Modular Sparger-Impeller Assembly for High Oxygen Transfer
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Solution Overview
Problem
Existing bioreactor systems with single-use bags face challenges in achieving high oxygen transfer rates and kLa values due to the use of multiple impellers, which result in a bulky format, increased complexity, and cost, making bag installation cumbersome and less user-friendly.
Innovation Solution
The development of a sparger assembly with modular, removably connected aeration manifolds and a base plate that supports impeller assemblies, allowing for customizable gas distribution and efficient oxygen transfer, with aeration manifolds positioned in close proximity to the impeller to optimize 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 patent combines the sparger and impeller into a single integrated assembly where the sparger serves as the impeller support structure. This merging eliminates the need for separate impeller shafts and multiple impellers while maintaining effective gas-liquid mixing through the integrated aeration and agitation functions.
Solution Approach 2:
The sparger assembly performs multiple functions simultaneously: it distributes gas through multiple manifolds and provides structural support for the impeller. This multi-functionality replaces the need for separate oxygen transfer devices while achieving the same productivity goals through combined aeration and mixing actions.
2Productivity
If multiple impellers are used to achieve high oxygen transfer rates, then gas distribution efficiency is improved, but ease of operation deteriorates due to cumbersome installation
Solution Approach 1:
The sparger is divided into multiple removable manifolds that can be independently assembled and configured. This segmentation allows for flexible assembly and easy installation while maintaining effective gas distribution throughout the bioreactor volume, eliminating the complexity of installing multiple separate impellers.
3Productivity
If multiple impellers are used to achieve high oxygen transfer rates, then oxygen transfer performance is improved, but manufacturing cost increases
Solution Approach 1:
By merging the sparger and impeller support functions into a single integrated structure, the patent reduces the total number of components that need to be manufactured and assembled. This consolidation lowers manufacturing costs while maintaining the oxygen transfer performance that would otherwise require multiple separate impellers.
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 enhances oxygen transfer rates and kLa values, providing efficient gas distribution and mixing in bioreactor systems, while allowing for easy customization and user-friendly installation.
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
An agitator assembly disposed within the bag is used to mix the fluid
Data Source
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AI summary
A sparger assembly for a bioprocessing system includes a base plate and at least one aeration manifold removably connected to the base plate. Each aeration manifold includes at least one inlet for receiving a gas and a plurality of gas outlet openings for delivering the gas to a fluid within the bioprocessing system.An impeller assembly for a bioprocessing system includes a hub and at least one blade operatively connected to the hub. The at least one blade includes a first portion connected to the hub and extending generally vertically, and a second portion extending at an upward angle from the first portion.