Static Mixer with Disposable Bags for Small Batch Mixing
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Solution Overview
Problem
Existing mixing systems fail to efficiently produce small quantities of mixed fluids under standardized conditions, particularly in personalized medicine, lacking flexibility, robustness, and high-throughput capabilities.
Innovation Solution
An apparatus and method using a static mixer with independent feed modules for each liquid, incorporating pressure reservoir chambers, pressurisable substrate chambers, and a pressure supply module to control gas pressure for rapid equilibration, enabling precise control of liquid flow without pumps, suitable for small batch aseptic processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous mixing systems with metering pumps are used, then productivity is improved for large-scale production, but device complexity and cleaning/sterilization requirements increase
Solution Approach 1:
The patent employs disposable single-use bags with integrated mixing chambers and static mixers that are discarded after a single use. This eliminates the need for complex cleaning and sterilization systems while maintaining high productivity. The disposable nature of the mixing system removes all cleaning/sterilization requirements and simplifies the overall device architecture.
Solution Approach 2:
The patent extracts the mixing function from a complex continuous system with multiple pumps and transfer mechanisms, isolating it into a simple disposable bag with static mixer. This extraction reduces device complexity while preserving the essential mixing function for small batch production.
2Stability of the object's composition
If rigid containers with pumps are used for mixing, then mixing homogeneity is improved, but ease of operation and cleaning complexity increase
Solution Approach 1:
The disposable bag system eliminates complex pump operations and rigid container handling. The flexible bag design with integrated static mixer provides sufficient mixing homogeneity through passive mixing elements, while the disposable nature eliminates all cleaning and sterilization operations, dramatically improving ease of operation.
Solution Approach 2:
The patent replaces active mechanical mixing (pumps with moving parts) with passive static mixing elements embedded in the disposable bag. This substitution eliminates the need for complex pump operations while achieving adequate mixing homogeneity for the application.
3Productivity
If large-volume mixing systems are used, then productivity for bulk production is improved, but adaptability to small batches deteriorates
Solution Approach 1:
The patent segments the mixing system into individual disposable bags, each capable of handling small batches independently. This segmentation allows the system to be scaled by simply adding more parallel disposable units rather than requiring a single large-volume system, providing both small batch adaptability and potential for scaled production.
Solution Approach 2:
The patent changes the scale parameter from fixed large-volume continuous systems to variable small-volume disposable bags. By changing the volume parameter to be adjustable through selection of different bag sizes or numbers of parallel bags, the system achieves both small batch adaptability and scalable productivity.
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 achieves precise, reproducible mixing of small batches with minimal ramp-up times and avoids contamination, reducing the need for cleaning and sterilization cycles, while maintaining product quality and efficiency.
Implementation Method 1
a pressurised gas which exerts pressure on an external surface of the flexible container such as to force said first and said second liquid through the static mixer
Data Source
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AI summary
An apparatus for mixing two liquids is provided. The apparatus comprises a static mixer, and a first (11) and second (12) feed module for feeding the two liquids to the mixer. The feed modules comprise pressurisable chambers (14a, 14b) for accommodating flexible containers which hold the liquids to be mixed. The liquids are forced through the static mixer when the chambers comprising the flexible containers are pressurised. Pressurisation is achieved by pressurised gas stored in pressure reservoir chambers (13a, 13b) that are connectable to the chambers holding the flexible containers. Related methods of mixing two liquids are also provided.