Reactor foam sensor systems and methods of use

1. A foam sensor system comprising:

a flexible bag comprised of a polymeric material and bounding a compartment;

a foam sensor assembly mounted on the flexible bag and comprising:

a base being secured to the flexible bag;

a foam contact being spaced apart from the base and disposed within the compartment of the flexible bag, the foam contact being comprised of a metal with at least a portion of the foam contact having a first diameter; and

a transition member comprised of a metal and extending between the base and the foam contact with at least a portion of the transition member being exposed within the compartment of the flexible bag, at least a portion of the transition member having a second diameter that is equal to or less than ⅓ of the size of the first diameter, the foam contact and transition member being connected together so that an electrical signal can pass therethrough; and

a ground assembly mounted on the flexible bag and comprising a ground contact disposed within the compartment of the flexible bag and being comprised of a metal, the foam sensor assembly and the ground assembly being configured so that an electrical potential can be applied between the foam contact and the ground contact.

2. The foam sensor system as recited in claim 1 , wherein the first diameter is larger than 3 mm and the second diameter is smaller than 1 mm.

3. The foam sensor system as recited in claim 1 , wherein the transition member is comprised of a nickel-titanium alloy or a copper-aluminum-nickel alloy.

4. The foam sensor system as recited in claim 1 , wherein the transition member can be bent over an angle of at least 180° without plastic deformation.

5. The foam sensor system as recited in claim 1 , wherein the transition member can be bent over an angle of at least 360° without plastic deformation.

6. The foam sensor system as recited in claim 1 , wherein the transition member has an exposed length in a range between 2 cm and 15 cm.

7. The foam sensor system as recited in claim 1 , wherein the base and the foam contact are comprised of metals that are different from the metal of the transition member.

8. The foam sensor system as recited in claim 1 , wherein the base comprises:

an elongated body having a first end and an opposing second end; and

an annular barb encircling and radially outwardly projecting from the body.

9. The foam sensor system as recited in claim 1 , further comprising an electrical wire coupled to the base.

10. The foam sensor system as recited in claim 1 , further comprising:

a housing secured to the flexible bag and comprising a stem with a flange radially outwardly projecting therefrom, the stem bounding an opening; and

the base being comprised of a metal and being at least partially disposed within the opening of the stem.

11. The foam sensor system as recited in claim 10 , wherein the housing comprises a port with the opening comprising a passageway that extends through the stem and is encircled by the flange.

12. The foam sensor system as recited in claim 10 , wherein the flange is welded onto a flexible bag so that the foam contact and at least a portion of the transition member are disposed within a compartment of the flexible bag.

13. The foam sensor system as recited in claim 10 , further comprising at least a portion of the transition member being disposed within a portion of the opening of the housing.

14. The foam sensor system as recited in claim 1 , further comprising:

a fluid disposed within the compartment of the flexible bag and having a top surface;

a gas filled gap being formed between the top surface of the fluid and an upper end of the flexible bag;

the ground contact being in contact with the fluid within the compartment;

the foam contact being disposed within the gap within the container so as to be spaced apart from the fluid; and

an electrical potential being applied between the foam contact and the ground contact.

15. The foam sensor system as recited in claim 14 , further comprising:

means for mixing the fluid within the compartment of the flexible bag;

the fluid comprising a live culture of cells or microorganisms; and

a CPU electrically coupled with the foam contact and the ground contact, the CPU being programed to dispense a quantity of an anti-foaming agent into the compartment of the flexible bag when an electrical signal passes between the foam contact and the ground contact within the container of the flexible bag.

16. The foam sensor system as recited in claim 1 , wherein the foam sensor assembly further comprises:

a housing comprised of a polymeric material and secured to the flexible bag, the base being secured to the housing.

17. The foam sensor system as recited in claim 16 , wherein the transition member comprises a wire made of a resiliently flexible metal that enables the wire to be bent over and angle of at least 180° without plastic deformation.

18. The foam sensor system as recited in claim 1 , wherein the ground assembly comprises:

a housing comprised of a polymeric material and secured to the flexible bag;

the ground contact secured to the housing, a portion of the ground contact projecting into the compartment of the container.

19. The foam sensor system as recited in claim 1 , wherein the ground assembly comprises:

a tube assembly comprised of a polymeric material and secured to the flexible bag, the tube assembly comprising a probe tube that projects into the compartment of the flexible bag and bounds a probe passage;

the ground contact being secured to the probe tube so as to communicate with the probe passage; and

a probe removably received within the probe passage and contacting the ground contact so that an electrical signal can pass between the probe and the ground contact.

20. The foam sensor system as recited in claim 19 , wherein the probe is pressed into the probe passage so that the probe is stretching the probe tube.

21. The foam sensor system as recited in claim 19 , wherein the tube assembly further comprises a sampling tube that projects into the compartment the flexible bag so that fluid can be drawn out of the compartment through the sampling tube.

22. The foam sensor system as recited in claim 1 , wherein the second diameter of the transition member is less than 2.5 mm.

23. A foam sensor system comprising:

a flexible bag comprised of a polymeric material and bounding a compartment;

a foam sensor assembly mounted on the flexible bag and comprising a foam contact disposed within the compartment of the flexible bag and being comprised of a metal; and

a ground assembly mounted on the flexible bag and comprising:

a tube assembly comprised of a polymeric material and secured to the flexible bag, the tube assembly comprising a probe tube that projects into the compartment of the flexible bag and bounds a probe passage;

a ground contact being secured to the probe tube so as to communicate with the probe passage, the ground contact being disposed within the compartment of the flexible bag and being comprised of a metal; and

a probe removably received within the probe passage and contacting the ground contact so that an electrical signal can pass between the probe and the ground contact,

the foam sensor assembly and the ground assembly being configured so that an electrical potential can be applied between the foam contact and the ground contact.

24. The foam sensor system as recited in claim 23 , wherein the probe is pressed into the probe passage so that the probe is stretching the probe tube.

25. The foam sensor system as recited in claim 23 , wherein the tube assembly further comprises a sampling tube that projects into the compartment the flexible bag so that fluid can be drawn out of the compartment through the sampling tube.