Disposable Bioreactor Sensor Architecture with Embedded Compensation
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Solution Overview
Problem
The life sciences industry faces challenges in monitoring and managing biological reactions in single-use bioreactors due to the need for precise control of variables like temperature, pressure, and pH, while existing technologies are costly and require complex clean-in-place infrastructure, limiting flexibility and scalability.
Innovation Solution
A bioreaction sensing assembly is provided, which includes a standardized process window for embedding sensors within disposable polymeric bags, coupled with a compliance box and process variable transmitter for accurate measurement and compensation of variables, allowing for wireless communication and reduced operational costs through disposable components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If stainless steel bioreactors with CIP infrastructure are used, then measurement precision and reliability are improved, but device complexity and capital costs increase significantly
Solution Approach 1:
The system divides the bioreactor into two distinct parts: a reusable stainless steel process control unit and a disposable polymeric bag containing embedded sensors. This segmentation allows the complex measurement infrastructure to be separated from the disposable reaction vessel, maintaining measurement precision while reducing overall system complexity for single-use applications.
Solution Approach 2:
The patent employs disposable polymeric bioreactor bags with integrated sensors that are discarded after a single use. This eliminates the need for complex clean-in-place infrastructure and high-end instrumentation designed to withstand steam cleaning cycles, significantly reducing capital costs while maintaining adequate measurement precision for the application.
2Device complexity
If disposable polymeric bioreactor bags are used, then device complexity and capital costs are reduced, but measurement precision and reliability may deteriorate
Solution Approach 1:
The patent merges the sensor elements directly into the polymeric bioreactor bag structure, creating an integrated sensing system. This combination ensures that the sensors are optimally positioned within the disposable bag to accurately monitor biological reactions, maintaining measurement precision while keeping the overall device simple and disposable.
Solution Approach 2:
The patent replaces complex mechanical clean-in-place infrastructure with a disposable polymeric system. The measurement function is maintained through carefully selected sensors that can operate within the polymeric environment, substituting the need for robust stainless steel infrastructure with a simpler disposable alternative that achieves the same measurement objectives.
3Reliability
If complex clean-in-place infrastructure is implemented, then reliability is improved, but capital costs and facility size increase
Solution Approach 1:
The patent employs disposable polymeric bioreactor bags with integrated sensors that are discarded after a single use. This eliminates the need for complex clean-in-place infrastructure and high-end instrumentation designed to withstand steam cleaning cycles, significantly reducing capital costs while maintaining adequate measurement precision for the application.
4Measurement precision
If stainless steel bioreactors are used, then measurement precision is improved, but ease of operation and flexibility deteriorate due to fixed infrastructure requirements
Solution Approach 1:
The patent transitions from a static, fixed stainless steel bioreactor system to a dynamic, flexible disposable polymeric bag system. The sensors are integrated directly into the flexible polymeric structure, allowing the system to be easily configured, deployed, and discarded, significantly improving ease of operation and flexibility while maintaining measurement capabilities through carefully selected sensor technologies.
Data Source
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AI summary
A sensor assembly (200) includes a first sensor (110, 112) and a second sensor (114, 130). An enclosure (116) is operably coupled to each of the first (110, 112) and second sensors (110, 112, 114, 130) and contains memory (134) that stores compensation data for each of the first and second sensors (110, 112, 114, 130). A connector (120) is operably coupled to the first and second sensors (110, 112, 114, 130). A bioreaction sensing assembly as well as a method (400) of manufacturing the bioreaction sensing assembly is also provided.