Toroidal Bioreactor Vessel with Textured Surface for Mixing
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Solution Overview
Problem
Current disposable bioreactors face challenges in achieving adequate mixing and sufficient aeration for cells or microbes requiring significant oxygen without causing destructive shear stress, and they are not scalable to large volume runs effectively.
Innovation Solution
A toroidal-shaped bioreactor vessel with a minimal number of parts, utilizing orbital motion to create a traveling wave for mixing and oxygenation, and featuring a textured surface for enhanced sparging, along with pre-calibrated sensors and adjustable lighting for optimal growth conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional glass/steel bioreactors are used, then mixing and aeration performance is reliable, but infrastructure cost and preparation time are high
Solution Approach 1:
The patent employs disposable polymeric bioreactor vessels that replace expensive, complex glass/steel infrastructure. These single-use vessels are pre-sterilized and require no cleaning or maintenance, eliminating the need for costly infrastructure while maintaining adequate mixing and aeration through integrated design features like wave motion mechanisms and sparger tubes.
Solution Approach 2:
The bioreactor system is segmented into disposable polymeric vessels that can be independently sterilized and disposed of after use. This segmentation separates the expensive infrastructure requirement from the actual bioreaction process, allowing reliable mixing and aeration to be achieved within the disposable vessel without requiring complex permanent infrastructure.
2Device complexity
If disposable polymeric bioreactors are used, then cost and preparation time are reduced, but mixing and aeration effectiveness is compromised
Solution Approach 1:
The disposable polymeric bioreactor incorporates dynamic wave motion mechanisms that actively mix the culture medium. The vessel is designed to be agitated in a controlled manner to create traveling waves that enhance mixing effectiveness. Additionally, sparger tubes are integrated to dynamically introduce gas phases, ensuring adequate aeration despite the disposable nature of the vessel.
Solution Approach 2:
The polymeric vessel incorporates localized structural features such as sparger tubes positioned at specific locations to optimize gas distribution. The wave motion mechanism is designed with specific geometric characteristics to create effective mixing patterns. These local quality enhancements ensure that despite the overall simplicity of the disposable design, mixing and aeration effectiveness are maintained.
3Ease of manufacture
If polymeric materials are used for the bioreactor, then cost and ease of use are improved, but chemical stability under optical illumination is compromised
Solution Approach 1:
The bioreactor vessel employs composite polymeric materials that combine the desirable properties of cost-effectiveness and ease of use with enhanced chemical stability. The polymeric material is selected or formulated to resist degradation under optical illumination conditions while maintaining biocompatibility and chemical inertness. This composite approach allows the disposable vessel to be both economical and chemically stable during the bioprocess.
Solution Approach 2:
The polymeric material is carefully selected or modified to change its chemical parameters in response to optical illumination conditions. The material properties are adjusted to maintain stability under the specific lighting conditions required for the bioprocess, while still retaining the cost and ease-of-use advantages of disposable polymeric vessels.
4Object-affected harmful factors
If wave motion is used for mixing, then shear stress is reduced, but mixing effectiveness for large volumes is compromised
Solution Approach 1:
The wave motion mixing mechanism operates in a three-dimensional pattern within the bioreactor vessel, creating traveling waves that propagate through the culture medium. This dimensional approach to mixing allows effective coverage of large volumes while maintaining gentle, low-shear motion patterns. The wave motion engages the fluid in multiple dimensions simultaneously, enhancing mixing effectiveness without subjecting cells to destructive shear forces.
Solution Approach 2:
The wave motion mixing employs periodic oscillations that create rhythmic traveling waves through the culture medium. This periodic action ensures thorough mixing over time while maintaining gentle conditions for cells. The oscillatory nature of the wave motion allows effective mixing to accumulate progressively without subjecting cells to continuous high-shear stress, making it suitable for both small and large volume bioreactors.
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 design ensures effective mixing and aeration, reduces shear stress, and is scalable to large volumes, achieving comparable or superior cell density and product yield to traditional systems while minimizing costs and complexity.
Implementation Method 1
utilizing orbital motion to create a traveling wave for mixing and oxygenation
Implementation Method 2
featuring a textured surface for enhanced sparging
Implementation Method 3
sufficient aeration for cells or microbes which require significant oxygen
Data Source
AI summary
A method for enhancing mixing and aeration of a liquid reaction medium in a toroidal bioreactor vessel includes dispensing a liquid reaction medium into an interior of a toroidal bioreactor vessel, the interior being bounded by an inner surface, a textured surface being arranged on at least a portion of the inner surface, the textured surface having a plurality of upstanding protuberances. The toroidal bioreactor vessel is rotated in an orbital motion such that there is a resonant frequency traveling wave of the fluid orbiting in one direction in the interior of the toroidal bioreactor vessel when a particular orbital speed is imparted to the toroidal bioreactor vessel.