Rotating Single-Use Bioreactor for Adherent Cell Cultivation
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Solution Overview
Problem
Existing bioreactors face challenges in handling adherent cells safely and easily, with issues such as contamination risk, complex handling, and inefficient cell cultivation processes.
Innovation Solution
A bioreactor design featuring a housing with a reactor vessel that can be rotated and agitated, equipped with gas and liquid transfer lines with sterile closures, and integrated sensors for process control, ensuring safe and efficient cultivation of adherent cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bioreactors use conventional designs for cell cultivation, then cell production can be achieved, but handling adherent cells becomes complex and contamination risk increases
Solution Approach 1:
The bioreactor system is divided into a disposable single-use bioreactor unit and a reusable process control system. The single-use bioreactor contains all components needed for cell cultivation (reactor vessel, substrate, sensors) that can be discarded after one use, eliminating cross-contamination risks while simplifying handling as a complete integrated unit.
Solution Approach 2:
The patent employs a single-use bioreactor design where the entire reactor vessel and its contents are disposed of after one cultivation cycle. This disposable approach eliminates contamination risk from reused components while the modular design keeps handling simple despite the single-use nature.
2Ease of operation
If bioreactors implement complex handling procedures for adherent cells, then cell cultivation can be maintained, but disease transmission risk increases
Solution Approach 1:
The system separates the single-use bioreactor (containing cells and culture medium) from the process control system. This segmentation allows easy connection and disconnection of the sealed bioreactor unit, simplifying handling while maintaining sterile barriers that prevent disease transmission between batches and environments.
Solution Approach 2:
The sealed reactor vessel with integrated closure units acts as an intermediary barrier between the cell culture environment and the external handling system. This intermediate sealed structure enables simple external manipulation while protecting against pathogen transmission.
3Manufacturing precision
If bioreactors use traditional cell harvesting methods, then cell collection is possible, but homogeneous cell suspensions are difficult to achieve
Solution Approach 1:
The substrate is designed with movable elements that can be dynamically adjusted between different positions. During harvesting, the substrate can be moved to facilitate complete cell detachment and suspension, ensuring homogeneous cell distribution while maintaining efficient harvesting throughput through automated movement control.
4Reliability
If bioreactors implement GMP-compliant analysis systems, then quality control is improved, but device complexity increases
Solution Approach 1:
Multiple GMP-compliant measurement functions (cell counting, viability assessment, concentration measurement) are merged into an integrated process control system that communicates with the single-use bioreactor. This consolidation achieves comprehensive quality control while reducing overall system complexity compared to separate dedicated devices for each measurement type.
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 bioreactor enables safe, easy handling and reliable cultivation of adherent cells with reduced contamination risk, allowing for homogeneous cell suspensions and GMP-compliant analysis, while minimizing the risk of disease transmission.
Implementation Method 1
at least one rotation module, designed and configured for the movement of the reactor vessel about the longitudinal axis
Implementation Method 2
a gas-permeable membrane for contacting the liquid cell culture medium with an oxygen source
Implementation Method 3
The inner filter bag wall must be formed at least partially by a filter medium
Data Source
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AI summary
The present invention relates to a bioreactor for cultivating cells, comprising a housing, a reactor vessel, at least one line for the transfer of gases or gas mixtures to and/or from the reactor vessel with at least one reversibly or irreversibly sealable closure unit, at least one line for the transfer of liquid systems to and/or from the reactor vessel with at least one reversibly or irreversibly sealable closure unit, and at least one rotation module designed and configured for the movement of the reactor vessel about its longitudinal axis. Furthermore, the invention relates to a process control system comprising at least one bioreactor according to the invention.