Sensor Port Support Structure for Flexible Bag Leak Prevention
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Solution Overview
Problem
Flexible disposable bags in bioreactors are vulnerable around integrated sensors due to lack of support, leading to potential tearing and medium leakage during hydrostatic pressure.
Innovation Solution
A rigid, plate-shaped support part with a receptacle for the sensor and a fastening element that attaches to the bag, stabilizing the sensor area by being supported at the window opening edges, forming a preassembled unit for easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the flexible bag is placed in a rigid container with a window opening for sensor access, then the sensor ports are accessible from outside, but the bag wall becomes vulnerable to tearing and medium leakage in the window opening area
Solution Approach 1:
The support part is divided into distinct functional zones: a first support surface for the window opening area, a second support surface for the sensor port area, and connecting structures. This segmentation allows each zone to address specific vulnerability points independently, with the first surface preventing bag protrusion through the window and the second surface supporting the sensor port base
Solution Approach 2:
The support part acts as an intermediary component between the flexible bag and the rigid container wall. It transfers and distributes the mechanical loads from the bag wall in the window opening area to the rigid container, preventing stress concentration that would otherwise lead to bag tearing or sensor port detachment
2Reliability
If additional support measures are added to stabilize the sensor area, then bag tearing is prevented, but device complexity increases
Solution Approach 1:
Multiple support functions are merged into a single integrated support part: window opening support, sensor port base support, and load distribution functions are combined in one component. This eliminates the need for multiple separate support elements while maintaining comprehensive protection of the sensor area
Solution Approach 2:
The support part is designed as a thin-walled structure that can be made of flexible or semi-rigid materials. This allows the support part to conform to the bag wall contour while providing sufficient mechanical support, reducing material usage and structural complexity compared to rigid bulk supports
3Ease of operation
If a preassembled stabilizing device is used, then ease of installation is improved, but manufacturing complexity increases
Solution Approach 1:
The support part is designed to be pre-assembled with the sensor port base before bag sealing. The holding means for the sensor port base are pre-positioned and secured to the support part, eliminating the need for complex assembly operations after bag filling. This preliminary assembly simplifies the overall installation process while the modular design keeps manufacturing manageable
Data Source
AI summary
A device for mechanically stabilizing a sensor port on a flexible bag including a rigid, substantially plate-shaped support part, which has a receptacle for a rigid connecting part integrated in the bag, in particular a sensor, and a holding mechanism on the receptacle. The device further includes a fastening element adapted to be attached to the holding mechanism of the support part such that it fixes the support part to the connecting part. The device may include a rigid support part which can be assembled from at least two parts, preferably struts. The parts surround a free area or an opening in which a rigid connecting part integrated in the bag can be placed. In an assembled state of the parts, the free area or the opening has a smaller diameter than the connecting part, so that the parts form a load-receiving mechanism for the connecting part.