Replaceable Fluid Sensor Mount to Minimize Dead Volume
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Solution Overview
Problem
Conventional fluid monitoring systems in pharmaceutical and biologic production processes face challenges with sensor integration, including dead volume issues due to integrated conduit segments and limited sensor size options, which complicate sensor replacement and increase contamination risks.
Innovation Solution
A fluid monitoring assembly with a conduit and integrally formed sensor mount that allows for removable sensor placement, featuring a housing that encapsulates the conduit and sensor, and includes pinch valves for flow modulation, enabling efficient sensor replacement and reduced contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are integrated directly into the production stream with conventional setups, then sensor functionality is achieved, but sensor replacement becomes time-consuming and expensive while increasing contamination risks
Solution Approach 1:
The sensor system is divided into separate components: a reusable sensor body and replaceable sensor elements. This segmentation allows the sensor element to be quickly swapped out without replacing the entire sensor assembly, reducing replacement time and minimizing contamination risk during maintenance operations.
Solution Approach 2:
The sensing element is extracted as a separate, removable component from the sensor assembly. This extraction enables independent replacement of the sensing element without disturbing the housing or other components, facilitating rapid maintenance and reducing contamination exposure during sensor element replacement.
2Reliability
If integrated conduit segments are used in single-use sensors, then sensor functionality is achieved, but dead volume increases and product residence time is extended
Solution Approach 1:
The conduit segment is extracted from the sensor element and separated into the reusable housing. This eliminates the need for integrated conduit segments in single-use sensor elements, thereby removing the associated dead volume and reducing product residence time in non-sterile zones.
Solution Approach 2:
A sterile barrier or membrane is introduced as an intermediary between the sensing element and the product stream. This allows the sensing element to function without direct product contact, eliminating dead volume concerns while maintaining sensing capability through the barrier.
3Ease of manufacture
If limited sensor size options are available, then manufacturing is simplified, but adaptability to different application requirements is reduced
Solution Approach 1:
The sensor housing and mounting structure are designed with universal features that can accommodate multiple sensor element sizes and types. This universality allows a single housing design to support various sensing element dimensions, providing adaptability without requiring multiple housing variants, thus maintaining manufacturing simplicity.
Solution Approach 2:
The sensor system allows changing the sensing element parameters (size, type, measurement capability) while keeping the housing constant. This parameter change approach provides versatility in sensor selection without complicating the overall manufacturing process, as only the sensing element needs to be manufactured in different specifications.
Data Source
AI summary
A fluid monitoring assembly includes a conduit having a wall defining a lumen for carrying fluid. A sensor mount is integrally formed with the wall of the conduit and extends generally transverse with respect to a longitudinal axis of the conduit, the sensor mount including an aperture defining an inner surface extending to the lumen. The assembly includes a sensor configured to be removably secured within the sensor mount, the sensor having an elongate body terminating at one end thereof in a sensing portion, the elongate body having a male projection on a portion thereof and configured to rest within the inner surface of the sensor mount. The assembly further includes a housing having first and second portions connected to one another, the housing defining an interior portion configured to encapsulate the conduit, at least a portion of the elongate body of the sensor, and the sensor mount.