Multi-chamber bioreactor with nested bags for volume expansion
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Solution Overview
Problem
Traditional single-use bioreactors require multiple bags and support structures of different volumes for cell culture expansion, leading to increased costs, space requirements, and the risk of contamination due to the need for multiple equipment setups and personnel intervention during the seed train process.
Innovation Solution
A multi-chamber single-use bioreactor apparatus with interconnected bags of varying volumes, supported by a single rigid structure and controlled by a single unit, allowing for fluidic transfer between chambers without opening the system, reducing the need for multiple bioreactors and minimizing contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-use bioreactors are used for cell culture expansion, then the risk of contamination is reduced and setup time is shortened, but multiple bags and support structures of different volumes are required, increasing equipment cost, storage space requirements, and operational complexity
Solution Approach 1:
The patent combines multiple separate bioreactor bags of different volumes into a single integrated multi-chamber bag system. The bag assembly includes a first bag, second bag, and third bag with different working volumes that are fluidly connected and supported by a single support structure, eliminating the need for multiple separate bags and reducing operational complexity while maintaining contamination prevention benefits
Solution Approach 2:
The single multi-chamber bag assembly serves multiple functions that previously required separate devices. It can accommodate different working volumes (1L, 10L, 100L, 1000L) within one system, support stepwise scale-up operations, and be controlled by a single control unit, making the system universally applicable across different production scales
2Productivity
If multiple bioreactor bags of different volumes are used for stepwise scale-up, then cell culture expansion from 1 mL to production scale is achieved, but the requirement for multiple support structures with different dimensions increases space requirements and storage area
Solution Approach 1:
The patent implements a nested configuration where the first bag, second bag, and third bag are positioned concentrically within each other. The smaller volume bags are nested inside larger volume bags, allowing all chambers to be supported by a single support structure and significantly reducing the space required for storage and operation compared to having separate bags
3Quantity of substance
If traditional single-use bioreactors require multiple bags for volume expansion, then the desired culture volume is achieved, but different control units are required for each bag, increasing equipment cost and operational complexity
Solution Approach 1:
The single control unit is designed to universally control all chambers (first, second, and third bags) of the multi-chamber bioreactor system. This multi-functional control unit can regulate parameters such as temperature, pH, and aeration across different working volumes, eliminating the need for multiple separate control units and reducing equipment cost
4Productivity
If stepwise scale-up process uses separate bags that require connecting under aseptic conditions, then cell culture is transferred from smaller to larger volumes, but highly trained personnel are required and contamination risk increases
Solution Approach 1:
The patent merges multiple separate bag connections into a single pre-connected multi-chamber system. The bags are already fluidly connected within the sealed system, eliminating the need for manual connection operations under aseptic conditions and reducing the skill level required for personnel while maintaining contamination prevention
Data Source
AI summary
A multi-chamber single-use bioreactor for cell culture expansion has bag assembly and a rigid support structure defining a bag receiving space. The bag assembly disposed in the bag receiving space of the rigid support structure and supported by the rigid support structure. The bag assembly has at least a first flexible bag and a second flexible bag. The first bag defines a first reaction chamber, and the second bag defines a second reaction chamber. The first reaction chamber has a first volume, a first inlet, and a first outlet, and the second reaction chamber has a second volume different from the first volume, a second inlet, and a second outlet. The second inlet of the second bag is fluidically connected to the first outlet of the first bag so liquid in first reaction chamber can be transferred to the second reaction chamber.