Modular Sparger and Angled Impeller for Bioreactor Oxygen Transfer
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Solution Overview
Problem
Existing single-use bioreactor systems face challenges in achieving high oxygen transfer rates and kLa values due to the bulky format and increased complexity of using multiple impellers, which complicates installation and increases costs.
Innovation Solution
The development of a sparger assembly with removably connected aeration manifolds and a modular impeller assembly that allows for customizable gas distribution and efficient mixing, featuring a base plate with vertically spaced manifolds and a hub with angled blades for optimized gas dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple impellers are used to achieve high oxygen transfer rates and kLa values, then oxygen transfer efficiency is improved, but device complexity and bulkiness increase
Solution Approach 1:
The bioreactor system segments the gas distribution function into separate sparger assemblies with multiple aeration manifolds positioned at different heights. Each manifold distributes gas independently, eliminating the need for multiple mechanical impellers while achieving enhanced oxygen transfer through distributed gas-liquid contact zones throughout the reactor volume.
Solution Approach 2:
The invention transitions from a single-plane impeller configuration to a three-dimensional gas distribution system with aeration manifolds positioned at multiple vertical levels. This spatial distribution of gas injection points creates multiple gas-liquid contact zones throughout the reactor, achieving high oxygen transfer without the mechanical complexity of multiple impellers.
2Productivity
If multiple impellers are mounted on a single shaft to increase kLa values, then oxygen transfer efficiency is improved, but ease of operation deteriorates due to cumbersome installation
Solution Approach 1:
The gas distribution system is segmented into modular sparger assemblies with removable aeration manifolds that can be independently positioned at different heights. This modular design allows simple installation by placing individual sparger assemblies rather than installing complex multi-impeller shaft assemblies, significantly improving ease of operation while maintaining high kLa values.
Solution Approach 2:
The sparger assemblies are designed with removable and reconfigurable aeration manifolds that can be dynamically adjusted to different positions and configurations. This dynamic adaptability allows the system to be easily installed and reconfigured for different operating conditions without the fixed complexity of multi-impeller shaft assemblies.
3Productivity
If multiple impellers are used to achieve high oxygen transfer rates, then gas surface area and bubble size distribution are improved, but device complexity increases requiring stabilization mechanisms
Solution Approach 1:
The invention replaces the mechanical multi-impeller mixing system with a gas-driven system where sparged gas itself provides the mixing and agitation. The rising bubbles create natural convection currents and turbulence that achieve effective mixing and high gas surface area without requiring complex mechanical stabilization mechanisms for multi-impeller shafts.
Solution Approach 2:
The gas distribution is segmented into multiple aeration manifolds at different heights, each creating localized gas-liquid contact zones. This segmentation of gas injection points throughout the reactor volume achieves high overall gas surface area and effective mixing without the mechanical complexity of stabilized multi-impeller assemblies.
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
Enhances oxygen transfer rates and kLa values while simplifying installation and customization, providing a user-friendly and efficient bioreactor system.
Implementation Method 1
A sparger outputs small gas bubbles into a liquid in order to agitate and/or dissolve the gas into the liquid
Implementation Method 2
A sparger outputs small gas bubbles into a liquid in order to agitate and/or dissolve the gas into the liquid
Implementation Method 3
The delivery of gas via spargers helps in mixing a substance, maintaining a homogenous environment throughout the interior of the bag
Data Source
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AI summary
A sparger assembly 100, 200, 300, 400, 500, 600, 700, 750, 760 for a bioprocessing system 10 includes a base plate 110, 210, 510, 610, 710, 754 and at least one aeration manifold 112, 114, 212, 214, 218, 512, 612, 614 removably connected to the base plate 110, 210, 510, 610, 710, 754. Each aeration manifold 112, 114, 212, 214, 218, 512, 612, 614 includes at least one inlet for receiving a gas and a plurality of gas outlet openings 120, 224, 514, 616, 716, 766 for delivering the gas to a fluid within the bioprocessing system 10. An impeller assembly 740, 800, 850, 870, 880, 900, 1000,1100 for a bioprocessing system 10 includes a hub 30, 810, 852, 910, 1010 and at least one blade 742, 812, 854, 912, 914, 1012 operatively connected to the hub 30, 810, 852, 910, 1010. The at least one blade 742, 812, 854, 912, 914, 1012 includes a first portion 816, 858 connected to the hub 30, 810, 852, 910, 1010 and extending generally vertically, and a second portion 818, 860 extending at an upward angle from the first portion.