Replaceable Fluid Sensor Mount for Sterile Low-Dead-Volume Monitoring
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Solution Overview
Problem
Conventional fluid monitoring systems in pharmaceutical and biologic production processes face challenges with sensor integration, including unnecessary dead volume and limited sensor size options, which can lead to contamination and increased costs due to complex and cumbersome setups.
Innovation Solution
A fluid monitoring assembly with a conduit and integrally formed sensor mount that allows for removable sensors, housed within a two-part encapsulating structure capable of withstanding high pressures, and featuring pinch valves for flow modulation, enabling efficient and sterile sensor replacement and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are integrated directly into the production stream, then process variables can be monitored, but sensor replacement becomes time-consuming and expensive
Solution Approach 1:
The sensor system is divided into a reusable sensor holder that remains in the production stream and replaceable sensor elements. This segmentation allows the sensor holder to stay permanently installed while only the sensor elements need replacement, significantly reducing replacement time and maintaining process monitoring capability.
Solution Approach 2:
The sensor element is extracted from the production stream as a separate, removable component. The sensor holder remains in place while the sensor element can be quickly removed and replaced without disturbing the production process or requiring complex disassembly procedures.
2Object-affected harmful factors
If single-use disposable sensors with integrated conduit are used, then contamination risks are reduced, but dead volume increases and sensor size options are limited
Solution Approach 1:
The system separates the conduit (which remains in the production stream) from the sensor element (which is disposable). This segmentation allows the conduit to be optimized for minimal dead volume while the disposable sensor element can be sterilized and replaced, maintaining low dead volume and reducing contamination risk.
Solution Approach 2:
The disposable sensor element provides localized sterilization and contamination prevention at the sensing interface, while the reusable conduit maintains minimal dead volume through optimized design. Each component has different quality requirements that can be independently optimized.
3Adaptability or versatility
If multiple individual processes and components are used in biologic production, then process control is achieved, but system complexity and sterilization requirements increase
Solution Approach 1:
The sensor holder serves multiple functions: it provides mechanical support for the sensor, maintains sealing with the production stream, and enables easy sensor replacement. This multi-functionality reduces the number of separate components needed and simplifies the overall system while maintaining process control capability.
Solution Approach 2:
The sensor holder combines mounting, sealing, and replacement mechanisms into a single integrated component. This merging reduces the number of separate parts that need to be sterilized and assembled, thereby reducing system complexity while maintaining adaptability for different sensor types.
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.