Perfusion Filter Assembly with Curved Support Plate
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Solution Overview
Problem
Traditional bioreactor systems, particularly those using stainless steel, are costly, labor-intensive to clean and sterilize, and inflexible for reconfiguration, leading to the adoption of single-use disposable bags. However, these bags face challenges with filter membrane sagging and fouling, especially when subjected to rocking motions during cell cultivation.
Innovation Solution
The development of a filter assembly for bioreactor bags that includes a support plate with a bonded filter membrane and at least one support structure, such as a post or frame, to prevent sagging of the filter membrane. This assembly ensures effective fluid flow and reduces fouling by creating a crossflow effect over the filter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a filter membrane is used in a single-use bioreactor bag, then cell retention and metabolite removal are achieved, but the filter membrane sags and fouls during rocking operation
Solution Approach 1:
The patent uses a flexible support structure comprising a flat plate with curved edges that conforms to the bioreactor bag wall, providing stable support for the filter membrane while accommodating the flexible nature of the single-use bag system. This prevents sagging without requiring rigid structures.
Solution Approach 2:
The patent creates a cross-flow effect by positioning the filter membrane at an angle to the bag wall using the curved support structure, transforming the flow from perpendicular to tangential across the membrane surface. This dimensional change in flow direction prevents fouling while maintaining filtration function.
2Volume of moving object
If the filter membrane is placed close to the bioreactor wall, then space is optimized, but fluid flow and crossflow effect are reduced
Solution Approach 1:
The support plate features curved edges that follow the contour of the bioreactor bag wall, optimizing space utilization while maintaining adequate flow channels. The curved geometry allows the filter to be positioned efficiently without compromising fluid dynamics.
Solution Approach 2:
The support structure is pre-formed with integrated flow channels and positioning features that ensure proper fluid flow paths are established before operation begins. This preliminary configuration guarantees adequate cross-flow effect without requiring additional adjustments during operation.
3Duration of action of stationary object
If traditional stainless steel bioreactor systems are used, then durability and reusability are achieved, but cleaning and sterilization are costly and labor-intensive
Solution Approach 1:
The patent implements a complete single-use filter assembly that is discarded after one use, eliminating the need for cleaning and sterilization operations. The low cost of the disposable filter allows it to be replaced rather than maintained, solving the operational complexity issue while providing sufficient duration for each cultivation process.
4Productivity
If perfusion cultivation is implemented to reduce inhibitory metabolites, then cell growth is improved, but filter fouling and clogging increase
Solution Approach 1:
The support structure is designed with integrated flow distribution channels that pre-establish uniform flow patterns across the filter surface before perfusion cultivation begins. This preliminary flow distribution prevents localized fouling and maintains consistent cross-flow effect throughout the cultivation process, enabling high cell density operation without excessive filter clogging.
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 proposed filter assembly effectively prevents sagging and fouling of filter membranes, maintaining efficient fluid flow and extending the lifespan of the filter. This solution addresses the limitations of traditional bioreactor systems by enhancing the performance and adaptability of single-use disposable bioreactor bags.
Implementation Method 1
culture medium is bled off by hydraulic flow through a filter which retains the cells but lets the metabolites and proteins pass through the filter
Implementation Method 2
This assembly ensures effective fluid flow and reduces fouling by creating a crossflow effect over the filter
Data Source
AI summary
Filter holders and membranes are provided that can be included within a bioreactor bag system. The filter holders and membranes include features that abut the bottom of the filter membrane and prevent or reduce sagging of the porous filter region during use.