and sensor 118 soldered to the second end 115b of the flexible circuit board, thus electrically connecting the pins 106 with the appropriate contacts of the PCB 120. In FIG. 13D, the binder connector 104 is coupled to the sensor cap 110 and is secured thereto via connector nut (not shown), which engages threads on a portion of the binder connector that extends through the sensor cap. In FIG. 13E, the sensor spacer 116 is coupled to the binder connector 104 and the sensor cap 110 such that a central portion 115c the flexible circuit board 115 extends through a recess 116a in the wall of the sensor spacer 116. In FIG. 13F, the flexible circuit board 115 is bent to position its second end 115b and the sensor 118 beneath the sensor spacer 116, and the sensor insert 122 is fit over the sensor. The resulting sensor subassembly 146 can then be coupled to the sensor housing 102, along with a sensor insert 22.

[0077] FIGS. 14A-23D illustrate various sensor housing 2 configured to receive the sensor assembly 1 of FIG. 1 or the sensor assembly 100 of FIG. 10. For example, FIGS. 14A-14D show a sensor housing 2 with a Luer end connection, FIGS. 15A-15D show a sensor housing 2 with 1-inch hose barb end connections, FIGS. 16A-16D show a sensor housing 2 with 1 / 2 -inch hose barb end connections, FIGS. 17A-17D show a sensor housing 2 with 1 / 4 -inch hose barb end connections, FIGS. 18A-18D show a sensor housing 2 with 1 / 8 - inch hose barb end connections, FIGS. 19A-19D show a sensor housing 2 with 1-1 / 2 - inch tube clamp end connections, FIGS. 20A-20D show a sensor housing 2 with 1-1 / 2 - inch hose barb end connections, FIGS. 21A-21D show a sensor housing 2 with 3 / 4- inch hose barb end connections, FIGS. 22A-22D show asensor housing 2 with 3 / 4-inch tube clamp end connections, and FIGS. 23A-23D show a sensor housing 2 with 3 / 8 - inch hose barb end connections.

[0078] Although the sensor fittings 2 of FIGS. 14A-23D include different tube connection sizes (from 1 / 8 - inch to 1-1 / 2 inch) and tube connection types (hose barb, Luer, TC), they all have an identical conical seat portion 34 (see FIG. 2) so that they all can receive and seal the sensor 18 and sensor insert 22 of the sensor assembly 1. All the sensor fittings 2 of FIGS. 14A-23D also include an identical upper flange 4 for engaging the sensor cap 10 of the sensor assembly 1. As will be appreciated, this arrangement enables a common sensor subassembly 46, 146 (FIGS. 6E and 13E) to be used with any of a variety of different sensor housings 2.

[0079] FIG. 24 illustrates a non-limiting example measurement and monitoring system 66 for use with the sensor assembly 1 of the present disclosure. A plug 68 can be coupled to the binder connector 4 to electrically connect to the pins 40 (FIG. 2) of the binder connector. The plug 68 can be coupled to a first converter 70 that in one example embodiment can convert 24VDC to 5VDC. The first converter 70 can be coupled to a second converter 72, which in one example embodiment is a 90-220 VAC to 24VDC converter. The second converter 72 can be electrically coupled to a common 90-220 VAC input (i.e., a wall plug) 74. A digital I / O module 76 can be coupled to the plug 68 and can be used to receive electrical signals from the sensor 18 of the connected sensor assembly The pressure values can be channeled to a signal conditioning module installed in user’s electrical / electronic enclosure or in an independent, tabletop reader. The pressure values are displayed (and can be trended) on the equipment human machine interface (HMI). Alternatively, an independent processor-based system such as a PC can also monitor andtrend pressure values. A pressure signal conversion module, which may be DIN rail mountable, can be installed in any low voltage electronic enclosure with other pressure reading-unrelated components or as an independently standing mini module with multiple pressure sensor connectivity (e.g., up to 8) to read, trend and historize pressure values in any process application. In some embodiments the pressure signal from the sensor of the sensor assembly 1 can be processed using a custom printed circuit board with firmware and may be visualized, trended and historized by a custom PC program or off the shelf signal converter with a connectivity to a PLC and visualized on a PC based SCADA program.

[0080] Pressure sensor arrangements according to the disclosure may be provided in the feed line, the retentate line, the permeate line, or any other desired location within a fluid processing system. Pressures obtained via such pressure sensors can be used, in non-limiting example embodiments, to determine transmembrane pressure (TMP) of a filter in the system.

[0081] While the present invention has been disclosed with reference to certain embodiments, numerous modifications, alterations and changes to the described embodiments are possible without departing from the spirit and scope of the invention, as defined in the appended claims. Accordingly, it is intended that the present invention not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof.

Claims

CLAIMSWhat is claimed is1. A system for monitoring pressure in a bioprocessing system, the pressure monitoring system comprising: a connector including a plurality of electrically conductive pins disposed therethrough, a sensor cap having an opening for receiving a distal portion of the connector, a sensor spacer having an upper end engageable with a surface of the sensor cap, a sensor having a printed circuit board (PCB) disposed thereon, the PCB including a plurality of wire solder points for electrically coupling to the plurality of electrically conductive pins, a sensor insert for receiving the sensor and a portion of the sensor spacer, the sensor insert having a sealing portion, and a sensor housing having a seat portion for receiving the sealing portion thereon, and an upper flange portion for coupling to the sensor cap.

2. The system of claim 1, further comprising a connector nut for threadably engaging threads disposed on the distal portion of the connector, and for fixing the connector to the sensor cap.

3. The system of claim 1, further comprising an o-ring disposed between the sensor cap and an upper surface of the sensor housing.

4. The system of claim 1, the sensor cap further comprising a plurality of resilient arms, each of said resilient arms having a barb at a distal end thereof for retaining the upper flange portion of the sensor housing when the sensor cap is snapped into engagement with the sensor housing.

5. The system of claim 1, the upper flange portion of the sensor housing including a plurality of openings for receiving the plurality of resilient arms and barbs therethrough.

6. The system of claim 1, wherein the sensor housing includes an opening in a wall of the sensor housing for exposing the sensor to an interior portion of the sensor housing.

7. The system of claim 1, wherein the sensor further includes a gel portion for sealing a sensing element of the sensor therein, the gel portion configured to prevent fluid disposed within the housing from contacting the sensing element.

8. The system of claim 1, wherein the connector includes a shorted connection between a selected two of said electrically conductive pins.

9. The system of claim 8, wherein the shorted connection between the selected two of said electrically conductive pins associated with a reading range of said sensor.

10. The system of claim 1, further comprising a monitoring and measuring system in electrical communication with at least some of the electrically conductive pins for receiving a signal from the sensor.

11. The system of claim 10, wherein the sensing system includes a processor executing instructions for recognizing the shorted connection and automatically adjusting the sensing system to recognize a predetermined pressure sensing range associated with the shorted connection.

12. The system of claim 1, wherein the connector is color-coded to correspond with a predetermined sensing range of said sensor.

13. The system of claim 1, wherein the plurality of wire solder points electrically couple to the plurality of electrically conductive pins via a plurality of wires.

14. The system of claim 1, wherein the plurality of wire solder points electrically couple to the plurality of electrically conductive pins via a flexible circuit board.

15. The system of claim 13, wherein the sensor spacer has a recess in a side wall thereof for receiving a central portion of the flexible circuit board.

16. The system of claim 1, wherein the system is configured to provide flexibility in measuring, trending, and historizing multiple pressure sensor readings by a variety of custom and standard signal converting devices integrating pressure sensors measurement to a variety of different technologies for monitoring, control and alarming of over / under pressure values.

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