Exchangeable Separator Insert for Sterile Gentle Centrifugal Separation
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Solution Overview
Problem
Existing centrifugal separators used in pharmaceutical and biopharmaceutical industries face challenges in providing a sterile, single-use solution that gently separates liquid mixtures into heavy and light phases while ensuring efficient surface area for separation.
Innovation Solution
A modular centrifugal separator system with an exchangeable separation insert featuring separation sheets that extend axially and radially, allowing for gentle inflow and outflow of liquid feed mixtures, and a base unit that supports the insert for repeated use, with parts manufactured by injection molding for ease and sterility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stainless steel equipment is used for separation, then the equipment can be sterilized between batches, but it requires complex sterilization procedures and high maintenance costs
Solution Approach 1:
The patent employs a disposable single-use portion that is discarded after one use, eliminating the need for complex sterilization procedures. The disposable portion includes a rotor casing and separation discs that are pre-sterilized and disposed of after use, replacing the need for repeated sterilization of permanent stainless steel equipment.
Solution Approach 2:
The centrifugal separator is divided into a reusable base unit and a disposable single-use portion. This segmentation allows the complex sterilization requirements to be applied only to the disposable portion, which is pre-sterilized and discarded, while the base unit requires minimal maintenance and no sterilization.
2Productivity
If conventional centrifugal separators are used, then separation can be achieved, but the liquid feed mixture experiences harsh inflow and outflow conditions
Solution Approach 1:
The patent introduces a tangential inlet arrangement where the liquid feed mixture enters the rotor casing tangentially rather than axially. This dimensional change in flow direction creates a gentler inflow condition that reduces turbulence and harmful flow effects while maintaining separation efficiency through the centrifugal field.
3Area of stationary object
If frustoconical separation discs are used, then separation surface area is provided, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent employs frustoconical separation discs with curved surfaces optimized for centrifugal separation. The curved geometry is manufactured using injection molding technology, which allows complex curved shapes to be produced efficiently at lower cost compared to traditional machining methods, thus maintaining high separation surface area while improving ease of manufacture.
4Reliability
If single-use portions are introduced, then sterilization is simplified, but the device requires modular design and exchangeable components
Solution Approach 1:
The centrifugal separator is divided into a reusable base unit and a disposable single-use portion that can be easily exchanged. This segmentation simplifies sterility assurance by pre-sterilizing the disposable portion, while the modular design manages the complexity through standardized interfaces and simple assembly/disassembly procedures.
Solution Approach 2:
The base unit is designed as a universal platform that can accommodate different single-use portions for various separation applications. This multi-functionality reduces overall system complexity by using a common base unit with standardized interfaces, allowing the modular structure to serve multiple purposes without requiring complex customization.
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 system provides efficient separation of liquid mixtures into heavy and light phases with a sterile environment, ensuring gentle handling and cost-effective, disposable components that maintain high surface area for separation efficiency.
Implementation Method 1
A modular centrifugal separator system configured for separating a liquid feed mixture into a heavy phase and light phase... a rotor casing configured to rotate about a rotational axis and forming a separation space
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The disclosure concerns a modular centrifugal separator system and an exchangeable separation insert (6). Separation aiding means (90) are arranged in a separation space (88) of the separation insert (6). The separation aiding means (90) comprises a number of separation sheets (92), each separation sheet (92) comprising axially extending surfaces (120, 122). A fluid connection (94) for separated heavy phase is arranged at a first axial end portion (85) of the insert (6), and a fluid connection (96) for liquid feed mixture is arranged at a second axial end portion (87) of the insert (6).