Bioreactor Double Jacket Spirally Circumferential Channel
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Solution Overview
Problem
Current bioreactors for cultivating cells or microorganisms face challenges such as economically unattractive designs, resource-intensive sterilization methods, suboptimal temperature control, and contamination risks due to inefficient heat transfer and sampling processes.
Innovation Solution
A reactor with a double jacket and a spirally circumferential channel bounded by inclined walls, allowing for uniform heat exchange and reduced energy loss, combined with 3D-printing for adaptable and sustainable production, eliminating the need for extra temperature control systems and minimizing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional water-jackets or heat blankets are used for temperature control, then heating or cooling can be achieved, but heat transfer is suboptimal and energy loss increases due to air sockets and material interfaces
Solution Approach 1:
The patent combines the heating/cooling medium flow path directly within the tank wall structure by forming flow channels in the printed circuit board (PCB) substrate. This integration eliminates the conventional separate water-jacket or heat blanket systems, removing air sockets and material interfaces that cause energy loss. The heating/cooling medium flows directly through channels in the PCB, ensuring optimal thermal contact with the culture medium without energy loss through air gaps or imperfect thermal interfaces.
Solution Approach 2:
The PCB substrate itself serves as the intermediary thermal transfer medium. Instead of using separate heating/cooling systems with poor thermal contact, the PCB acts as a direct thermal bridge between the heating/cooling medium and the culture medium. The flow channels are formed directly in the PCB, allowing efficient heat transfer while the PCB's rigid structure eliminates air sockets and ensures consistent thermal contact across the entire culture surface.
2Adaptability or versatility
If specialized bioreactors or impellers are designed for different cell or microorganism cultures, then optimal growth conditions can be achieved, but device complexity and cost increase
Solution Approach 1:
The patent creates a universal reactor design where the PCB-based temperature control system can be adapted to different cell and microorganism cultures without requiring specialized bioreactor designs. The modular PCB structure with configurable flow channels allows the same basic reactor design to serve multiple cultivation purposes. The system achieves versatility through software control and flow channel configuration rather than hardware specialization, reducing device complexity while maintaining adaptability to different cultural conditions.
3Measurement precision
If intermittent sample extraction is performed to analyze nutrient supply, then nutrient requirements can be monitored, but contamination risk increases and only spot checks are possible
Solution Approach 1:
The patent replaces the mechanical sample extraction process with an optical sensing system integrated into the reactor. Sensors are embedded in the PCB or positioned to contact the culture medium through the PCB structure, allowing continuous monitoring of nutrient levels, pH, and other parameters without mechanical intervention. This substitution eliminates contamination risk associated with opening the reactor for sampling while providing continuous, precise measurements rather than intermittent spot checks.
4Reliability
If repeated sterilization procedures are applied to water-based temperature regulation equipment, then decontamination can be achieved, but resource consumption and environmental hazard increase
Solution Approach 1:
The integrated PCB-based temperature control system with internal flow channels eliminates the need for separate external water-jackets that require repeated sterilization. The system's sealed internal channels and reduced surface area minimize contamination risk, and the rigid PCB structure allows for easier, less resource-intensive cleaning protocols. The design inherently reduces the need for chemical sterilization by minimizing exposed surfaces and eliminating external connections that are prone to contamination.
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 reactor achieves homogeneous temperature regulation, reduces energy consumption, and minimizes contamination risks while being economically and environmentally sustainable, with the ability to adapt to various uses and processes.
Implementation Method 1
the tempering medium usually is introduced via a first opening, flows through the spirally circumferential channel and is discharged via a second opening
Implementation Method 2
a homogenous and direct heat exchange with a tempering medium through only a single wall is ensured
Implementation Method 3
the inclined walls having a slope of 40° to 90° with respect to the horizontal... the tempering medium flows downwards along the spirally circumferential channel
Data Source
Figure 1
AI summary
The invention relates to a reactor for cultivating cells or multicellular microorganisms comprising a tank (3) with a double jacket (9), wherein the double jacket (9) encloses a jacket space (11), wherein at least one spirally circumferential channel (13) is formed in the jacket space (11), the spirally circumferential channel (13) being laterally bounded by inclined walls (15), the inclined walls (15) having a slope of 40° 90° with respect to the horizontal. The invention further relates to a process for cultivating cells or multicellular microorganisms using the reactor (1) and to a process for producing the tank (3).