Acoustophoretic Reflector for Bioreactor Cell Separation
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Solution Overview
Problem
Current bioreactor systems for producing biomolecules like recombinant proteins and monoclonal antibodies face high costs and inefficiencies due to the need for complex cell retention devices and costly filtration processes, which lead to non-productive downtime and material loss.
Innovation Solution
The implementation of an acoustophoretic device that uses multi-dimensional acoustic standing waves generated by ultrasonic transducers and a thin, acoustically transparent reflector to separate cells and cell debris from the desired products, allowing for efficient clustering and gravity separation without the need for traditional filtration methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional filtration methods are used to separate cells and cell debris from biomolecules, then separation can be achieved, but equipment complexity increases and non-productive downtime occurs
Solution Approach 1:
The patent replaces mechanical filtration systems with an acoustophoretic separation system that uses acoustic standing waves to separate cells and cell debris from biomolecules. The ultrasonic transducer generates acoustic radiation pressure that selectively traps cells at nodes while allowing biomolecules to pass through, eliminating the need for complex mechanical filters and reducing equipment downtime.
Solution Approach 2:
The patent extracts and removes the cell retention function from the traditional filtration system by implementing a disposable flow chamber with integrated acoustophoretic separation. This allows the separation mechanism to be built into the flow chamber itself rather than requiring separate complex retention equipment, thereby simplifying the overall system.
2Manufacturing precision
If costly filtration processes are used for product recovery, then separation efficiency improves, but operational costs increase
Solution Approach 1:
The patent employs a disposable flow chamber that contains the acoustophoretic separation mechanism. Instead of maintaining expensive, complex filtration systems that require cleaning and maintenance, the entire flow chamber can be discarded after use, reducing operational costs while maintaining high separation efficiency through the acoustic field generated by the ultrasonic transducer.
3Quantity of substance
If cell retention devices are implemented in perfusion bioreactors, then cell density increases, but operational reliability decreases due to malfunction risks
Solution Approach 1:
The patent replaces mechanical cell retention devices with an acoustophoretic separation system that uses acoustic standing waves to trap cells at nodes. This non-mechanical approach eliminates moving parts and complex valve systems that are prone to malfunction, thereby improving operational reliability while maintaining the ability to achieve high cell densities through continuous perfusion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the cost and effort of bioreactor operations by efficiently separating cells and cell debris from biomolecules, minimizing product loss and enhancing bioreactor productivity, while also being applicable in various bioreactor modes including perfusion and fed-batch processes.
Implementation Method 1
at least one ultrasonic transducer located on a wall of the flow chamber, the transducer including a piezoelectric material driven by a voltage signal to create a multi-dimensional acoustic standing wave in the flow chamber
Implementation Method 2
high intensity standing waves of sound can exert forces on particles in a fluid when there is a differential in both density and/or compressibility, otherwise known as the acoustic contrast factor
Implementation Method 3
A thin structure is located on the wall on the opposite side of the flow chamber from the at least one ultrasonic transducer. The thin structure provides a pressure release boundary that acts as a reflector
Implementation Method 4
the transducer including a piezoelectric material driven by a voltage signal to create a multi-dimensional acoustic standing wave in the flow chamber
Implementation Method 5
allowing for efficient clustering and gravity separation without the need for traditional filtration methods
Data Source
AI summary
An apparatus includes a flow chamber having at least one inlet and at least one outlet. At least one ultrasonic transducer is located on a wall of the flow chamber, which operates to create a multi-dimensional acoustic standing wave in the flow chamber. A reflector is located on the wall on the opposite side of the flow chamber from the at least one ultrasonic transducer. The reflector is formed from a thin structure that provides a pressure release boundary, such as a plastic film/air interface.