Polymeric Sensor Interface for Single-Use Bioreactor Pressure Measurement
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Solution Overview
Problem
In the life sciences industry, single-use bioreactors require accurate pressure measurement, but existing inexpensive sensors using crude methods like silicone gel lead to inaccurate readings, which are unacceptable for supporting biological reactions.
Innovation Solution
A polymeric sensor interface is developed to couple single-use containers to high-precision, re-usable pressure measuring instruments, using a pre-sterilized polymeric remote seal system or direct coupling to a re-usable measuring instrument, ensuring accurate and precise pressure measurement while allowing the sensor interface to be disposable with the single-use container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If inexpensive sensors with crude fluid isolation methods (e.g., silicone gel) are used in single-use bioreactors, then the capital cost is reduced, but the measurement precision deteriorates to unacceptable levels
Solution Approach 1:
The patent introduces a fluid isolation barrier (membrane or gel layer) as an intermediary between the process fluid and the pressure sensor. This barrier transmits pressure information to the sensor while preventing direct contact between the process fluid and sensor, thereby maintaining measurement accuracy without requiring expensive sterilizable sensors
Solution Approach 2:
The patent employs disposable single-use sensor interfaces that are pre-sterilized and discarded after one use. These inexpensive single-use interfaces eliminate the need for expensive, sterilizable sensors while ensuring measurement accuracy through proper fluid isolation design
2Ease of manufacture
If pre-sterilized disposable sensors are used in single-use bioreactors, then the facility capital cost is reduced, but the measurement precision remains insufficient due to crude isolation methods
Solution Approach 1:
The patent employs disposable single-use sensor interfaces that are pre-sterilized and discarded after one use. These inexpensive single-use interfaces eliminate the need for expensive, sterilizable sensors while ensuring measurement accuracy through proper fluid isolation design
Solution Approach 2:
The patent introduces a fluid isolation barrier (membrane or gel layer) as an intermediary between the process fluid and the pressure sensor. This barrier transmits pressure information to the sensor while preventing direct contact between the process fluid and sensor, thereby maintaining measurement accuracy without requiring expensive sterilizable sensors
3Measurement precision
If reusable high-precision measuring instruments are used with single-use containers, then the measurement precision is improved, but the device complexity and cleaning requirements increase
Solution Approach 1:
The patent divides the measurement system into two separate segments: a disposable single-use sensor interface that contacts the process fluid and a reusable high-precision measuring instrument that does not. This segmentation allows the reusable instrument to maintain high measurement precision without requiring cleaning or sterilization, as the disposable interface handles all contact with the single-use container
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
This solution provides accurate and precise pressure measurement in single-use bioreactors, enabling the use of reusable, high-precision instruments without the need for cleaning, and allows for integration with advanced control systems, improving measurement confidence and flexibility in biopharmaceutical manufacturing processes.
Implementation Method 1
A deflectable polymeric diaphragm is coupled to the interface portion of the polymeric flange
Data Source
AI summary
A single-use sensor interface for coupling a single-use container to a re-usable sensing instrument is provided. The single-use sensor interface includes a polymeric flange couplable to a wall of the single-use container. The polymeric flange has a sidewall and an interface portion configured to receive a deflectable polymeric diaphragm. A deflectable polymeric diaphragm is coupled to the interface portion of the polymeric flange. An instrument coupling portion is sealingly coupled to the polymeric flange. The instrument coupling portion is configured to couple to the re-usable sensing instrument. Another single-use sensor interface for coupling a single-use container to a re-usable sensing instrument includes a polymeric hose adapter and at least one instrument attachment portion. The polymeric hose adapter portion has at least one hose barb configured to retain a hose slid thereover. The hose adapter portion has at least one interface portion that is configured to receive a deflectable polymeric diaphragm. A deflectable polymeric diaphragm is coupled to the interface portion. At least one instrument attachment portion is coupled to the hose adapter portion. The at least one instrument attachment portion has a cylindrical sidewall.