Disposable Separator Insert With Magnetic Bearings for Hygienic Centrifugation

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Solution Overview

Problem

Existing centrifugal separators are large and require complex cleaning or sterilization processes, making them unsuitable for applications like laboratories where space and hygiene are critical, and there is a need for a disposable and easily replaceable separator insert to minimize cross-contamination.

Innovation Solution

A separator design featuring a pre-assembled, disposable separator insert with a rotatable drum and housing, utilizing magnetic bearings for contactless coupling, and a hermetically sealed inlet and outlet system, allowing for easy replacement and disposal, and minimizing cross-contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a traditional centrifugal separator is used, then separation function is achieved, but the device is large and requires complex cleaning/sterilization processes

Engineering Contradiction:

Improvecleaning and sterilization processVSAvoidseparator size

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The separator is divided into a reusable drive unit and a disposable separator insert. The insert includes a drum, housing, and inlet/outlet systems that can be easily replaced after each use, eliminating the need for complex cleaning and sterilization processes while maintaining effective separation functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The separator insert is designed as a single-use disposable component. After completing the separation function, the entire insert (drum, housing, inlet/outlet systems) is discarded and replaced with a new sterile insert, eliminating cleaning requirements and reducing the effective separator size needed in the laboratory.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Object-affected harmful factors

If a disposable separator insert is used, then cross-contamination is minimized, but the device complexity increases due to magnetic bearing systems

Engineering Contradiction:

Improvecross-contaminationVSAvoidmagnetic bearing system

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Traditional mechanical bearings that require cleaning and sterilization are replaced with magnetic bearing systems. The magnetic bearings support the rotatable drum without physical contact, eliminating mechanical wear and the need for bearing maintenance. While the magnetic system adds complexity, it enables the disposable insert design by eliminating the need to clean mechanical components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Object-affected harmful factors

If a separator insert is made disposable, then hygiene is improved, but the ease of replacement depends on the coupling mechanism

Engineering Contradiction:

ImprovehygieneVSAvoidseparator insert replacement

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The separator insert is extracted as a complete, self-contained unit including the drum, housing, and inlet/outlet systems. This extraction allows the entire insert to be replaced as a single component, simplifying the replacement process while maintaining hygiene standards. The magnetic bearing system enables this extraction by providing contactless support, eliminating the need to disassemble or clean individual components.

Inventive Principle:

Principle #2Taking out (Extraction)

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, contamination-free separation processes by allowing for simple disposal of the separator insert, reducing the need for cleaning and sterilization, and ensuring hygiene in applications like pharmaceuticals and biotechnology.

Implementation Method 1

at least two rotor units for magnetic bearing devices at two axially spaced locations of the rotor with the drum, with which the rotor with the drum can be suspended within the housing during operation

Methodology Applied

Scientific EffectMagnetic bearing: Maglev

Implementation Method 2

separate a free-flowing suspension into phases of different densities using a centrifugal field

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Data Source

PatentEP4499318B1Separator

Publication Date: 2025.12.17 GEA WESTFALIA SEPARATOR GROUP

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AI summary

The invention relates to a separator comprising a frame (I) which comprises receiving areas (I-4, I-5) for rotatably supporting the separator insert (II, III), each receiving area having a stator device (4a, 4b) as a sub-element of a magnet bearing device (4 or 5), and a separator insert (II, III) as a pre-assembled replaceable unit for inserting into stator units (4a, 4b) on a frame (I) or in a housing (68) of the separator. The separator insert (II, III) has at least the following: i) a rotor (2, 65) which can be rotated about a rotational axis (D) and which comprises a drum (3, 66) and a drum wall, and ii) at least two rotor units (4b, 5b) as sub-elements of the magnet bearing devices (4, 5) at two axially spaced positions of the rotor (2) with the drum, said rotor units being used to hold, rotatably support, and rotate the rotor (2) together with the drum (3) in a suspended manner within the housing during a separation mode, wherein the separator has at least one linear drive (50) for linearly moving at least one of the two receiving areas (I-4 and I-5) relative to the separation insert (II, III).