Static Mixer Feed Modules for Aseptic Small-Batch Liquid Mixing
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Solution Overview
Problem
Existing mixing systems are inadequate for producing small quantities of mixed fluids or products under standardized conditions, requiring methods and apparatuses that are flexible, robust, fast, and reliable, particularly for applications in personalized medicine.
Innovation Solution
A static mixer apparatus with independent feed modules and pressure supply modules that utilize pressurized gas to control the flow of liquids into a static mixer, achieving precise and reproducible mixing through rapid pressure equilibration and avoiding contamination, with disposable components to minimize cleaning and sterilization cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid container with non-invasive pump is used for mixing, then cleaning and sterilization steps are prevented through single-use design, but the system is not suitable for producing small quantities (μl- or ml amounts) and requires bulky containers
Solution Approach 1:
The system divides the mixing process into separate functional modules: a disposable mixing chamber for single-use sterile mixing, and a reusable external pressurization system. This segmentation allows the sterile single-use aspect to be separated from the pressurization mechanism, enabling small volume production while maintaining sterilization-free operation through the disposable chamber design.
Solution Approach 2:
The patent introduces an intermediary pressurization system that connects the reusable external device to the disposable mixing chamber. This intermediary approach allows the reusable pressurization system to interface with single-use chambers, enabling flexible small-volume production without compromising the sterile barrier provided by the disposable components.
2Productivity
If continuous production systems with metering pumps are used, then higher production amounts are achieved, but the systems are not suitable for small quantity production and require complex pre-mixing systems
Solution Approach 1:
The patent extracts the complex metering pump and pre-mixing system from the overall apparatus, replacing them with a simpler pressurization mechanism that acts on pre-filled disposable chambers. This extraction eliminates the need for complex continuous flow control systems while maintaining the ability to produce various volumes by simply changing the chamber size or number of chambers used.
Solution Approach 2:
The system performs preliminary action by pre-filling the disposable mixing chambers with the required amounts of components before use. This eliminates the need for complex real-time metering and pre-mixing systems during operation, as the dosing is completed in advance during chamber preparation, simplifying the operational system while enabling flexible production volumes.
3Speed
If rapid pressure equilibration is achieved through direct connector design, then mixing speed is improved, but pressure control precision may be compromised
Solution Approach 1:
The patent employs a dynamically adjustable valve mechanism in the connector that can modulate the opening size. This allows the system to provide rapid pressure equilibration when needed by opening the valve fully, while maintaining pressure control precision by partially closing the valve to regulate flow. The dynamic adjustability of the valve opening resolves the contradiction between speed and precision in pressure control.
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 apparatus enables aseptic processing of small batches with minimal ramp-up times and reduced fluid contamination, ensuring high-throughput production of mixed fluids with controlled flow rates and minimal product loss.
Implementation Method 1
a pressure reservoir chamber for holding a pressurized gas, said pressure reservoir chamber having an inlet and/or an outlet for pressurized gas
Implementation Method 2
a pressure sensor for measuring the pressure of the pressurized gas in the feed module at or downstream of the pressure reservoir chamber
Data Source
AI summary
An apparatus for mixing two liquids is provided. The apparatus includes a static mixer, and a first and second feed module for feeding the two liquids to the mixer. The feed modules include pressurizable chambers for accommodating flexible containers which hold the liquids to be mixed. The liquids are forced through the static mixer when the chambers including the flexible containers are pressurized. Pressurization is achieved by pressurized gas stored in pressure reservoir chambers that are connectable to the chambers holding the flexible containers. Related methods of mixing two liquids are also provided.