Bioreactor Sensor Receptacle With Sterile Membrane Interface
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Solution Overview
Problem
Existing single-use bioreactors lack a simple and efficient method to measure analytes without compromising sterility, as conventional sensors require sterilization or modification.
Innovation Solution
A bioreactor system with a pre-sterilized single-use bioreactor and a detachable sensor receptacle that maintains sterility by using a flexible membrane to allow analyte measurement, enabling the use of unmodified standard sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional sensor is used with a single-use bioreactor, then analyte measurement is enabled, but the sterility of the bioreactor is compromised due to complex pre-sterilization requirements
Solution Approach 1:
The sensor system is segmented into two parts: a reusable sensor unit and a disposable sensor receptacle with sterile barrier. The sensor receptacle including the flexible membrane is discarded after single use, while the sensor itself can be reused without sterilization, resolving the contradiction between measurement capability and sterility maintenance
Solution Approach 2:
A flexible membrane serving as a sterile barrier is introduced as an intermediary between the non-sterile sensor and the sterile bioreactor environment. This membrane allows analyte diffusion while maintaining sterility, enabling measurement without compromising the bioreactor's sterile state
2Reliability
If a conventional sensor is pre-sterilized for single-use bioreactor compatibility, then sterility is maintained, but the complexity of pre-sterilization and storage increases
Solution Approach 1:
The sensor receptacle including the flexible membrane is designed as a disposable component that is discarded after single use. This eliminates the need for complex pre-sterilization and storage requirements for the sensor itself, as only the inexpensive receptacle needs to be sterile
Solution Approach 2:
The sterile barrier function is extracted from the sensor and placed in a separate disposable receptacle. This allows the sensor to remain non-sterile and reusable, while the receptacle provides the necessary sterility without requiring complex handling procedures
3Productivity
If the sensor is made reusable for single-use bioreactors, then cost is reduced, but the sensor must be sterilized and stored with the bioreactor
Solution Approach 1:
The system is segmented into a reusable sensor and a disposable receptacle. The sensor can be reused without sterilization, while the receptacle is discarded after single use, eliminating the need for sterilization and storage procedures while maintaining productivity benefits
4Reliability
If a fluid-tight connection is made between sensor and bioreactor, then sterility is maintained, but the sensor cannot be easily detached for reuse
Solution Approach 1:
The connection is segmented into a permanent fluid-tight seal between the receptacle and bioreactor, and a detachable connection between the sensor and receptacle. This allows easy sensor removal for reuse while maintaining sterility through the sealed receptacle
Solution Approach 2:
The detachable connection feature is extracted and applied only to the sensor-receptacle interface, while the receptacle-bioreactor interface remains permanently sealed. This enables easy sensor detachment for reuse while maintaining fluid-tight sterility protection
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
Enables efficient and sterile measurement of analytes in single-use bioreactors without requiring sterilization or modification of sensors, allowing for reuse and maintaining bioreactor sterility.
Implementation Method 1
at least said portion of the wall of the sensor receptacle is formed from a flexible membrane, which is permeable to the analyte so that the analyte can pass through the flexible membrane to the permeable region of the sensor
Data Source
AI summary
A bioreactor system (1) has a pre-sterilized single-use bioreactor (2) with a reactor wall (20) surrounding an interior chamber (21) that receives a fluid medium (M). A sensor (3) for detecting an analyte in the medium has a sensor housing (30) with an outside thread (31) and a sensor shaft (32), a distal end portion (33) of which has an end face (34) with a region (35) permeable to the analyte. A sensor receptacle (4) connected to the reactor wall receives the sensor, to maintain the sterility of the single-use bioreactor. A circumferential flange (40) fixes the sensor receptacle to the reactor wall. The flange has an inside thread (42) that receives the outside thread. A wall (43) of the sensor receptacle is connected to the flange, and together with the sensor shaft, protrudes into the interior chamber, separating the sensor from the interior chamber.