Bioreactor Drive Head Coupling With Ferrous Impeller Connectors
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Solution Overview
Problem
Existing bioreactor systems face challenges with impellers containing costly permanent magnets that are discarded after single use, require significant magnetic gaps, and need complex lifting equipment for coupling and decoupling, limiting torque and rotational speed.
Innovation Solution
The impeller design incorporates ferrous connectors instead of permanent magnets, allowing for magnetic coupling and decoupling using a selectively magnetizable drive head with ferrous connectors, eliminating the need for lifting equipment and reducing magnetic gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If permanent magnets are used in impellers for magnetic coupling, then magnetic bond strength is improved, but cost increases and the magnets are discarded after single use
Solution Approach 1:
The patent replaces expensive permanent magnets in the impeller with inexpensive ferrous connectors that can be discarded with the single-use bag. The drive head contains the permanent magnets and can be reused. This resolves the contradiction by making the disposable component (impeller) cheap and the reusable component (drive head) contain the valuable magnets.
Solution Approach 2:
The patent enables discarding of the impeller with ferrous connectors after single use, while recovering and reusing the expensive drive head containing permanent magnets. This resolves the contradiction by separating the disposable ferrous connectors from the reusable permanent magnets in the drive head.
2Manufacturing precision
If a magnetic gap is provided between drive head and impeller magnets, then design tolerances are accommodated, but holding torque and rotational speed decrease
Solution Approach 1:
The patent changes the magnetic properties of the drive head from permanently magnetized to selectively magnetizable. This allows the magnetic field strength to be dynamically adjusted - strong enough for coupling and torque transmission, and can be controlled to minimize gap effects. This resolves the contradiction by making the magnetic interaction controllable rather than fixed.
Solution Approach 2:
The patent makes the magnetic coupling dynamic through selective magnetization and demagnetization of the drive head. The magnetic state can be changed on demand to optimize performance. This resolves the contradiction by allowing the system to adapt magnetic field strength to operational needs rather than being constrained by a fixed permanent magnet configuration.
3Power
If torque and rotational speed are increased in magnetic drive systems, then mixing performance is improved, but the number and size of magnets must be increased which is not possible
Solution Approach 1:
The patent replaces the mechanical constraint of fixed permanent magnet arrangements with a controllable magnetic field system. The selectively magnetizable drive head allows torque and speed control through magnetic field manipulation rather than being limited by physical magnet size and number. This resolves the contradiction by substituting mechanical limitations with controllable magnetic properties.
Solution Approach 2:
The patent enables torque and rotational speed optimization by changing the magnetic state parameters of the drive head. The selective magnetization allows adjustment of magnetic field strength and distribution to achieve desired power output without increasing magnet quantity or size. This resolves the contradiction by using parameter control rather than physical scaling.
4Ease of operation
If lifting equipment is used to couple drive head with impeller, then coupling is achieved, but equipment complexity and cost increase
Solution Approach 1:
The patent enables the drive head to self-couple with the impeller through magnetic attraction when brought into proximity. The selective magnetization creates automatic alignment and bonding without requiring external lifting or positioning equipment. This resolves the contradiction by making the coupling process self-service through magnetic forces rather than requiring complex mechanical equipment.
Solution Approach 2:
The patent replaces mechanical coupling equipment with magnetic coupling. The selectively magnetizable drive head creates magnetic bonds that automatically couple the drive head to the impeller, eliminating the need for lifting equipment. This resolves the contradiction by substituting mechanical coupling systems with magnetic coupling.
5Ease of operation
If significant forces are applied to decouple magnets, then separation is achieved, but equipment requirements and complexity increase
Solution Approach 1:
The patent uses periodic or reversible magnetic action for decoupling. The selective magnetization can be turned off or reversed to automatically release the magnetic bond, enabling easy decoupling without applying significant separating forces. This resolves the contradiction by using reversible magnetic action rather than forceful mechanical separation.
Solution Approach 2:
The patent replaces mechanical force-based decoupling with magnetic field-based decoupling. The selective magnetization control allows bond release through magnetic field manipulation rather than requiring significant mechanical forces. This resolves the contradiction by substituting mechanical separation forces with controllable magnetic field changes.
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 design increases holding torque and rotational speed, reduces costs by using less expensive ferrous connectors, and simplifies the coupling and decoupling process, minimizing parts and maintenance.
Implementation Method 1
The drive head and the impeller are selectively magnetically couplable to one another
Implementation Method 2
a magnetic bond between the ferrous connector and a selectively magnetizable drive head connector of the external motor
Data Source
AI summary
A vessel including an interior volume configured to contain a liquid and a magnetically driven impeller located within the interior volume. The impeller including a rotatable base portion with a blade, a rotatable shaft, and a ferrous connector. The impeller may be coupled to an external motor and rotated to agitate liquid in the interior volume, via a magnetic bond between the ferrous connector and a selectively magnetizable drive head connector of the external motor. The ferrous connector is not a permanent magnet.