Modular Fixed-Bed Bioreactor for Parallel Biomass Estimation
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Solution Overview
Problem
Bioreactors face challenges such as complex assembly, high manufacturing costs, difficulty in maximizing cell density, and inefficiencies in scaling and operating under varied conditions, leading to resource wastage and sub-optimal process evaluation.
Innovation Solution
A modular bioreactor system with a single-piece housing, removable fixed bed support, and interlocking components that allow for easy assembly and disassembly, featuring a fixed bed structure with a central and peripheral portion, and a support system that includes projections and positioners for uniform spacing and fluid flow, along with a snap-fit impeller connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple separate bioreactor systems are used to evaluate process parameters simultaneously, then parameter optimization can be conducted in parallel, but the physical resources and space required increase significantly
Solution Approach 1:
The patent combines multiple bioreactor chambers into a single integrated system with a common housing, control mechanism, and operational infrastructure. Multiple fixed bed supports with cell-laden structures are positioned within individual chambers of the same bioreactor, allowing simultaneous evaluation of different parameters across multiple chambers while sharing common resources like the housing structure, sealing mechanisms, and control systems.
Solution Approach 2:
The bioreactor system is designed with universal components that can accommodate multiple different configurations and experimental conditions within a single device. The standardized fixed bed supports and interchangeable chamber designs allow the same bioreactor to perform multiple functions and evaluate various parameters simultaneously, replacing the need for multiple specialized single-chamber systems.
2Reliability
If packed beds are used to promote cell growth, then cell growth is enhanced, but the volume of space required in the bioreactor increases
Solution Approach 1:
The patent implements a nested configuration where fixed bed supports with cell-laden structures are positioned within compact chambers of a multi-chamber bioreactor. The fixed bed supports are designed to nest efficiently within the available chamber volume, maximizing the use of vertical and radial space. Multiple layers or stacked arrangements of cell culture structures are employed to increase cell density without proportionally increasing the overall bioreactor volume.
Solution Approach 2:
The invention transitions from traditional horizontal packed bed configurations to vertical or multi-dimensional cell culture arrangements. Fixed bed supports are designed with three-dimensional cell culture structures that utilize vertical space and radial dimensions more efficiently, allowing higher cell densities to be achieved within the same footprint volume by exploiting additional spatial dimensions rather than simply expanding the horizontal volume.
3Adaptability or versatility
If complicated housing arrangements with multiple parts are used, then manufacturing flexibility is increased, but assembly complexity and manufacturing costs increase
Solution Approach 1:
The bioreactor is divided into modular segments including interchangeable chambers, removable fixed bed supports, and separable sealing components. Each module can be manufactured independently using standardized processes and then assembled through simple interlocking mechanisms. The segmented design allows different chamber configurations to be produced using the same base manufacturing processes, maintaining flexibility while simplifying assembly compared to complex multi-part housings.
Solution Approach 2:
Complex sealing and assembly functions are extracted as separate, standardized components rather than being integrated into the housing structure itself. Removable seals, gaskets, and connection mechanisms are designed as independent elements that can be easily installed and removed, reducing the overall assembly complexity while maintaining the adaptability to configure different chamber arrangements.
Data Source
AI summary
A bioreactor includes a housing with a number of removable parts for modular construction and easy assembly or disassembly. The removable parts include a fixed bed and a support for the fixed bed. More than one support may be provided. The multiple supports may interlock with each other or a lid of the bioreactor. The support interlocks with the housing to prevent relative rotation. The multiple supports include a support frame for supporting the fixed bed an allowing fluid to flow through the support frame. The fixed bed forms a peripheral chamber between the support and the housing to hold the fixed bed. One or more probes and tubes may be inserted into the bioreactor to test parameters of or to add to or remove liquid from inside.