Reusable Magnetic Core Encapsulation for Single-Use Impellers
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Solution Overview
Problem
The manufacturing of magnetically levitated impellers for mixing or pumping devices in biotechnology and pharmaceutical industries is costly and environmentally inefficient due to the high cost and disposal issues of permanent magnets, and the design as single-use components is time-consuming and costly.
Innovation Solution
A method for reusing the permanent magnetic core of a used impeller by demagnetizing, separating it from the casing, and encapsulating it with plastic to form a new impeller, reducing material costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanent magnets are used in magnetically levitated impellers, then magnetic levitation and driving functions are achieved, but manufacturing costs and environmental impact increase due to high material costs and disposal issues
Solution Approach 1:
The patent applies the discarding and recovering principle by collecting permanent magnets from discarded single-use impellers and reusing them in new impellers. The method involves removing permanent magnets from used impellers, storing them, and then incorporating them into newly manufactured impellers. This recovers valuable magnetic materials that would otherwise be discarded, significantly reducing the need for new permanent magnet material production and lowering manufacturing costs while maintaining the magnetic levitation function.
2Reliability
If impellers are designed as single-use components, then high purity standards are maintained, but manufacturing time and costs increase
Solution Approach 1:
The patent applies segmentation by separating the impeller into two distinct parts: a reusable permanent magnet core and a disposable single-use impeller body. The permanent magnet core is removed from used impellers, stored for reuse, while the single-use impeller body is discarded after one use to maintain purity standards. This segmentation allows the expensive permanent magnet component to be recovered and reused multiple times, while the contact-with-substance portion remains single-use for purity, thereby improving manufacturing efficiency without compromising purity requirements.
3Reliability
If permanent magnets are disposed of after single use, then contamination risk is eliminated, but material waste and environmental impact increase
Solution Approach 1:
The patent implements discarding and recovering by establishing a system where permanent magnets from used impellers are collected, stored in a magnetic field, and reused in new impeller manufacturing. This prevents the permanent magnet material from being discarded after single use, eliminating waste of valuable magnetic materials and reducing environmental impact, while the single-use impeller body is still disposed of to prevent contamination of the permanent magnets.
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
Significantly reduces manufacturing costs and environmental footprint by reusing the permanent magnet core, while maintaining high purity standards and reducing the need for costly sterilization processes.
Implementation Method 1
the rotor, which typically forms the impeller, is located inside the mixing vessel. Outside the mixing vessel, a stator is provided, which uses magnetic or electromagnetic fields to drive the rotor through the wall of the mixing vessel without physical contact and magnetically holds it in a predetermined position without physical contact
Implementation Method 2
The electrical windings of the stator generate a rotating magnetic field that exerts a torque on the rotor, causing it to rotate
Implementation Method 3
The electrical windings of the stator generate a rotating magnetic field that exerts a torque on the rotor, causing it to rotate, and also exerts an adjustable lateral force on the rotor, allowing its radial position to be actively controlled or regulated
Data Source
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AI summary
A method is proposed for manufacturing an impeller for a mixing or pumping device with a magnetically levitated impeller, comprising the following steps: providing a magnetically levitated impeller (10) having a permanent magnetic core (4) completely enclosed by a casing (30), wherein the casing (30) is made of a plastic and wherein a plurality of vanes (20) for mixing or conveying substances are provided on the casing (30); removing all vanes (20) from the casing (30); separating the permanent magnetic core (4) from the casing (30); attaching an encapsulation (3) made of a plastic, which completely encloses the permanent magnetic core (4); attaching a plurality of vanes (2) to the encapsulation (3).