Single-Use Bioreactor Baffles for Fluid Dynamics
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Solution Overview
Problem
Existing single-use bioreactors with flexible walls are unsuitable for parallel bioreactor systems and lack the scalability and fluid dynamics required for microbiology applications, while dimensionally stable single-use bioreactors are expensive and not adaptable for microbiology research or process engineering.
Innovation Solution
A dimensionally stable single-use bioreactor with baffles extending from the head plate into the reaction chamber, featuring an inner fluid compartment for enhanced fluid flow and temperature control, allowing for improved mixing efficiency and cost-effective construction suitable for microbiology applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flexible wall single-use bioreactors are used, then cost is reduced and ease of manufacture is improved, but dimensionally stable structure required for parallel bioreactor systems and proper fluid dynamics are lost
Solution Approach 1:
The bioreactor employs a flexible pouch structure made of thin film material that provides dimensional stability when filled with culture medium, while maintaining ease of manufacture through cost-effective molding processes. The flexible shell achieves the desired dimensional stability through fluid pressure support rather than rigid construction.
Solution Approach 2:
The bioreactor transitions from a collapsed flexible pouch to an expanded dimensional stable structure by changing the parameter of internal fluid pressure. When filled with culture medium, the flexible walls expand and maintain a stable dimensional configuration suitable for parallel bioreactor systems and proper fluid dynamics.
2Ease of manufacture
If flexible wall single-use bioreactors are used, then production cost is reduced, but scalability and fluid dynamics required for microbiology applications are compromised
Solution Approach 1:
The flexible pouch construction enables cost-effective manufacturing while the internal baffle structure and fluid-filled design provide the dimensional stability and fluid dynamics characteristics needed for scalable microbiology applications in parallel bioreactor systems.
Solution Approach 2:
The flexible pouch acts as an intermediary structure that bridges the gap between low-cost single-use design and the dimensional stability requirements for scalability. The pouch is molded with integrated baffle structures that mediate between the flexible container walls and the culture medium to achieve proper fluid dynamics.
3Ease of manufacture
If flexible wall single-use bioreactors are used, then cost is reduced, but temperature control capability is lost
Solution Approach 1:
The flexible pouch serves as a thermal intermediary with high surface area to volume ratio, enabling efficient heat transfer for temperature control. The thin flexible walls facilitate thermal exchange between the culture medium and external temperature control systems while maintaining cost-effective single-use construction.
Solution Approach 2:
The thin flexible film walls provide excellent thermal conductivity for temperature control while maintaining structural integrity. The flexible shell design allows for efficient heat transfer surfaces to be integrated into the bioreactor structure without compromising the cost-effective single-use nature.
4Productivity
If dimensionally stable single-use bioreactors are used, then scalability and fluid dynamics are improved, but production cost increases
Solution Approach 1:
The flexible pouch construction with integrated baffle structures provides a cost-effective alternative to rigid dimensionally stable bioreactors. The flexible shell achieves the necessary dimensional stability when filled, enabling scalability while maintaining low production costs through efficient molding processes.
Solution Approach 2:
The bioreactor achieves dimensional stability through parameter change from collapsed to expanded state when filled with culture medium. This allows the use of cost-effective flexible materials that gain dimensional stability under operating conditions, enabling scalability without high production costs.
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
The bioreactor provides effective fluid flow, mixing, and temperature control, reducing costs and enabling its use in microbiology research and process engineering with improved scalability and fluid dynamics, while maintaining a low production cost.
Implementation Method 1
The inner fluid compartment can be provided with a cooling fluid flow so that the baffle simultaneously functions as a baffle and as a temperature control device
Implementation Method 2
providing at least one baffle within the reaction chamber which is projecting from the head plate and which has an inner fluid compartment
Data Source
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AI summary
The invention relates to a single-use bioreactor, suitable in particular for use in a bioreactor system, for growing biomass particles, comprising a head plate, a dimensionally stable container and a mixer, wherein the head plate and the container enclose a reaction chamber with the mixer positioned in the reaction chamber, the head plate having an inner side facing towards the reaction chamber, and an outer side which faces away from the reaction chamber and which has a plurality of connectors, and comprising at least one baffle extending from the head plate into the reaction chamber, the baffle having an inner fluid compartment.