Modular Impeller Segments for Bioreactor Mixing Efficiency

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Solution Overview

Problem

Conventional impellers with parabolic blades for fluid mixing systems, such as bioreactors and fermentors, are difficult and costly to produce in large quantities due to their complex geometry, making them impractical for mass production and increasing production costs.

Innovation Solution

A modular impeller system comprising multiple segments with identical configurations, each with two mixing blades, that can be easily assembled and secured to a drive member, allowing for concurrent rotation and efficient mixing without the need for complex molds or welding, using a flexible drive member that can twist without plastic deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If impellers with parabolic blades are used to improve mixing efficiency, then mixing efficiency is improved, but manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvemixing efficiencyVSAvoidimpeller geometry complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The impeller is divided into multiple discrete blades that are separately manufactured and then assembled onto a hub. Each blade can be produced using simple injection molding techniques, and the blades are attached to the hub through overmolding or adhesive bonding, creating the parabolic blade configuration without requiring complex single-piece molds

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple simple components (blades and hub) are combined to form the complete impeller assembly. The blades are merged with the hub through bonding processes that create the functional parabolic blade structure while maintaining manufacturing simplicity of individual components

Inventive Principle:

Principle #5Merging (Combining)

2Shape

If impellers with parabolic blades are manufactured by welding individual blades to a hub, then the complex geometry is achieved, but production time and cost increase

Engineering Contradiction:

Improveparabolic blade geometryVSAvoidmanufacturing time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The blades are pre-formed using injection molding of simple geometric shapes, and then the hub and blades are assembled in a single bonding operation. This preliminary formation of blade shapes eliminates the need for complex molds and subsequent welding operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical welding process is replaced with chemical bonding methods such as adhesive bonding or overmolding. This substitution eliminates the time-consuming welding steps while achieving the same functional result of attaching blades to the hub

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If conventional impellers with simple shapes are used, then mass production is easy and cost-effective, but mixing efficiency is reduced

Engineering Contradiction:

Improvemass production capabilityVSAvoidmixing efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The impeller is segmented into multiple blades that can be independently manufactured using simple injection molding techniques. This segmentation allows each blade to be produced with standard manufacturing processes while the overall assembly achieves the complex parabolic geometry needed for efficient mixing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The impeller is constructed as a composite assembly of multiple components (blades and hub) that are bonded together. This composite structure combines the manufacturing simplicity of individual molded parts with the functional complexity of the parabolic blade configuration

Inventive Principle:

Principle #40Composite materials

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 modular impeller system enhances mixing efficiency while simplifying production and reducing costs, allowing for scalable and cost-effective manufacturing of fluid mixing systems, ensuring consistent sterility and ease of assembly and maintenance.

Implementation Method 1

using a flexible drive member that can twist without plastic deformation

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

Rotation of the drive shaft and impeller facilitates mixing and/or suspension of the fluid contained within flexible bag

Methodology Applied

Scientific EffectMechanical agitation: Stirring

Data Source

PatentUS20250010252A1Fluid mixing systems with modular impellers and related methods

Publication Date: 2025.01.09 LIFE TECHNOLOGIES CORP

AI summary

A mixing system for mixing a liquid includes a first impeller segment having a first mount and a first mixing blade secured to the first mount and a second impeller segment having a second mount and a first mixing blade secured to the second mount, the second impeller segment being separate and discrete from the first impeller segment. One or more drive members are secured to the first impeller segment and the second impeller segment for concurrently rotating the first impeller segment and the second impeller segment about a rotational axis. The first impeller segment and the second impeller segment are secured to the one or more drive members so that a plane extending normal to the axis of rotation intersects with the first mixing blade of the first impeller segment and the first mixing blade of the second impeller segment.