Small-Scale Bioreactor Dip-Tube Assembly for Precise Delivery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Small-scale bioreactors face challenges in labor-intensive setup, inefficient fluid and gas delivery, inaccurate temperature sensing, and durability of agitation systems, which hinder their ability to replicate large-scale reactors effectively and economically.
Innovation Solution
The bioreactor design includes a dip tube assembly with radially distributed inner tubes for precise gas and liquid delivery, a condenser with hydrophobic surfaces to minimize liquid loss, a magnetically driven agitation system with enhanced temperature sensing, and a modular headplate for improved connectivity and sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional bioreactor setup procedures are used, then basic functionality is achieved, but setup time and labor intensity are excessive
Solution Approach 1:
The patent combines multiple separate bioreactor components (agitation system, gas delivery system, liquid delivery system, temperature sensing system) into an integrated vessel assembly where the shaft extends through the headplate to provide magnetic coupling, eliminating the need for separate mounting operations and reducing setup time
Solution Approach 2:
The shaft serves multiple functions simultaneously: it provides magnetic coupling for agitation, supports the impeller for mixing, extends through the headplate for sealing and drive coupling, and works with the dip tube assembly for fluid delivery. This multi-functionality reduces the number of separate components needed and simplifies assembly
2Productivity
If conventional gas and liquid delivery systems are used, then basic delivery is achieved, but delivery efficiency and precision are insufficient
Solution Approach 1:
The dip tube assembly is nested within the vessel, with the shaft extending through the headplate and coupling to the dip tube assembly. The gas delivery system and liquid delivery system are integrated within this nested structure, allowing efficient delivery while maintaining a compact design
Solution Approach 2:
The delivery system is segmented into separate gas delivery channels and liquid delivery channels within the dip tube assembly, allowing independent optimization of each delivery pathway while maintaining overall system efficiency
3Measurement precision
If standard temperature sensing methods are used, then temperature monitoring is achieved, but measurement accuracy is insufficient
Solution Approach 1:
The shaft acts as an intermediary structure that extends through the headplate to provide both mechanical support for the impeller and a pathway for temperature sensing. This intermediary structure enables accurate temperature measurement at the vessel bottom while maintaining system integration
4Loss of substance
If traditional condenser designs are used, then basic condensation is achieved, but liquid loss is excessive
Solution Approach 1:
The condenser incorporates hydrophobic surface treatments or coatings on its internal surfaces, creating a composite structure that combines the condensation function with liquid-repellent properties. This reduces liquid loss by preventing condensed liquid from adhering to condenser surfaces
5Reliability
If conventional agitation systems are used, then basic mixing is achieved, but system durability is insufficient
Solution Approach 1:
The patent replaces traditional mechanical drive systems with magnetic coupling through the headplate. The shaft extends through the headplate to provide magnetic coupling between the drive mechanism and the impeller, eliminating mechanical seals and reducing wear while improving durability
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 design reduces setup time, enhances fluid delivery performance, minimizes consumable costs, and improves temperature accuracy, ensuring reproducible results and efficient operation of small-scale bioreactors.
Implementation Method 1
a condenser with hydrophobic surfaces to minimize liquid loss
Implementation Method 2
a condenser with hydrophobic surfaces to minimize liquid loss
Implementation Method 3
a magnetically driven agitation system with enhanced temperature sensing
Data Source
AI summary
Bioreactors including bioreactors having features for improved performance, sensing and ease of use. Many embodiments provide bioreactors having improved dip-tubes, magnetically coupled agitators, condensers and sensing ability. Particular embodiments provide a bioreactor including a vessel having an inner volume for liquid contents and a head plate (HP) for coupling a plurality of components to the bioreactor where the HP is coupled to a top portion of the vessel and includes a plurality of ports. A diametric magnetic (DM) drive assembly (DMDA) and agitation shaft (AS) including at least one impeller are rotatably coupled to the HP. The DMDA and AS are rotated by non-vertical magnetic forces from a rotating DM positioned above the HP. A dip tube assembly (DTA) having a plurality of inner fluidic channels is positioned through a HP port such that a DTA end extends into the vessel for delivery liquids and sparging gasses.