Diaphragm Sensor Connector for Sterile Single-Use Pressure Sensing

Solution Overview

Problem

The life sciences industry faces challenges in accurately monitoring pressure and other variables in single-use bioreactors due to the use of inexpensive, low-accuracy pressure sensors that can lead to inaccurate measurements, which are unacceptable for supporting biological reactions.

Innovation Solution

A sensor connector with a diaphragm that maintains media integrity and allows high-quality reusable instrumentation to monitor parameters without direct contact, enabling precise measurements while protecting the instrument from contamination and corrosion, and allowing for sterilization of the single-use containers and tubing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If inexpensive, pre-sterilized pressure sensors are used in single-use bioreactors, then the capital cost is reduced and the system is easier to sterilize, but the measurement accuracy deteriorates

Engineering Contradiction:

Improvecost reductionVSAvoidpressure measurement accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The system is divided into two segments: a disposable single-use bioreactor bag with crude fluid isolation, and a reusable external measurement instrument. This segmentation allows the sensor to remain outside the sterile field while still measuring process variables, enabling the use of high-precision instruments without requiring them to be sterilized.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A fluid isolation interface (such as a diaphragm or membrane) acts as an intermediary between the bioreactor media and the pressure sensor. This intermediary transmits pressure information from the media to the sensor while preventing direct contact, allowing accurate measurements without contaminating the sensor or requiring its sterilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If high-quality reusable measurement instruments are used, then measurement accuracy improves, but the complexity of sterilization and the risk of contamination increase

Engineering Contradiction:

Improveparameter measurement accuracyVSAvoidsterilization requirements

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

A fluid isolation interface (such as a diaphragm or membrane) acts as an intermediary between the bioreactor media and the pressure sensor. This intermediary transmits pressure information from the media to the sensor while preventing direct contact, allowing accurate measurements without contaminating the sensor or requiring its sterilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The measurement instrument is extracted from the sterile field and placed outside the single-use bioreactor system. Only the essential connecting components (tubing, connectors) remain inside the sterile field, while the complex sensor electronics remain external, eliminating the need to sterilize the instrument itself.

Inventive Principle:

Principle #2Taking out (Extraction)

3Measurement precision

If direct contact between sensor and bioreactor media is established, then measurement accuracy improves, but the risk of contamination and corrosion increases

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidcontamination and corrosion risk

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

A fluid isolation interface (such as a diaphragm or membrane) acts as an intermediary between the bioreactor media and the pressure sensor. This intermediary transmits pressure information from the media to the sensor while preventing direct contact, allowing accurate measurements without contaminating the sensor or requiring its sterilization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

A flexible diaphragm or thin film membrane is used as the fluid isolation interface. This flexible barrier allows transmission of pressure and other mechanical variables while maintaining complete fluid isolation, preventing contamination and corrosion of the sensor.

Inventive Principle:

Principle #30Flexible shells and thin films

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 accurate and precise monitoring of biological reactions by maintaining media integrity and protecting the measurement instrument, allowing for the use of high-quality sensors without the need for sterilization, and facilitating the reuse of instruments after each reaction.

Implementation Method 1

A sensor connector with a diaphragm that maintains media integrity and allows high-quality reusable instrumentation to monitor parameters without direct contact

Methodology Applied

Scientific EffectPhysical separation barrier:

Implementation Method 2

allows high-quality reusable instrumentation to monitor parameters without direct contact, enabling precise measurements

Methodology Applied

Scientific EffectPressure transmission through diaphragm:

Data Source

PatentEP3685136B1Compact sensor connector for single-use fluid measurement

Publication Date: 2024.06.05 ROSEMOUNT INC

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Figure 2A

AI summary

A connector (200) for coupling a single-use container (102) to a measurement instrument (104) includes a connector region (210). The connector (200) includes a deflectable diaphragm (208) sealed to the connector region (202) and configured to contact a media sample.