DETECTING FOAM IN A BIOREACTOR PLANT
20230125762 · 2023-04-27
Assignee
Inventors
- Andreas Prediger (Göttingen, DE)
- Sina Götemann (Bovenden, DE)
- Marco Leupold (Göttingen, DE)
- Jochen Scholz (Göttingen, DE)
Cpc classification
H03K2017/9602
ELECTRICITY
G01F23/26
PHYSICS
International classification
G01F23/26
PHYSICS
Abstract
System for detecting at least one presence of foam of a medium in a bioreactor plant, wherein the system comprises: —a bioreactor plant having at least one disposable container for receiving the medium that may comprise the foam; and—at least two capacitive sensor units which are attached at at least two different situating positions of the bioreactor plant, wherein the capacitive sensor units each comprise at least one electrode system for capacitive measurement and are able to detect the presence of foam at the at least two situating positions on the basis of the capacitive measurement; and wherein the capacitive sensor units are designed to transmit captured data relating to the presence of foam to at least one monitoring unit for monitoring, open-loop and/or closed-loop control of foam formation in the bioreactor plant on the basis of said data.
Claims
1. A system for detecting at least the presence of foam of a medium in of a bioreactor plant, wherein the system comprises: a bioreactor plant having at least one single-use container for receiving the medium, that can have the foam; and at least two capacitive sensor units, that are attached at at least two different situating positions of the bioreactor plant, wherein the capacitive sensor units each comprise at least one electrode system for a capacitive measurement and can detect the presence of foam at the at least two situating positions on the basis of the capacitive measurement; and wherein the capacitive sensor units are designed to transmit recorded data concerning the presence of foam to at least one monitoring unit for monitoring, open-loop control and/or closed-loop control of foam formation in the bioreactor plant based on said data.
2. The system according to claim 1, wherein at least one of the capacitive sensor units has an adhesive strip on which the electrode system is at least partially arranged, wherein the adhesive strip is designed such that the at least one capacitive sensor unit can be arranged on the bioreactor plant.
3. The system according to claim 1, wherein at least one of the capacitive sensor units is a capacitive arc sensor unit, wherein the shape of the capacitive arc sensor unit comprises at least a section of an arc, in particular a circular arc.
4. The system according to claim 3, wherein the bioreactor plant has at least one port, in particular a circular port to fluidically connect the interior of the single-use container to another element and/or the exterior of the single-use container, and wherein the at least one capacitive arc sensor unit is designed to at least partially envelop the port.
5. The system according to claim 4, wherein the bioreactor plant has at least one hose and/or a tube fluidically connected to the port, wherein the at least one capacitive arc sensor unit is designed to at least partially envelop the hose and/or the tube.
6. The system according to claim 1, wherein at least one of the capacitive sensor units, in particular a capacitive patch sensor unit is designed to detect the presence of foam, in particular a foam level in the single-use container and is arranged at a situating position in the interior of the single-use container, in particular on an interior container envelope, and wherein the at least one capacitive sensor unit preferably can be, and in particular is, sterilized.
7. The system according to claim 1, wherein at least one of the capacitive sensor units, in particular a capacitive arc sensor unit and/or a collar sensor unit can be, or is, arranged at a situating position outside of the single-use container, in particular on an exterior container envelope and/or on a port and/or on a hose or a tube or a line.
8. The system according to claim 7, wherein the situating position on the exterior container envelope is at least one of the following situating positions: the situating position at a height slightly below the height of an exhaust port of the single-use container, in particular not in the immediate vicinity of the exhaust port; the situating position in the immediate vicinity of the exhaust port; the situating position in the immediate vicinity of a port for an upper inlet/upper outlet of the single-use container; the situating position on an exhaust hose of the bioreactor plant, wherein the exhaust hose is fluidically connected to the exhaust port and the situating position is located in the immediate vicinity of the exhaust port; the situating position on the exhaust hose of the bioreactor plant in the immediate vicinity of a filter of the exhaust hose, in particular between the exhaust port and the filter.
9. The system according to claim 6, wherein the situating position on the interior container envelope is at least one of the following situating positions: the situating position in the proximity, preferably at a height slightly above a height, of a predetermined maximum fill level of the single-use container, in particular above a limit line of a predetermined maximum fill level; the situating position in the proximity, preferably at a height slightly above a height, of a predetermined minimum fill level of the single-use container, in particular a limit line of a predetermined minimum fill level; the situating position at a height between the height of the predetermined minimum fill level and the height of the predetermined maximum fill level, in particular between a limit line of the predetermined minimum fill level and a limit line of the predetermined maximum fill level.
10-13. (canceled)
14. A method for detecting at least one presence of foam of a medium, comprising: Provide a bioreactor plant having at least one single-use container for receiving the medium that can comprise the foam; Arrange at least two capacitive sensor units at at least two situating positions of the bioreactor plant, wherein the capacitive sensor units each have at least one electrode system for a capacitive measurement; Record data concerning the presence of foam on the at least two measurement positions based on the capacitive measurements; and Transmit the recorded data concerning the presence of foam to at least one monitoring unit for monitoring, open-loop control and/or closed-loop control of foam formation in the bioreactor plant based on the data using the capacitive sensor units.
15. The method according to claim 14 comprising monitoring, open-loop control and/or closed-loop control of foam formation in the bioreactor plant using the monitoring unit based on the transmitted data.
16. The method according to claim 14, wherein open-loop control and/or closed-loop control comprises feeding a substance that is designed to prevent or at least reduce foam formation when the presence of foam is detected by at least one capacitive sensor unit, preferably when the presence of foam is detected by at least one capacitive sensor unit at a situating position outside of the single-use container, in particular using a capacitive arc sensor unit.
17. The method according to claim 14, comprising: Trigger an alarm when the presence of foam is detected by at least one capacitive sensor unit at a situating position in the interior of the single-use container and/or at a situating position outside of the single-use container; and/or Trigger an emergency shutoff when the presence of foam is detected by at least one sensor at a situating position outside of the single-use container.
18. A method for installing a system for detecting at least one presence of foam of a medium in of a bioreactor plant, comprising: Provide a bioreactor plant having at least one single-use container for receiving the medium that can comprise the foam; Provide at least two capacitive sensor units, wherein the capacitive sensor units each have at least one electrode system for a capacitive measurement; Arrange the at least two capacitive sensor units at respectively one situating positions of the bioreactor plant; and Connect the at least two capacitive sensor units to at least one monitoring unit for monitoring, in particular for monitoring, open-loop control and/or closed-loop control of foam formation in the bioreactor plant based on the capacitive measurements.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0144] The following is a detailed description of several exemplary embodiments, wherein the invention is not limited to the described exemplary embodiments. Several features that are described in a specific embodiment can be arbitrarily combined, provided they do not rule each other out. Moreover, various features that are provided together in the exemplary embodiments are not to be regarded as restricting the invention.
[0145] Bioreactors or bioreactor plants are in particular plants having one or several containers to receive media. A bioreactor is generally designed to monitor, control by open and/or closed loop biochemical and/or chemical processes. Bioreactors are in particular used as fermenters for cultivating microorganisms, cells, single-cell and/or multi-cell organisms. A bioreactor can in particular be formed as a single-use container and can comprise further elements of a bioreactor. A bag can for example represent a principal element of a bioreactor, wherein the bag can be held by a stainless steel frame.
[0146] The single-use container (or SU container) is in particular design for single use for one or several consecutively running biochemical processes. After use, a single-use container can be disposed without first having to be cleaned using potentially elaborate means.
[0147] Media filled into bioreactors and/or intermediate products of these media can under certain circumstances form foam, in particular during mixing operations or during one or during several processes. Foam formation is problematic for several reasons. Firstly, foam can block inlets/outlets and/or ports, and secondly, foam can negatively impact processes within the bioreactor. It is therefore essential to monitor bioreactors and bioreactor plants concerning the generation of foam. It is in particular advantageous to monitor rapidly propagating foams because these can occur in short time frames and because potentially valuable media can be placed at risk in a bioreactor due to malfunctions caused by foam. Fermentation processes are in particular also subject to the risk that not detected foam for example grows or reaches into the exhaust filter of a bioreactor plant and blocks a filter there. This can potentially result in a very fast pressure increase in the bioreactor plant, and can for example prevent a closed loop control of the oxygen concentration of the liquid medium. It can happen as a result that the entire media filling of the bioreactor plant must be discarded. In a worst-case, this can result in loss of production and high costs. It is therefore important to efficiently and continuously detect foam formation.
[0148] For this purpose, sensor units, in particular capacitive sensor units, can be arranged on and/or in a bioreactor plant. This involves using at least a two-point monitoring or even a multipoint monitoring, wherein the two-point or multi-point monitoring each require two or more capacitive sensor units at respectively different positions of the bioreactor plant, such that foam formation can be monitored at several positions of the bioreactor plant. A combination of at least one patch sensor unit and at least one arc sensor unit is preferred in this case, wherein the at least one patch sensor unit is in particular arranged to monitor a foam level, and the at least one arc sensor unit is arranged to monitor the presence of foam on a port and/or a hose and/or a tube.
[0149]
[0150] The connecting lip 28 represents a substantially elongated connecting section, in particular an electrically conductive path to supply the electrode system 19 with current or voltage and/or to conduct signals, and on whose one end the rectangular field 18.sub.a is located, and on whose other end the connecting unit 24 is located. The connecting unit 24 for example is used for signal transmission and/or power supply. By applying alternating current, an electrical alternating field can be generated in this manner in the electrode system 19, and the resulting current flow can be detected as a signal.
[0151] A capacitive sensor unit substantially acts like an open capacitor. In particular, an electrical field is generated between the sensor electrode and the mass electrode. When a material with a dielectric constant ε.sub.r greater than air penetrates the electrical field, the capacitance of the sensor arrangement increases as a function of ε.sub.r of this material.
[0152] The sensor unit further has an electronic unit that can detect this capacitance increase, and the signal detected in this manner can be analyzed in the subsequent signal processing step.
[0153] Sensor units that have a mass electrode, and are therefore based on a three-electrode system, can be installed in, and/or arranged on, a material flush with the active surface—that is to say with the surface from which the electrical field substantially propagates for measurement. Because the electrical field on these sensor units propagates for measurement from the sensor electrode to the integrated mass electrode, a defined electrical field for measurement or a measurement field is generated. Such sensor units are particularly suited for detecting or recording nonconductive materials, such as oils, glass, wood, and/or plastics. But conductive materials can likewise be detected. A further compensation electrode can also be incorporated into the sensor unit, in particular to render the sensor unit resistant to potential dirt deposits and moisture on the sensor surface.
[0154] Sensor units that do not have a mass electrode, and are therefore based on a two-electrode system, are generally not installed flush into, and/or arranged flush on, a material. The mass electrode is in this case not integrated into the sensor unit, but is instead formed by the object and/or medium to be detected, in particular by the foam that potentially occurs in the proximity of the sensor unit. Sensor units without a mass electrode are generally relatively resistant to dirt and are particularly suitable for detecting fill levels. Sensor units that do not have a mass electrode are particularly suited for detecting conductive media, in particular media that are grounded.
[0155] Capacitive sensor units can in particular detect conductive as well as nonconductive media that have a dielectric constant of ε.sub.r>1. The dielectric constant ε.sub.r (also called permittivity constant or dielectric conductivity) of a material determines by how much the electrical flow density increases when the corresponding material penetrates the measurement field instead of vacuum or air.
[0156] Conductive materials in particular have an electrical conductivity of >approximately 20 pS/cm. They can generally be relatively reliably detected by all sensor types, including those with mass electrode or those without mass electrode.
[0157] Typical media regarded as conductive can for example be the following: Water with ions or salts, blood, ink, milk, acetone, and metallic substances.
[0158] Nonconductive media typically have an electrical conductivity of <approximately 20 μS/cm. Such media can be particularly readily detected using sensor units that have a mass electrode, that is to say with three-electrode systems. When a nonconductive object is introduced into the field of the sensor, the field is amplified as a function of the dielectric constant and the size of the material to be detected, and therefore amplifies the capacitance of the sensor arrangement. The lower the value ε.sub.r, the more difficult it is to detect the medium.
[0159] The capacitive patch sensor unit 10.sub.A can generally have an arbitrary size. An overall length I.sub.1 of the capacitive patch sensor unit 10.sub.A including the connection section 25 and the connecting unit 24 can in particular be selected such that it ranges between approximately 1 cm and approximately 20 cm, in particular between approximately 3 cm and approximately 15 cm and preferably between approximately 8 cm and approximately 12 cm. In the exemplary case described here, the overall length is approximately 98.5 mm, or approximately 9.85 cm. A length I.sub.2 of the rectangular field 18.sub.a can in particular be selected such that it ranges between approximately 0.5 cm and approximately 10 cm, in particular between approximately 1 cm and approximately 6 cm and preferably between approximately 3 cm and approximately 5 cm. In the exemplary case described here, the length I.sub.2 of the rectangular field 18.sub.a is approximately 42 mm, or 4.2 cm.
[0160] A width b.sub.b of the rectangular field 18.sub.a can in particular be selected such that it ranges between approximately 1 cm and approximately 15 cm, in particular between approximately 3 cm and approximately 12 cm and preferably between approximately 5 cm and approximately 10 cm. In the exemplary case described here, the width b.sub.b of the rectangular field 18.sub.a is approximately 70.5 mm, or 7.5 cm.
[0161] A width b.sub.a of the connecting lip 28 of the connection section 25 can in particular be selected such that it ranges between approximately 0.2 cm and approximately 5 cm, in particular between approximately 0.5 cm and approximately 3 cm and preferably between approximately 1 cm and approximately 2 cm. In the exemplary case described here, the width b.sub.a of the connecting lip 28 of the connection section 25 is approximately 14 mm, or approximately 1.4 cm.
[0162] A length I.sub.3 of the connecting unit 24 can in particular be selected such that it ranges between approximately 0.2 cm and approximately 7 cm, in particular between approximately 0.5 cm and approximately 5 cm and preferably between approximately 2 cm and approximately 4 cm. In the exemplary case described here, the length I.sub.3 of the connection section 25 is approximately 30.5 mm, or approximately 3.05 cm.
[0163] The exemplary capacitive patch sensor unit 10.sub.A is designed to be arranged on an interior container envelope and/or an exterior container envelope and/or another element of a bioreactor plant, in particular by means of an adhesive strip 18, such that the electrode system 19 can preferably contactlessly detect a change of permittivity using a capacitive measurement, and determine therefrom whether a foam is present in the immediate vicinity or at an immediate distance or in the immediate surroundings or environment.
[0164] The connecting unit 24 can in particular have an M8 connector. The connecting lip 28 of the connection section 25 can in particular be connected to this M8 connector and can have a potting compound that holds both elements together. The potting compound can in particular be comprised on an ABS plastic. The electrode system 19 is connected to the connecting unit 24 in particular by means of a distribution line.
[0165]
[0166] The connecting lip 28 can potentially be sensitive; in other words, this means it can contribute toward a change in the permittivity or capacitance being generated and/or measured. A permittivity change behind the lip can in particular contribute toward the measured capacitance and therefore to the total signal of the sensor.
[0167] Because the connecting lip 28 may not have a substantially defined position because it is preferably not glued to the surface of the bioreactor plant, false positive signals can be generated when the connecting lip 28 is moved during the course of the process (for example by tensile forces on the cable or by pressure variations in the bioreactor). However, gluing on the connecting lip 28 does not represent a preferred embodiment because the connecting lip 28 would then no longer be flexible or movable, and because the connecting lip 28 would also readily come detached by cable movement.
[0168] A spacer 28a of the sensitive surface, which at least partially encloses and/or covers the connecting lip 28, can serve to reduce or even avoid such undesired effects, such as measuring a false positive signal. The spacer 28a can in particular be a jacket that for example consists of or comprises polypropylene (PP). Alternative shielding substances with a low ε.sub.r, in particular plastics or foams are likewise conceivable.
[0169] The spacer 28a can in particular have a thickness of approximately 0.2 mm to approximately 3 mm, preferably from approximately 0.8 mm to approximately 1.3 mm, and particularly preferably from approximately 1 mm. A thickness of approximately 1 mm permits a high flexibility of the connecting lip 28, while at the same time ensuring sufficient distance from potential foreign bodies to prevent a signal coupling in the sensitive areas of the connecting lip.
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[0171] In the present case, the arc section 18.sub.b is in particular used to arrange an electrode system 19. The function of the arc section 18.sub.b at least partially corresponds to the function of the rectangular field 18.sub.a in a patch sensor unit 10.sub.A. The arc section 18.sub.b can likewise have an adhesive strip 18 or an adhesive gluing field.
[0172] The capacitive arc sensor unit 10.sub.B has an electrode system 19 that is arranged on the arc section 18.sub.b and on the connecting lip 28 of a sensor section 25. The electrode system 19 comprises a sensor electrode 20, a protective electrode 21 and preferably a mass electrode 22. The electrodes 20, 21, 22 at least partially mimic the shape of the capacitive arc sensor unit 10.sub.B, in particular the arc shape of the arc section 18.sub.b, in that they are each arranged along the edges of the capacitive arc sensor unit 10.sub.B and each form a closed loop.
[0173] Alternatively, in particular in the capacitive arc sensor unit 10.sub.B, the electrode system 19 can in general—that is to say in all embodiments—also be formed as a two-electrode system instead of as a three-electrode system, and then only has a sensor electrode 20 and a protective electrode 21 and no mass electrode 22.
[0174] A spacer 28a is shown as a schematic representation. The spacer 28a can at least partially be arranged over the connecting lip 28 such that it at least partially envelops the latter.
[0175] The capacitive arc sensor unit 10.sub.B can generally be sized arbitrarily. An overall length I.sub.5 of the capacitive arc sensor unit 10.sub.B including the connecting lip 28 of the sensor section 25 can in particular be selected such that it is between approximately 1 cm and approximately 20 cm, in particular between approximately 5 cm and approximately 15 cm, and preferably between approximately 8 cm and approximately 12 cm. In the exemplary case described here, the overall length I.sub.5 is approximately 100.75 mm, or approximately 10 cm.
[0176] An overall width be of the capacitive arc sensor unit 10.sub.B between the two outer edges of the capacitive arc sensor unit 10.sub.B can in particular be selected such that it lies between approximately 1 cm and approximately 15 cm, in particular between approximately 5 cm and approximately 13 cm, and preferably between approximately 8 cm and approximately 12 cm. In the exemplary case described here, the overall width be is approximately 98 mm, or approximately 9.8 cm.
[0177] An overall width b.sub.c of the arc-shaped strip of the capacitive arc sensor unit 10.sub.B between the two outer edges of the strip can in particular be selected such that it lies between approximately 0.2 cm and approximately 5 cm, in particular between approximately 1 cm and approximately 4 cm, and preferably between approximately 1.5 cm and approximately 3 cm. In the exemplary case describes here, the width b.sub.c of the arc-shaped strip of the capacitive arc sensor unit 10.sub.B is approximately 20 mm, or 2 cm.
[0178] A minimum width b.sub.d of the arc that mimics the electrodes can in particular be selected such that it lies between approximately 0.1 cm and approximately 1.5 cm, in particular between approximately 0.4 cm and approximately 1.2 cm, and preferably between approximately 0.6 cm and approximately 1.0 cm. In the exemplary case described here, the minimum width b.sub.d of the arc is approximately 8.6 mm, or 0.86 cm.
[0179] A length I.sub.4 of the connecting lip 28 of the sensor section 25 can in particular be selected such that it ranges between approximately 0.1 cm and approximately 3.5 cm, in particular between approximately 1 cm and approximately 2.5 cm, and preferably between approximately 1.5 cm and approximately 2.3 cm. In the exemplary case described here, the length I.sub.4 of the connecting lip 28 of the sensor section 25 is approximately 20.75 mm, or approximately 2.1 cm.
[0180] In the case described here, the capacitive arc sensor unit 10.sub.B has an arc section 18b having a uniform radius R that can lie between approximately 0.8 cm and approximately 10 cm, in particular between approximately 1.3 cm and approximately 5 cm, and preferably between approximately 1.8 cm and approximately 2.4 cm. In the example shown, the radius R is approximately 29 mm, or approximately 2.9 cm. The arc section 18.sub.b can alternatively also have a variable radius, which would for example be the case for an ellipse shape.
[0181] The arc of an arc section 18.sub.b generally has a curved shape. The curved shape can be described by at least one curve radius r. The arc can substantially have the shape of at least a section of a circular arc, for example approximately that of a quarter, one third, one half, two thirds, or of a three-quarter circular arc, or even that of a full circular arc. Alternatively, the arc can at least substantially correspond to a section of an arc deviating from a circular arc, for example that of an ellipse arc. Other arc shapes having an irregular radius r are likewise conceivable.
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[0183]
[0184] A medium or a bioreactor media filling 9 is positioned in the container interior 2 above the container inner floor 4. The bioreactor media filling 9 can comprise a liquid medium 9 on which a foam 9.sub.2 has formed. Additionally or alternatively, a foam 9.sub.3 can also be present on the interior container envelope 1a, wherein the foam either formed there and/or remained attached on the interior container envelope 1a during the fill level change. A foam 9.sub.3 can in particular also form in and/or on an exhaust hose 12a and/or on another tube or hose. A foam can for example also enter a tube 13a that can act as an upper inlet and is arranged on a corresponding port 13b of the container inner ceiling 3.
[0185] In order to have the ability to detect the presence of foam 9.sub.2, 9.sub.3, at least two, in particular three capacitive patch sensors 10.sub.A1, 10.sub.A2, 10.sub.A3 are correspondingly arranged on the interior container envelope 1a at respectively different situating positions, in particular at the situating positions A1, A2, A3. A first capacitive patch sensor unit 10.sub.A1 is arranged just in the proximity slightly above a limit line 6 that indicates the maximum fill level. The arrow indicates the direction in which the first capacitive patch sensor unit 10.sub.A1 is arranged at the situating positions A1. A second capacitive patch sensor unit 10.sub.A2 is arranged in the proximity slightly above a limit line 7 that indicates or corresponds to the minimum fill level. A third capacitive patch sensor unit 10.sub.A3 is arranged between the limit lines 7, 8.
[0186] The term “slightly above” refers to a distance between the respectively stated height and the lower edge of the sensor unit, said distance being between approximately 0.2 cm and approximately 10 cm, in particular between 0.5 cm and 5 cm, and preferably between approximately 1 cm and 3 cm.
[0187] At least a part of the capacitive patch sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 can alternatively also for contactless measurement be arranged on the exterior container envelope 1b. Additional sensor units can in particular also be arranged on the bioreactor plant 50 for detecting the foam level. The arrangement of the capacitive patch sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 is in particular suited to determine whether a medium 9, in particular a foam 9.sub.2, 9.sub.3 is present at a tolerable level between the minimum and the maximum fill level, or whether, potentially in particular foam 9.sub.2, 9.sub.3 grows above the limit line 6 that indicates the maximum fill level, and can potentially enter one of the tubes 12a, 13a.
[0188] The limit line 7 that indicates the minimum fill level is designed to indicate whether the single-use container 1 is sufficiently filled with a medium 9, in particular a liquid medium 9.sub.1, which would in particular be the case when the height h.sub.6 of the fluidic medium 9.sub.1 were approximately at the height of the limit line 7. The limit line 6 that indicates the maximum fill level is designed to indicate whether the single-use container 1 is filled to a maximum with a medium 9, in particular a liquid medium 9.sub.1, which would in particular be the case when the height h.sub.6 of the fluidic medium 9.sub.1 or the height h.sub.6 of the foam sitting above it were approximately at the height of the limit line 6. A height in this case corresponds to a distance from a container inner floor 4 to the maximum height of the foam 9.sub.2, 9.sub.3 or of the fluidic medium 9.sub.1.
[0189] The distance from the container inner floor 4 to the limit line 7 corresponds to the height h.sub.4 and the distance from the container inner floor 4 to the limit line 6 corresponds to the height h.sub.2. The distance from the container inner floor 4 to the bottom edge of the first patch sensor unit 10.sub.A1 corresponds to the height h.sub.3. The distance from the container inner floor 4 to the bottom edge of the second patch sensor unit 10.sub.A2 corresponds to the height h.sub.5. The distance from the container inner floor 4 to the bottom edge of the third patch sensor unit 10.sub.A3 corresponds to the height h.sub.7. The distance from the container inner floor 4 to the container inner ceiling 3 corresponds to the height h.sub.1.
[0190] One of the capacitive sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 is preferably designed to be switched off or disabled. In particular, a capacitive sensor unit 10.sub.A2 that is arranged at a situating position A2 in the bottom third of the bioreactor plant 50 is designed to be switched off. A patch sensor unit 10.sub.A1, 10.sub.A2, 10.sub.A3 and/or an arc sensor unit 10.sub.B can be switched off.
[0191] The system 100 is optionally designed to switch off one of the capacitive sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3. In particular, the system 100 is designed to switch off a capacitive sensor unit 10.sub.A2, that is arranged at a situating position A2 in the bottom third of the bioreactor plant 50.
[0192] Likewise, several capacitive sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 can be switched off, depending on up to what level the bioreactor plant 50 is filled or what fill level the medium has within the bioreactor plant 50. Different fill levels for different processes can be reached within the bioreactor plant 50 in particular on fed batch processes. This would have the consequence that one or several capacitive sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 would detect a medium instead of the presence or absence of a foam, resulting in a misinterpretation of the recorded data. It can therefore for example be erroneously assumed that a foam is present in the immediate environment of a capacitive sensor unit 10.sub.A1, 10.sub.A2, 10.sub.A3, because the latter detects a change in permittivity caused by filling with the medium. For this purpose, the bioreactor plant 50, the system 100 or the capacitive sensor unit 10.sub.A1, 10.sub.A2, 10.sub.A3 can be designed to automatically and/or manually switch off or disable the respective capacitive sensor unit 10.sub.A1, 10.sub.A2, 10.sub.A3. “Switching off” in this case means that no state is detected, but at a minimum that no data are forwarded by the respectively switched off capacitive sensor unit 10.sub.A1, 10.sub.A2, 10.sub.A3.
[0193] The capacitive patch sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 are connected to a monitoring unit 14 by a cable 11, for example to transfer data, to be controlled, and/or to be supplied with power. Data can alternatively also be transmitted wirelessly. The cables 11 are in this case respectively guided through a cable port 8.sub.1, 8.sub.2 from the container interior 2 to the container exterior AR.
[0194]
[0195] The patch sensor units 10.sub.A′1, 10.sub.A′6 are designed to contactlessly and/or through the container wall detect a foam level within the bioreactor plant 50, in particular within the single-use container 1. When patch sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 are arranged in the container interior 2, the patch sensor units 10.sub.A′1, 10.sub.A′6 on the exterior container envelope 1b can be optional. Otherwise, two or more patch sensor units on the exterior container envelope 1b can be an alternative to the patch sensor units 10.sub.A1, 10.sub.A2, 10.sub.A3 on the exterior container envelope 1b.
[0196] The capacitive arc sensor units 10.sub.B2, 10.sub.B3 are designed to detect the presence of foam 9.sub.2, 9.sub.3 at critical positions B2, B3. An arc sensor unit 10.sub.B2 is for example arranged on a port 12b of the exhaust hose 12a at the situating position B2 in order to detect in this manner whether foam 9.sub.2, 9.sub.3 is entering the exhaust hose 12a. In the same manner, it can for example be prevented that foam 9.sub.2, 9.sub.3 blocks and/or contaminates a filter 12c on the exhaust hose 12a.
[0197] At least one, in particular two (further) sensor units, that is to say two collar sensor units 10.sub.C1, 10.sub.C2 are arranged on the exterior on the exhaust hose 12a, each on one or several situating positions C1 and C2. The collar sensor unit 10.sub.C1/10.sub.C2 is preferably a capacitive sensor unit, similar to the patch sensor unit 10.sub.A and or the arc sensor unit 10.sub.B.
[0198] The collar sensor unit 10.sub.C1 is in particular arranged directly or immediately behind port 12b at the situating position C1 at the exhaust hose 12a. This collar sensor unit 10.sub.C1 can detect whether foam 9.sub.2, 9.sub.3 has entered the interior IR of the exhaust hose 12a. The collar sensor unit 10.sub.C1 can just like the collar sensor unit 10.sub.C2 be a (preferably substantially rectangular) strip or a (preferably substantially rectangular) patch that is, or can be, placed in particular along its length axis at least partially about the circumference of a hose and/or a tube or line, thus forming a collar around the circumference of the tube. In other words, the shape of this sensor unit is preferably that of a strip that is at least partially taped with its surface around the hose. The collar sensor units 10.sub.C1 and/or 10.sub.C2 in particular form an arc when they are placed around the hose or the tube or the line, wherein they for example merely represent a (preferably substantially rectangular) sensor unit prior to being placed around the hose or the tube or the line.
[0199] A collar sensor unit 10.sub.C1 and/or 10.sub.C2 can generally be designed to envelop at least substantially half, preferably at least substantially two thirds, and particularly preferably substantially three quarters of the circumference of a tube and/or a hose. Prior to being placed onto the hose and/or tube, the collar sensor unit 10.sub.C1 and/or 10.sub.C2 for example has the shape of a patch sensor unit, or is at least similar to this shape. In other words, prior to being placed or attached onto a tube or a line, the collar sensor unit 10.sub.C1/10.sub.C2 substantially has no curvature, and in particular has a substantially two-dimensional planar surface that forms a flat plane.
[0200] When at least partially enveloping a tube or a line, the collar sensor unit 10.sub.C1/10.sub.C2 assumes a curved shape, resulting not in a flat plane but in a curved surface whose curvature is in particular determined by the radius of the tube. The collar sensor unit is preferably placed around the tube or line with its length axis, substantially vertically to the length axis of the tube or line. The curvature of the collar sensor unit 10.sub.C1/10.sub.C2 is in this case substantially coaxial to the length axis (of at least a part) of the tube or line. Alternatively, the collar sensor unit 10.sub.C1/10.sub.C2 can also be placed onto the tube or line in an “oblique” orientation, meaning that the length axis of the collar sensor unit 10.sub.C1/10.sub.C2 is not vertical in relation to the length axis of the tube or line.
[0201] All sensor units, and therefore also the sheet and patch sensor units, can principally all have a curvature that is substantially determined by the radius of the element on which they are placed. But this radius is generally greater than on a collar sensor unit 10.sub.C1/10.sub.C2 because the collar sensor unit 10.sub.C1/10.sub.C2 is generally placed onto tubes or lines and not on the container of a bioreactor plant. The curvature of the collar sensor unit 10.sub.C1/10.sub.C2 is for this reason generally more pronounced than on the arc sensor unit 10.sub.B or the patch sensor unit 10.sub.A.
[0202] This curvature, which results from the fact that the sensor units 10.sub.A 10.sub.B, 10.sub.C are flexible and can be placed onto the (preferably exterior) shape of a surface, such as that of a single-use container or bioreactor 1 is not to be confused with the curvature of the arc of an arc sensor unit 10.sub.B. The arc of an arc sensor unit 10.sub.B can lie in a two-dimensional plane, in particular when the arc sensor unit 10.sub.B was not yet arranged on the system 100 or the container 1.
[0203] In other words, an arc sensor unit 10.sub.B already has an arc in its two-dimensional form, wherein the latter lies in a plane before it is arranged on a bioreactor plant 100 or a container 1. If the surface onto which the arc sensor unit 10.sub.B will be arranged corresponds to a flat plane without arc, the arc sensor unit 10.sub.B can be at least partially arranged around a port (such as port 12b) without its surfaces assuming a curvature. The collar sensor unit 10c by contrast always has a curvature when it is arranged on a hose or tube or a line.
[0204] The distance between Port 12b and situating position C1 is for example between approximately 2 cm and approximately 30 cm, in particular between approximately 5 cm and approximately 15 cm, and preferably between approximately 7 cm and approximately 12 cm. The further collar sensor unit 10.sub.C2 is arranged directly upstream of filter 12c at the situating position C2 on the exhaust hose 12a. This collar sensor unit 10.sub.C2 can detect whether foam 9.sub.2, 9.sub.3 has already entered the interior IR of the exhaust hose 12a, that is to say in the immediate vicinity of filter 12c. The distance between filter 12c and situating positions C2 is for example between approximately 2 cm and approximately 30 cm, in particular between approximately 5 cm and approximately 15 cm, and preferably between approximately 7 cm and approximately 12 cm.
[0205] The exhaust hose 12a is arranged at a comparatively high position, for example in the upper half, in particular in the upper third, and preferably in the upper quarter of the single-use container 1. The distance between the container inner floor 4 and the bottom edge of port 12b for the exhaust hose 12a corresponds to the height h.sub.8.
[0206] A further arc sensor unit 10.sub.B3 is arranged on the port 13b for the upper inlet 13a in order to detect at this situating position B3 whether a foam has entered, or will enter, the hose of the upper inlet 13a.
[0207] The capacitive arc sensor units 10.sub.B2, 10.sub.B3 are connected to the monitoring unit 14 by cable 11. The computing unit 15 of the monitoring unit 14 can in this case receive and analyze and/or process data, and forward the data to the open-loop and/or closed-loop control unit 16 such that the open-loop and/or closed-loop control unit 16 can initiate an action, in particular when a critical state is detected. The open-loop and/or closed-loop control unit 16 can for example initiate an action to add an anti-foaming agent 23 to the container interior 2 through a hose 17, such that foam formation can be reduced and/or suppressed. Several ports can in particular be arranged on the bioreactor plant 50, such that an anti-foaming agent 23 can be locally deployed at the place where a foam 9.sub.2, 9.sub.3 is present.
[0208] Actions can at least one be one of the following: Trigger a visible and/or audible alarm, trigger the addition of anti-foaming agent 23, stop the addition of anti-foaming agent 23, switch off any foam-forming apparatus, for example switch off a mixing device and/or switch off a substance addition.
[0209]
[0210] The maximum fill level 6 is in particular a predetermined value for the recommended maximum filling with a medium, which is for example indicated by a fill level marking on and/or in the bioreactor plant, in particular on and/or in the single-use container. The minimum fill level 7 is in particular a predetermined value for the recommended minimum filling with a medium, which is for example indicated by a fill level marking on and/or in the bioreactor plant, in particular on and/or in the single-use container.
[0211] Safe and reliable operation of the bioreactor plant is in particular recommended for filling with a medium within the limits between approximately the maximum fill level 6 and approximately the minimum fill level 7.
[0212] The respective situating positions can in particular be drawn or marked on the corresponding bioreactor plant such that the user can readily arrange the sensor unit at the corresponding situating positions.
[0213] A capacitive patch sensor unit in particular has at least one adhesive strip or at least one adhesive strip that for example substantially has a rectangular or circular shape. A capacitive patch sensor unit can in particular be similar to the shape of a medical patch. A substantially rectangular adhesive strip for example has a length and/or a width of respectively approximately 0.5 cm to approximately 10 sent is, in particular from approximately 1.5 cm to approximately 7 cm, and preferably from approximately 2 cm to approximately 5 cm.
[0214] The measurement surface and/or the taping surface of the adhesive strip of capacitive sensor units, preferably of capacitive patch sensor units, in particular has a geometrically substantially “non-eccentric” design. Advantageous surface shapes can for example be substantially circular, square, rectangular. On substantially rectangular measurement surfaces, a preferred edge length ratio is a value of approximately less than 2, such as approximately 1 for substantially square services, or approximately 1.5 or approximately 0.5 rectangular surfaces that are not square in shape.
[0215] A capacitive arc sensor unit in particular at least partially has a substantially round shape, in particular a circular arc shape. The capacitive arc sensor unit can for example have the shape of a semicircular arc. The shape in this case in particular has a curved strip that has a width of approximately 0.3 cm to approximately 10 cm, in particular from approximately 1 cm to approximately 7 cm, and preferably from approximately 1.5 cm to approximately 3 cm, such that the capacitive arc sensor unit can for example envelop a port. The radius of a circular arc of a capacitive arc sensor unit sensor unit can in particular lie between approximately 0.5 cm and approximately 10 cm, in particular between approximately 1 cm and approximately 7 cm, and preferably between approximately 1.5 cm and approximately 3 cm. The capacitive arc sensor unit in particular has a substantially straight connection section.
[0216] A sensor unit is in particular a capacitive single-use sensor unit for substantially single use arrangement on a bioreactor plant. Alternatively, the capacitive sensor unit can also be a capacitive multi-use sensor unit that is designed to be arranged on a bioreactor plant multiple times.
[0217] A sensor unit can be a so-called “fill level switch”. Measurements using capacitive switches detect a change of the dielectric constant Cr, and said change is then converted into a control signal. The advantage of this technology is that the medium can for example be detected behind a dielectric container wall.
[0218]
[0219] The capacitive patch sensor unit 10.sub.A has a connection section 25 having a connecting unit 24 and a connecting lip 28. The connecting lip 28 represents a substantially elongated connecting section, in particular an electrically conductive path to supply the electrode system 19 with power, and on whose one end the rectangular field 18.sub.a is located, and on whose other end the connecting unit 24 is located. The connecting unit 24 for example is used for signal transmission and/or power supply. By applying alternating current, an electrical alternating field can be generated in this manner in the electrode system 19, and the resulting current flow can be detected as a signal.
[0220] A connecting lip 28 is advantageous to maintain the flexibility of the connection or of the connection section between the rectangular field 18.sub.a of the patch sensor unit 10.sub.A and the transmitter cable (not shown) that is, or can be, connected to the connecting unit 24. In other words, a substantially flexible connecting lip 28 is provided between the connecting unit 24 and the rectangular field 18.sub.a of the patch sensor unit 10.sub.A. Provided the connecting unit 24 is removable or detachable, the connecting unit 24 can then also be readily connected to, or disconnected from, the rectangular field 18.sub.a of the patch sensor unit 10.sub.A. The connecting lip 28 is also advantageous to bring the specified base capacitance of the patch sensor unit 10.sub.A into a desired range by lengthening the conductive paths of the patch sensor unit.
[0221] The connecting lip 28 in particular does not have a defined—or permanently constant and pre-determined—position, as is for example preferably the case with the rectangular field 18.sub.a of the patch sensor unit 10.sub.A because the connecting lip 28 is preferably not taped to the container. As a result, undesirable interference signals, such as false positive signals, can be generated and detected by the electrode system, in particular when the connecting lip 28 is moved during the course of the process, for example by tensile forces on the cable or pressure fluctuations in the bioreactor.
[0222] However, the connecting lip 28 should not be fixed to the container with restricted movement, and should in particular not be taped, because the connecting lip 28 in this case does not provide the required flexibility and freedom of motion, and the connecting lip 28 could potentially also at any rate easily come detached due to cable movement. Interference signals can then in particular not be prevented or reduced by fixing, in particular taping, the connecting lip 28 to the container.
[0223] The spacer 28a is preferably provided on the sensitive surface, in particular on the connecting lip 28. The spacer 28a in particular is a jacket made of Polypropylene. Other plastics can alternatively also be used. This has the advantage that previously described interference signals can be reduced or even avoided.
[0224] The material of the spacer can preferably at least partially have a thickness of approximately 1 mm, firstly in order to be substantially flexible, and secondly to ensure a sufficiently large distance from potential foreign bodies to the sensitive region of the connecting lip.
[0225] The spacer 28a in particular covers a major part of the sensitive surface. The spacer 28a can be aligned by a tab on an over-molding of the connector. The locking mechanism is preferably reversibly lockable such that the spacer can be used multiple times. The spacer has rounded or deburred edges in particular to avoid cutting into a single-use container, and additionally a thin area such that the spacer can be designed as a single part and can envelop the connecting lip 28 like a strap.
[0226] The disclosure therefore in particular relates to a capacitive patch sensor unit 10.sub.A having: [0227] a field, in particular a rectangular field 18.sub.a for attaching on a surface; [0228] an electrode system 19 that is at least partially arranged on the field and that is designed to detect changes of permittivity and/or capacitance in the immediate vicinity or environment, and in particular for capacitive measurements at one of the situating positions of the bioreactor plant 50 and for detecting the presence of foam 9.sub.2, 9.sub.3 at the situating position A1-A3; B1-B6 based on the capacitive measurement; [0229] a connecting lip 28 to electrically connect a power supply to the electrode system; and preferably [0230] a spacer 28a designed to at least partially envelop or cover the connecting lip 28.
[0231] The disclosure also in particular relates to a capacitive arc sensor unit 10.sub.A having: [0232] a field, in particular an arc section 18.sub.b for attaching to a surface; [0233] an electrode system 19 that is at least partially arranged on the field and that is designed to detect changes of permittivity and/or capacitance in the immediate vicinity or environment, and in particular for capacitive measurements at one of the situating positions of the bioreactor plant 50 and for detecting the presence of foam 9.sub.2, 9.sub.3 at the situating position A1-A3; B1-B6 based on the capacitive measurement; [0234] a connecting lip 28 to electrically connect a power supply to the electrode system; and preferably [0235] a spacer 28a designed to at least partially envelop or cover the connecting lip 28.
[0236] In general, a sensor field can have a field of any conceivable shape, wherein the field can be attached to a surface of the bioreactor plant. Such a sensor unit can have a connecting lip and a spacer, entirely independently of the shape of said field. The connecting lip is in particular designed such that it is not fixed and/or taped to the surface of the bioreactor plant. The connecting lip connects an electrode system arranged on the field to a connecting unit, preferably electrically.
TABLE-US-00001 1 Single-use container of a bioreactor 1a Interior container envelope 1b Exterior container envelope 2 Container interior or interior of the single-use container 3 Container inner ceiling 4 Container inner floor 5 Container length axis 6 Limit line for maximum fill level 7 Limit line for minimum fill level 8.sub.1, 8.sub.2 Cable port 9 Medium or bioreactor media filling 9i Fluidic medium 92 Foamy medium/foam on fluidic medium 93 Foamy medium/foam as deposit on the interior container envelope 10.sub.A Capacitive (patch) sensor unit 10.sub.A1, 10.sub.A2, First, second, and third capacitive patches 10.sub.A3 sensor unit for detecting the level of a foam, in particular from the interior container envelope. 10.sub.A′6, 10.sub.A′1 Capacitive patches sensor unit for detecting the level of a foam, in particular from the exterior container envelope. 10.sub.B Capacitive (arc) sensor unit 10.sub.B2, 10.sub.B3 First and second capacitive arc sensor unit for detecting the presence of foam with exterior attachment 10.sub.C1, 10.sub.C2 Collar sensor units that can be at least partially placed around a tube and/or a hose 11 Cable 12a Exhaust hose 12b Exhaust port or ports for exhaust hose 12c Filter 13a Tube or hose upper inlet/outlet 13b Port for upper inlet/outlet 14 Monitoring unit 15 Computing unit 16 Open-loop and/or closed-loop control unit 17 Tube or hose for open-loop control and/or closed-loop control of foam formation or the foam level 18 Adhesive strip 18.sub.a Rectangular field 18.sub.b Arc section 19 Electrode system 20 Sensor electrode 21 Protective electrode 22 Mass electrode 23 Substance for reducing and/or preventing foam (foam formation) or anti-foaming agent 24 Connecting unit 25 Connection section 26 Mixing unit 28 Connecting lip of the sensor section 25 28a Spacer 50 Bioreactor plant 100 System for detecting at least one presence of foam A1, A2, A3 First, second, and third situating position for a capacitive sensor unit for detecting the level of a foam, in particular from the interior container envelope. AR Container exterior B1, B2, B3, First to sixth situating position for a capacitive C1, C2, B6 sensor unit for detecting the presence, in particular the level, of a foam, in particular from the exterior container envelope b.sub.a Width of the rectangular field b.sub.b Width of the rectangular field b.sub.e Width of the strip of the arc section b.sub.d Minimum width of the arc, of the electrodes b.sub.e Overall width of the arc section h.sub.5 Height from the bioreactor inner floor to the bottom edge of the second capacitive patch sensor unit 10.sub.A2 h.sub.6 Height from the bioreactor inner floor to the actual fill level of the fluidic bioreactor media filling or the height of the fluid h.sub.r Height from the bioreactor inner floor to the bottom edge of the third capacitive patch sensor unit 10.sub.A3 h.sub.a Height from the bioreactor inner floor to the actual fill level of the foamy bioreactor media filling or the height of the foam IR Hose interior I.sub.1 Overall length, including connection section I.sub.2 Length of the rectangular field I.sub.3 Length of the connecting unit I.sub.4 Length of the connection section I.sub.5 Overall length, including connection section R Radius