3D-Printed Filter-Sparger Assembly for Downtime-Free Media Selection
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Solution Overview
Problem
Current sparging and filtration systems require component swapping, leading to process interruptions and increased downtime due to inefficiencies in component exchange.
Innovation Solution
Selectable media filter and sparger assemblies fabricated via additive manufacturing, featuring a plurality of filtration and sparging members with independent connection ports, allowing for seamless switching between different filtration and sparging operations without system interruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If component swapping is used for sparging and filtration, then operational flexibility is achieved, but process interruptions and downtime increase
Solution Approach 1:
The patent combines multiple sparging and filtration components into a single integrated assembly that can be installed once and operated continuously. The assembly includes multiple porous elements with different pore sizes that can be selectively activated without removing the entire assembly, thereby eliminating downtime associated with component swapping while maintaining operational flexibility.
Solution Approach 2:
The patent implements a dynamic system where different porous elements can be selectively activated or deactivated during operation. This allows the system to adapt to different operational requirements (sparging vs. filtration, different filtration levels) without physical reconfiguration, thus maintaining versatility while avoiding process interruptions.
2Productivity
If multiple filtration and sparging members are integrated into a single housing, then process continuity is improved, but device complexity increases
Solution Approach 1:
The patent divides the integrated assembly into distinct modular porous elements, each with specific functions (sparging or filtration at different levels). These segmented elements are arranged within a single housing but can be independently selected and activated, managing complexity through functional modularity while maintaining process continuity.
Solution Approach 2:
The patent designs a universal assembly that performs multiple functions (sparging, coarse filtration, fine filtration) within a single housing. The same structural framework supports different operational modes, reducing the need for multiple separate devices while maintaining productivity through continuous operation.
3Adaptability or versatility
If additive manufacturing is used for fabrication, then manufacturing flexibility and customization are enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes additive manufacturing to precisely control porous structure parameters (pore size, porosity, wall thickness) during the fabrication process. By adjusting manufacturing parameters such as laser power, scan speed, and layer thickness, the system achieves the required manufacturing precision for different filtration levels while maintaining design flexibility for customization.
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
Enables efficient and flexible operation by allowing control over mass transfer rates and filtration levels without process interruptions, enhancing throughput and enabling in-situ measurements in applications like bio-reactors and fermentation tanks.
Implementation Method 1
fabricated at least in part by additive manufacturing (e.g., via a 3D printing process, such as, for example, via a laser powder bed fusion (LPBF) process
Implementation Method 2
via an electron-beam melting ('EBM') process
Implementation Method 3
via an inkjet or a binder-jet additive manufacturing process
Implementation Method 4
via an inkjet or a binder-jet additive manufacturing process
Implementation Method 5
filtration members having an independent connection port... filtration and/or sparging members... plurality of filtration and/or sparging members attached to a single housing
Implementation Method 6
sparging applications that require gas or liquid mass transfer... plurality of filtration and/or sparging members... gas or liquid mass transfer
Data Source
AI summary
The present disclosure provides advantageous selectable media filter and sparger assemblies, and improved systems/methods for utilizing and/or fabricating the selectable media filter and sparger assemblies. More particularly, the present disclosure provides selectable media filter and sparger assemblies fabricated at least in part by additive manufacturing (e.g., via a 3D printing process, such as, for example, via a laser powder bed fusion (LPBF) process, via an electron-beam melting (“EBM”) process, via an inkjet or a binder-jet additive manufacturing process, etc.), the selectable media filter and sparger assemblies including a plurality of filtration and/or sparging members attached to a single housing, with each filtration/sparging member having an independent connection port.