Bioreactor Optical Foam Sensor with Photocatalytic Window
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Solution Overview
Problem
Bioreactor vessels with flexible outer walls face challenges in reliably detecting foam development due to foam accumulation on contact surfaces, leading to potential leaks and overuse of antifoaming agents, and existing solutions either enlarge the detector space or fail to accurately measure foam regression.
Innovation Solution
A bioreactor vessel with a window in its outer wall serving as a foam contact surface, coupled with an illumination and detection unit containing LEDs and photodetectors for visible light, and a UV-activatable photocatalytic titanium dioxide coating to actively break down foam, allowing for accurate foam detection and prevention without a separate foam detection space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate foam detection space is provided in the foam sensor, then foam can be detected, but the detector space becomes enlarged and complex
Solution Approach 1:
The patent merges the foam contact surface directly with the outer wall of the bioreactor vessel by incorporating a transparent window. This eliminates the need for a separate foam detection space while maintaining reliable foam detection capability, as the window serves both as a structural component of the vessel and as the foam contact surface for optical sensing.
2Reliability
If foam accumulates on the contact surface, then foam detection is enabled, but the detector cannot recognize foam regression and leads to overmetering of antifoaming agents
Solution Approach 1:
The patent converts the harmful effect of foam accumulation into a beneficial self-cleaning mechanism by applying a photocatalytic coating to the window surface. When UV light activates the coating, it breaks down organic foam residues, ensuring the contact surface remains clean and optically active. This enables continuous accurate foam detection and prevents overmetering of antifoaming agents.
3Ease of manufacture
If the bioreactor vessel has flexible outer walls, then it is suitable for disposable use, but foam development can cause pressure rise and leaks
Solution Approach 1:
The patent implements a feedback control system using the optical foam sensor to monitor foam levels in real-time. When foam is detected, the system can trigger antifoaming agent injection or adjust process parameters, preventing pressure buildup that would compromise the flexible vessel's integrity and prevent leaks.
4Reliability
If antifoaming agents are metered addition to counter foam development, then foam is controlled, but the biological process is adversely affected and cost increases
Solution Approach 1:
The patent enables precise partial action in foam control by using the optical foam sensor to detect foam only when and where it forms. This allows metered addition of antifoaming agents at minimal effective doses rather than continuous or excessive application, reducing interference with the biological process and lowering 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 solution enables reliable and fast foam detection, preventing leaks and minimizing antifoaming agent usage by using a reusable illumination and detection unit that can be sterilized, while the photocatalytic coating ensures the window remains clean and free of organic dirt, improving process control in bioreactors.
Implementation Method 1
an outer side of the window is coupled to an illumination and detection unit comprising at least one first light source of visible light and at least one photodetector which makes it possible to detect light from the first light source that is reflected in the bioreactor vessel
Implementation Method 2
a UV-activatable photocatalytic titanium dioxide coating to actively break down foam
Implementation Method 3
at least one photodetector which makes it possible to detect light from the first light source that is reflected in the bioreactor vessel
Data Source
AI summary
A bioreactor vessel has an optical foam sensor (36) with a foam contact surface for contacting the foam to be detected. The foam contact surface is an inner side of a window (38) transparent to light from the visible and ultraviolet spectral range in an outer wall of the bioreactor vessel (10). An outer side of the window (38) is coupled to an illumination and detection unit (52) with at least one first light source (56) of visible light and at least one photodetector (58) to detect light from the first light source (56) that is reflected in the bioreactor vessel (10). The foam contact surface has a titanium dioxide coating (44) superhydrophilizable by photoactivation with ultraviolet light and the illumination and detection unit (52) has at least one second light source (66) of ultraviolet light.