Integrated Sparger-Impeller Assembly for High kLa Bioprocessing
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Solution Overview
Problem
Existing bioreactor systems with single-use bags face challenges in achieving high oxygen transfer rates and kLa values due to bulky formats and complex designs with multiple impellers, leading to increased cost and cumbersome installation.
Innovation Solution
The development of sparger assemblies with removably connected aeration manifolds and impeller assemblies that include a base plate and aeration manifolds with gas inlet and outlet openings, along with a hub and blades, allowing for customizable gas distribution and efficient mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple impellers are used to achieve high oxygen transfer rates, then oxygen transfer efficiency is improved, but device complexity and bulkiness increase
Solution Approach 1:
The patent combines the sparger and impeller into a single integrated assembly, where the sparger serves as the impeller support structure and the impeller is mounted directly on the sparger. This integration eliminates the need for separate impeller shafts and support structures, achieving high oxygen transfer rates through coordinated gas sparging and impeller mixing while reducing overall device complexity
Solution Approach 2:
The sparger assembly serves multiple functions simultaneously: it provides gas distribution through sparger outlets, supports the impeller structure, and enables efficient gas-liquid mixing. This multi-functionality allows a single component to replace what would traditionally require separate gas distribution systems and impeller support structures
2Productivity
If multiple impellers are used to achieve high kLa values, then gas dispersion efficiency is improved, but manufacturing cost increases
Solution Approach 1:
By integrating the sparger and impeller into a single manufactured assembly, the patent reduces the number of separate components that need to be produced, assembled, and sterilized. This integration simplifies manufacturing processes and reduces costs while maintaining the high kLa values needed for efficient gas transfer
3Productivity
If multiple impellers are used to achieve high oxygen transfer rates, then mixing efficiency is improved, but ease of installation deteriorates
Solution Approach 1:
The integrated sparger-impeller assembly is designed as a single installable unit that attaches directly to the bioreactor vessel. This integration eliminates the need for complex shaft installations and multiple component assemblies, making installation straightforward while maintaining high mixing efficiency through the coordinated action of sparged gas and impeller rotation
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
Enhances oxygen transfer rates and kLa values while providing a modular, user-friendly, and cost-effective solution for bioreactor systems, supporting increased cell culture densities.
Implementation Method 1
A sparger outputs small gas bubbles into a liquid in order to agitate and/or dissolve the gas into the liquid
Implementation Method 2
A agitator assembly disposed within the bag is used to mix the fluid
Data Source
AI summary
A sparger assembly (700) for a bioprocessing system includes a base plate (710) and at least one aeration manifold (712, 714) removably connected to tire base plate. Each aeration manifold includes at least one inlet for receiving a gas and a plurality of gas outlet openings for delivering tire gas to a fluid within the bioprocessing system. An impeller assembly (740) fora bioprocessing system includes a hub and at least one blade (742) operatively connected to the hub. The at least one blade includes a first portion connected to the hub and extending generally vertically, and a second portion extending at an upward angle from tire first portion.