Single-Piece Eductor Design for Sterile Bioprocessing
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Solution Overview
Problem
Eductors used in biotechnological and pharmaceutical industries require complex assembly and integration into mixing systems, making them time-consuming to install and exchange, especially when high purity and sterility are demanded, leading to a need for simpler and faster integration and exchange solutions.
Innovation Solution
Designing the eductor as a one-piece unit comprising a converging inlet nozzle, suction chamber, and outlet nozzle, which can be easily integrated into mixing systems without the need for assembly or connections, and manufacturing it as a single-use injection-molded part to reduce dead zones and enhance hygiene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the eductor is assembled from multiple components (inlet nozzle, suction chamber, outlet nozzle), then it allows for flexible manufacturing and assembly, but it increases assembly complexity and installation time
Solution Approach 1:
The patent combines the inlet nozzle, suction chamber, and outlet nozzle into a single integrated component made from a single piece of material. This merging eliminates the need for separate assembly of multiple parts, reducing assembly complexity while maintaining manufacturing flexibility through modular design options.
2Ease of repair
If the eductor is assembled from multiple components with connections, then it allows for easy replacement of individual parts, but it increases assembly time and potential leakage points
Solution Approach 1:
By integrating all nozzle components into a single piece, the patent eliminates connection points that could leak and reduces assembly time. While individual part replacement is less flexible, the entire eductor can be quickly replaced as a single unit, and the integrated design ensures no leakage at connection points.
3Ease of operation
If the eductor uses separate components with connections, then it allows for modular assembly, but it creates dead zones and material deposits at connection points
Solution Approach 1:
The integrated single-piece design eliminates connection points between components, thereby removing dead zones where material could accumulate. The continuous flow path from inlet to outlet without interruptions prevents material deposits at connection interfaces.
Solution Approach 2:
The patent incorporates rounded corners and smooth transitions throughout the eductor design, particularly at the inlet and outlet openings. These curved surfaces prevent material accumulation by eliminating sharp corners and flat surfaces where deposits could form, ensuring easy cleaning and maintenance.
4Reliability
If the eductor is designed for sterilization, then it meets hygiene requirements, but sterilization processes are time-consuming and costly
Solution Approach 1:
The rounded corner design throughout the eductor eliminates hard-to-reach areas and crevices that would require extensive sterilization. Smooth, continuous surfaces allow for faster and more effective sterilization processes while maintaining complete hygiene compliance.
Solution Approach 2:
The single-piece construction eliminates internal connections and joints that would create dead zones requiring prolonged sterilization. The integrated design allows for more straightforward and quicker sterilization while ensuring complete sanitation of all surfaces.
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
This approach simplifies the integration and exchange of eductors, reduces assembly time, and enhances hygiene by eliminating dead zones and material deposits, while being cost-effective and suitable for high-purity applications.
Implementation Method 1
Based on Bernoulli's equation, a negative pressure is created in the suction chamber, by which the secondary substance is sucked into the flow of the primary fluid
Implementation Method 2
Downstream of the suction chamber, an outlet nozzle is provided in which the primary fluid and the secondary substance mix with each other. The outlet nozzle is often designed as a Venturi nozzle.
Data Source
AI summary
An eductor for mixing a primary fluid with a flowable secondary substance includes a primary inlet for the primary fluid, a secondary inlet for the secondary substance, an outlet and a suction chamber, A converging inlet nozzle is provided, which is arranged between the primary inlet and the suction chamber so that the primary fluid can flow from the primary inlet into the suction chamber. An outlet nozzle is provided between the suction chamber and the outlet, through which the primary fluid and the secondary substance can flow to the outlet, and the secondary inlet is provided at the suction chamber so that the secondary substance can flow from the secondary inlet into the suction chamber.