Disposable Sensor Port Assembly for Biopharmaceutical Concentration Measurement
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Solution Overview
Problem
Existing single-use systems in biopharmaceutical manufacturing face challenges in accurately measuring chemical concentration and temperature due to difficulties in integrating sensors with disposable containers, leading to increased costs and contamination risks.
Innovation Solution
A disposable sensor system with a miniaturized, fully integrated interface package that includes a chemical concentration or temperature sensor, interfaced with a single-use system via a port assembly featuring an optically transparent window, allowing for accurate measurements without physical contact and reducing sterilization requirements, thereby lowering costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are integrated with disposable containers to enable accurate measurements, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensor and disposable container are merged into a single integrated unit. The sensor is directly integrated with the disposable container, eliminating the need for separate sensor mounting and reducing integration complexity while maintaining measurement precision.
Solution Approach 2:
The disposable container is designed to serve multiple functions: it acts as both the process vessel and the sensor housing. This multi-functionality reduces the number of separate components needed, simplifying the overall device while enabling accurate chemical concentration measurements.
2Measurement precision
If sensors are integrated with disposable containers, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The sensor and disposable container are manufactured as a single integrated component, eliminating separate assembly steps and reducing manufacturing costs. The integration is designed to be achieved through standard manufacturing processes rather than complex post-assembly procedures.
Solution Approach 2:
The sensor is designed as a disposable component with the container, optimized for single-use applications. This approach reduces the need for expensive, durable materials and complex sterilization processes, lowering overall manufacturing costs while maintaining measurement precision during the service life.
3Measurement precision
If sensors contact the chemical directly to obtain accurate measurements, then measurement precision is improved, but contamination risk increases
Solution Approach 1:
The sensor and container are designed as a disposable unit that is discarded after single use. This eliminates cross-contamination risks between batches while maintaining direct chemical contact for accurate measurements during the process. Each new container-sensor unit is sterile and contamination-free.
Solution Approach 2:
The sensor system is extracted from reusable systems and integrated directly into the disposable container. This separation allows the sensor to contact chemicals directly for accurate measurements while the disposable nature prevents contamination carryover to subsequent processes.
4Reliability
If reusable stainless steel systems are replaced with single-use systems, then reliability is improved, but device complexity increases
Solution Approach 1:
The sensor is merged with the disposable container as a single integrated unit, eliminating the complexity of integrating sensors into reusable systems. This integration maintains contamination control through disposability while simplifying the overall device architecture.
Solution Approach 2:
The system uses disposable containers with integrated sensors rather than reusable systems. This approach improves reliability by eliminating cross-contamination risks while the integration is designed to be simple and cost-effective, reducing overall device complexity.
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 provides accurate, sensitive, and cost-effective chemical concentration and temperature measurements, reducing contamination risks and system configuration costs by integrating sensors directly with disposable containers, enabling improved data collection and process control.
Implementation Method 1
The port assembly includes an optically transparent window and be configured such that the sensor may be mechanically attached to the port assembly to interface with the optical window
Data Source
AI summary
Embodiments as disclosed herein may provide a sensor system including a container, such as a bag, having a port assembly integrated therewith. The port assembly includes an optically transparent window and be configured such that a sensor may be mechanically attached to the port assembly to interface with the optical window. The sensor may include an index of refraction (IoR) sensor that measures the chemical concentration of a liquid inside the container based on a refractive index.