Single-Use Valve Block Layout for Low Dead Space Bioprocessing
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Solution Overview
Problem
Existing single-use valve systems for bioprocesses have a large footprint, high dead space, numerous hose connections leading to leaks and complex assembly, and unfavorable fluid dynamics, resulting in inefficient chromatographic separations and potential damage to target molecules.
Innovation Solution
A compact valve block with integrated valve units, featuring a main conduit and secondary conduits within a single block body, with actuators sealed from the medium, allowing for reduced hose connections and minimized void volume, enabling precise control and easy handling, and capable of withstanding high pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If peristaltic or diaphragm-type regulating valves are used for single-use applications, then the system is disposable and eliminates cleaning/validation requirements, but the footprint becomes large and dead space increases
Solution Approach 1:
Multiple valve units are integrated into a single valve block with a common body, merging what would otherwise be separate disposable valve assemblies. This consolidation reduces the overall footprint and dead space while maintaining the disposable advantage of eliminating cleaning and validation requirements.
Solution Approach 2:
The valve block design provides a universal platform that can accommodate multiple valve units with different functions (e.g., different conduit connections) within a single integrated structure, allowing one disposable component to perform multiple regulatory functions that would otherwise require several separate valves.
2Ease of manufacture
If peristaltic or diaphragm-type regulating valves are used, then the system is simple to implement, but the number of hose connections increases leading to more leaks and complex assembly
Solution Approach 1:
Multiple valve units are integrated into a single valve block with a common body, merging what would otherwise be separate disposable valve assemblies. This consolidation reduces the overall footprint and dead space while maintaining the disposable advantage of eliminating cleaning and validation requirements.
Solution Approach 2:
The hose connections are extracted from the valve units and consolidated into a common connection system on the valve block, reducing the number of individual hose connections required and thereby reducing leak points and assembly complexity.
3Adaptability or versatility
If conventional valve assemblies with multiple hose connections are used, then the system is flexible in configuration, but the risk of leaks and assembly complexity increases
Solution Approach 1:
Multiple valve units are integrated into a single valve block with a common body, merging what would otherwise be separate disposable valve assemblies. This consolidation reduces the overall footprint and dead space while maintaining the disposable advantage of eliminating cleaning and validation requirements.
Solution Approach 2:
The hose connections are extracted from the valve units and consolidated into a common connection system on the valve block, reducing the number of individual hose connections required and thereby reducing leak points and assembly complexity.
4Ease of operation
If conventional valve components are used, then the system is easy to assemble, but the void volume and dead space are large causing unwanted dilution and mixing effects
Solution Approach 1:
Multiple valve units are integrated into a single valve block with a common body, merging what would otherwise be separate disposable valve assemblies. This consolidation reduces the overall footprint and dead space while maintaining the disposable advantage of eliminating cleaning and validation requirements.
Solution Approach 2:
The valve units are nested within a compact block structure, with conduits and valve components arranged in a space-efficient configuration that minimizes void volume and dead space while maintaining ease of assembly through modular integration.
Data Source
AI summary
A valve block for single use in a bioprocess, having a plurality of valve units and a one-piece block body having a main conduit. Each valve unit includes a secondary conduit, a valve seat between the secondary conduit and the main conduit, a closure part having a gripping portion, and an actuator coupled to the gripping portion which can transfer the closure part from a first switching position, in which the closure part is pressed against the valve seat and blocks a fluid communication between the secondary conduit and the main conduit, to a second switching position, in which the closure part is lifted from the valve seat and unblocks the fluid communication between the secondary conduit and the main conduit. The gripping portion is sealed against both the main conduit and the secondary conduit in both switching positions of the valve unit.