Bioreactor Inlet Flow Diverter for Splash and Foam Reduction
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Solution Overview
Problem
Existing bioprocessing technologies face challenges in delivering fluids to bioreactors without causing splashing or aeration, leading to foaming, and result in stagnant areas and reagent waste due to the use of pumps and submerged inlets, which are costly to sterilize and inefficient.
Innovation Solution
A flow diverter system that directs fluids above the fluid level in bioreactors, using a conduit and hood or deflecting film to minimize splashing and foaming, and incorporates multiple diverters and baffles to enhance mixing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fluids are delivered above fluid level using conventional ports, then delivery speed is improved, but splashing and foaming occur
Solution Approach 1:
A flow diverter component is introduced as an intermediary element between the inlet port and the bioreactor fluid. This diverter redirects the incoming fluid stream along the inner wall of the bioreactor, preventing direct impact and splashing while maintaining efficient fluid delivery above the fluid level.
Solution Approach 2:
The flow diverter utilizes a hood or deflecting film structure that can be integrated into the bioreactor wall. This flexible or semi-rigid component effectively redirects fluid flow without creating turbulence, eliminating splashing and foaming during rapid fluid delivery.
2Reliability
If pumps and submerged inlets are used, then sterilization reliability is improved, but device complexity and cost increase
Solution Approach 1:
The pump component is completely removed from the system. Instead of using a submerged pump to deliver fluids, the invention employs passive flow diverters that redirect incoming fluid streams, eliminating the need for complex sterilizable pumping mechanisms while maintaining delivery effectiveness.
Solution Approach 2:
The flow diverters are designed as simple, disposable components that can be easily sterilized or replaced. This approach trades the high cost and complexity of reusable pumps for inexpensive, single-use diverters that eliminate sterilization complexity while ensuring reliability.
3Ease of operation
If submerged inlets are used, then fluid delivery is simplified, but stagnant areas and reagent waste occur
Solution Approach 1:
Instead of delivering fluid horizontally at the bottom level, the flow diverter redirects the fluid stream vertically along the bioreactor wall from above. This dimensional change in fluid delivery path eliminates dead spots and ensures complete mixing, preventing reagent waste while maintaining operational simplicity.
4Stability of the object's composition
If multiple flow diverters and baffles are added, then mixing efficiency is improved, but device complexity increases
Solution Approach 1:
Multiple flow diverters are strategically positioned at different locations within the bioreactor to create segmented flow patterns. This segmentation of the fluid stream enhances mixing efficiency by preventing stagnant areas, while the modular placement keeps the overall device complexity manageable through systematic distribution rather than random addition of components.
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 flow diverter system effectively reduces splashing and foaming, enhances mixing, and prevents reagent waste by ensuring uniform distribution of fluids within bioreactors, improving process efficiency and reducing costs.
Implementation Method 1
a fluid diverter capable of directing a fluid down a sidewall of the bioreactor, attenuating a splashing or foaming condition
Data Source
AI summary
Some embodiments of the present disclosure comprise a flow diverter for use in a biocontainer or bioreactor, comprising a shoulder having a first surface and a second surface opposite the first surface, a conduit extending from the first surface of the shoulder, an inlet at a first end of the conduit, wherein the first end comprises a connector, an outlet formed within the second surface of the shoulder in fluid communication with the inlet at an end opposite the first end of the conduit and a hood adjacent to the outlet, wherein a fluid diverter is capable of directing a fluid down a sidewall of the biocontainer or bioreactor, attenuating a splashing or foaming condition.