Filter and methods of making and using same

Abstract

The invention relates to filters and methods of making and using the same. The filter includes: a first housing member having a fluid inlet port; a second housing member positioned axially below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first housing member and the second housing member; and a thermoplastic overmolded member molded on the peripheries of the housing members, sealing the peripheries of the housing members together to form an interior volume housing the porous filter element, where the first housing member includes a radial sidewall including at least one axial step, and the thermoplastic overmolded member is molded on the peripheries of the housing members to seal the peripheries of the housing members together to form the interior volume housing the porous filter element. And wherein the second housing member comprises a substantially rectilinear radial sidewall.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to filters, and more particularly to filters for use in a sterile environment. BACKGROUND

[0002] Disposable disc filters are typically mass produced in industry and can be used in chemical, physical, and pharmaceutical laboratories for pressure filtration of fluids. Traditionally, disc filters generally include a filter element, which is typically a filter septum, fixed (e.g., by welding) between two housing portions of a filter housing. Typically, the filter element is supported across its entire surface by a filter support device formed as part of the housing within the housing portions. In some cases, these filters can provide inadequate flow uniformity, excessive flow resistance, and inadequate burst strength across a wide range of fluids of different flow rates and characteristics. Accordingly, there is a need for improved filters, particularly to enable filters to achieve optimal flow uniformity, flow resistance, and burst strength. SUMMARY

[0003] In one aspect, the present invention provides a filter, the filter comprising:

[0004] a first housing member having a fluid inlet port; and

[0005] a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port;

[0006] a porous filter element disposed between the first housing member and the second housing member; and

[0007] a thermoplastic overmold molded on a periphery of the housing members, sealing the periphery of the housing members together to form an interior volume containing the porous filter element, wherein the first housing member includes a radial sidewall including at least one axial step, and wherein the second housing member includes a substantially straight radial sidewall.

[0008] In another aspect, the present invention provides a filter, the filter comprising:

[0009] a first housing member having a fluid inlet port; and

[0010] a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port;

[0011] a porous filter element disposed between the first housing member and the second housing member; and

[0012] a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an interior volume that houses the porous filter element, wherein at least one of: 1) the first housing member comprises a radial sidewall comprising at least one axial step, provides a relative burst strength of at least 40 Pa / mm^2 (strength per unit filtration area), or 2) the second housing member comprises a substantially straight radial sidewall, defines a pressure drop of no greater than 29,000 Pa at a fluid flow rate of 75 ml / min through the filter.

[0013] In yet another aspect, the present application provides an assembly, the assembly comprising:

[0014] a fluid inlet conduit;

[0015] a fluid outlet conduit; and

[0016] a filter coupling the fluid inlet conduit to the fluid outlet conduit, wherein the filter comprises:

[0017] a first housing member having a fluid inlet port; and

[0018] a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port;

[0019] a porous filter element disposed between the first housing member and the second housing member; and

[0020] a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an interior volume that houses the porous filter element, wherein the first housing member comprises a radial sidewall comprising at least one axial step, and wherein the second housing member comprises a substantially straight radial sidewall.

[0021] In yet another aspect, the present application provides a method, the method comprising:

[0022] providing a fluid inlet conduit;

[0023] providing a fluid outlet conduit;

[0024] providing a filter coupling the fluid inlet conduit to the fluid outlet conduit, wherein the filter comprises:

[0025] a first housing member having a fluid inlet port; and

[0026] a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port;

[0027] a porous filter element disposed between the first housing member and the second housing member; and

[0028] a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an interior volume containing the porous filter element, wherein the first housing member comprises a radial sidewall comprising at least one axial step, and wherein the second housing member comprises a substantially straight radial sidewall; and

[0029] flowing a fluid through the fluid inlet conduit into the filter and into the fluid outlet conduit. BRIEF DESCRIPTION OF DRAWINGS

[0030] Embodiments are illustrated by way of example, and not limitation, in the figures of the accompanying drawings in which:

[0031] Figure 1 A front side view of a prior art filter is shown.

[0032] Figure 2A A front side view of a filter according to various embodiments of the disclosure is shown.

[0033] Figure 2B A perspective cross-sectional view of a filter according to various embodiments of the disclosure is shown.

[0034] Figure 2C A cross-sectional view of a filter according to various embodiments of the disclosure is shown.

[0035] Figure 2D1 A perspective top view of a first housing member of a filter according to various embodiments of the disclosure is shown.

[0036] Figure 2D2 A perspective top view of a first housing member of a filter according to various embodiments of the disclosure is shown.

[0037] Figure 2D3 A perspective top view of a first housing member of a filter according to various embodiments of the disclosure is shown.

[0038] Figure 2E A perspective top view of a first housing member of a filter according to various embodiments of the disclosure is shown.

[0039] Figure 2F A perspective top view of a second housing member of a filter according to various embodiments of the disclosure is shown.

[0040] Figure 3A plot of pressure (bar) applied on the filter versus maximum principal strain (mm / mm) is shown for a conventional filter (A) versus a filter according to embodiments herein (B).

[0041] Those skilled in the art realize that the elements in the figures are shown for the purpose of simplicity and clarity and are not necessarily to scale. For example, the dimensions of some of the elements in the figures can be exaggerated relative to other elements to help improve the understanding of the embodiments of the application. DETAILED DESCRIPTION

[0042] The following description in connection with the appended drawings is provided to assist in understanding the teachings disclosed herein. The discussion below will focus on specific implementations and embodiments of the teachings. This discussion is not intended as a limitation on the scope of the teachings, but is intended to provide a description of specific embodiments and implementations of the teachings. In addition, the discussion is intended to explore the teachings of the application based on what is currently considered to be a representative set of implementations.

[0043] The terms "comprises", "comprising", "includes", "including", "has", "having", "contains", "containing", or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but can include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0044] Also, use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the application. This description should be read to include one, at least one, or the singular as also including the plural, or vice versa, unless it is otherwise indicated herein or otherwise clearly contradicted by context. For example, the use of the singular "a" or "an" should be interpreted as meaning "at least one" or "one or more." Similarly, the use of "at least one" should be construed to mean one, two, three, or more, unless otherwise indicated herein or otherwise clearly contradicted by context.

[0045] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing acts are conventional and can be found in textbooks and other sources within the filter art.

[0046] The following disclosure describes filters adapted to provide better fluid filtration efficiency and movement of filters through adjacent pieces of a connecting conduit. These concepts will be better understood in view of the embodiments described below, which illustrate and do not limit the scope of the present invention.

[0047] Figure 1 A front side view of a prior art filter 1 is shown. The filter 1 comprises a filter element or membrane 2 disposed inside a housing 3 having an inlet opening 5 and an outlet opening 7 on two parts 4 and 6 respectively. The parts can be assembled and fused or bonded into a unitary filter 1 by means of a plastic injection sealing member 8 of thermoplastic material. The sealing member 8 completely surrounds and fills the joint 9, thereby forming a unitary part of the filter 1. In the embodiment shown, at least one of the housing parts has a shortened outer lip 10, 11 so that at least a portion of the side surface of the filter element 2 will be directly exposed to the thermoplastic sealing member 8.

[0048] For illustrative purposes, Figure 2A A front side view of a filter according to various embodiments of the present disclosure is shown. For illustrative purposes, Figure 2B A perspective cross-sectional view of a filter according to various embodiments of the present disclosure is shown. For illustrative purposes, Figure 2C A cross-sectional view of a filter according to various embodiments of the present disclosure is shown. As Figures 2A to 2C As shown, in various embodiments, the filter 100 can include a first axial end 112 oriented downward along a central axis 1000, a second axial end 114, an inner radius edge 116, and an outer radius edge 118. In various embodiments, the filter 100 can include a housing 120. The housing 120 can include a first housing member 122 and a second housing member 124. In various embodiments, the first housing member 122 can have a generally flat cross-section in a plane perpendicular to the central axis. In various embodiments, the first housing member 122 can be a generally polygonal cross-section (e.g., rectangular). In various variations, the first housing member 122 can have a polygonal, elliptical, circular, semi-circular, or substantially circular cross-section. In various embodiments, the second housing member 124 can have a generally flat cross-section in a plane perpendicular to the central axis. In various embodiments, the second housing member 124 can be a generally polygonal cross-section (e.g., rectangular). In various variations, the second housing member 124 can have a polygonal, elliptical, circular, semi-circular, or substantially circular cross-section. In certain embodiments, as best shown in Figure 2A In certain embodiments, as best shown in Figure 2AAs best shown, the second housing member 124 can comprise a generally circular cross-sectional profile. Further, in certain embodiments, as shown, the second housing member 124 can comprise a substantially straight radial sidewall 125. Further, in certain embodiments, as shown, the substantially straight radial sidewall 125 of the second housing member 124 can be substantially perpendicular to the central axis 1000 of the filter 100.

[0049] In various embodiments, as Figure 2A As best shown, the filter 100 can have an outer radius OR F For the purposes of the embodiments described herein and as best shown in Figure 2A As best shown, the filter 100 can have an outer radius OR F from the central axis 1000 to the outer radius edge 118. According to certain embodiments, the filter 100 can have an outer radius OR F According to other embodiments, the filter 100 can have an outer radius OR F It will be appreciated that the filter 100 can have an outer radius OR F which can be within a range between any of the minimum and maximum values described above. It will also be appreciated that the filter 100 can have an outer radius OR F .

[0050] In various embodiments, as Figures 2A to 2C As best shown, the filter 100 can have an inner radius IR F For the purposes of the embodiments described herein and as best shown in Figures 2B to 2C As best shown, the filter 100 can have an inner radius IR F from the central axis 1000 to the inner radius edge 116. According to certain embodiments, the filter 100 can have an inner radius IR F According to other embodiments, the filter 100 can have an inner radius IR FIt should be appreciated that the filter 100 can have an inner radius IR F which can be within a range between any of the minimum and maximum values noted above. It should also be appreciated that the filter 100 can have an inner radius IR F which can be any value between any of the minimum and maximum values noted above.

[0051] In various embodiments, the filter 100 can have an axial length L F For the purposes of the embodiments described herein and as shown in Figure 2A , the length L F of the filter 100 is the distance from the first axial end 112 to the second axial end 114. According to certain embodiments, the length L F of the filter 100 can be at least about 10 mm, at least 25 mm, at least 50 mm, at least 100 mm, at least about 150 mm, or at least about 200 mm, or at least about 250 mm, or at least about 300 mm, or even at least about 500 mm. According to other embodiments, the length L F of the filter 100 can be no greater than about 1500 mm, no greater than about 1200 mm, or even no greater than about 1000 mm. It should be appreciated that the length L F of the filter 100 can be within a range between any of the minimum and maximum values noted above. It should also be appreciated that the length L F of the filter 100 can be any value between any of the minimum and maximum values noted above.

[0052] In various embodiments, the first shell member 122 can have a thickness T FH For the purposes of the embodiments described herein and as shown in Figure 2C , the thickness T FH of the first shell member 122 can be at least about 0.001 mm, such as at least about 0.005 mm, at least about 0.01 mm, at least about 0.05 mm, at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or even at least about 0.5 mm. According to other embodiments, the thickness T FH of the first shell member 122 can be no greater than about 10 mm, such as no greater than 5 mm, no greater than 1 mm, no greater than about 0.5 mm, or even no greater than about 0.25 mm. It should be appreciated that the thickness T FH of the first shell member 122 can be within a range between any of the minimum and maximum values noted above. It should also be appreciated that the thickness T FH of the first shell member 122 can be any value between any of the minimum and maximum values noted above. In various embodiments, the thickness T FHIt can be between 1μm and 1000μm, such as between 5μm and 500μm, or between 20μm and 350μm.

[0053] In several embodiments, the second housing member 124 may have a thickness T SH For the purposes of the embodiments described herein and as follows Figure 2C As shown, the thickness T of the second housing member 124 SH The thickness can be at least about 0.001 mm, such as at least about 0.005 mm, at least about 0.01 mm, at least about 0.05 mm, at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or even at least about 0.5 mm. According to other embodiments, the thickness T of the second housing member 124... SH It may not exceed approximately 10 mm, such as not exceeding 5 mm, not exceeding 1 mm, not exceeding approximately 0.5 mm, or even not exceeding approximately 0.25 mm. It should be understood that the thickness T of the second shell member 124... SH It can be within any of the minimum and maximum values ​​mentioned above. It should also be understood that the thickness T of the second shell member 124... SH It can be any value between any of the above minimum and maximum values. In several embodiments, the thickness T of the second housing member 124... SH It can be between 1μm and 1000μm, such as between 5μm and 500μm, or between 20μm and 350μm.

[0054] In several implementation schemes, such as Figure 2C As shown, filter 100 may have an internal volume V F For the purposes of the embodiments described herein, the volume V of filter 100 is... F The volume can be at least about 0.1 mL, 1 mL, 10 mL, 50 mL, 100 mL, 250 mL, 500 mL, or 0.1 L, such as at least about 0.5 L, at least about 1 L, at least about 2 L, at least about 5 L, or even at least about 10 L. According to other embodiments, the volume V of filter 100... F It may not exceed approximately 150L, ​​such as not exceeding approximately 100L, not exceeding approximately 50L, or even not exceeding approximately 25L. It should be understood that the first volume V of filter 100... F It can be within any of the minimum and maximum values ​​mentioned above. It should also be understood that the first volume V of filter 100... F It can be any value between any of the above minimum and maximum values.

[0055] like Figures 2A to 2CAs shown, the first housing member 122 can include a radial sidewall 123 that includes at least one axial step 127. In various embodiments, the at least one axial step 127 can be generally polygonal in cross-section (e.g., rectangular). In various variations, the at least one axial step 127 can have a polygonal, elliptical, circular, semi-circular, or substantially circular cross-section. In various embodiments, the at least one axial step 127 can have a generally flat cross-section in a plane perpendicular to the central axis. In various embodiments, the first housing member 122 can include a radial sidewall 123 that includes a plurality of axial steps 127. For illustrative purposes, Figure 2D1 A cross-sectional view of a first housing member of a filter according to various embodiments of the present disclosure is shown. For illustrative purposes, Figure 2D2 A cross-sectional view of a first housing member of a filter according to various embodiments of the present disclosure is shown. For illustrative purposes, Figure 2D3 A cross-sectional view of a first housing member of a filter according to various embodiments of the present disclosure is shown. As Figures 2D1 to 2D3 As shown, the axial steps 127 can extend upwardly along the radial sidewall 123 of the first housing member. Further, as Figures 2D1 to 2D3 As shown, the at least one axial step 127 can include at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10 axial steps. Further, as Figures 2D1 to 2D3 As shown, the at least one axial step 127 can be linear or arcuate.

[0056] Referring back to Figure 2B In various embodiments, at least one of the first housing member 122 or the second housing member 124 can include at least one vent 135. In various embodiments, the at least one vent 135 can vent air from the filter 100 to the ambient environment outside of the housing 120. The at least one vent 135 can be integral with at least one of the first housing member 122 or the second housing member 124.

[0057] Referring now to Figures 2A to 2C In various embodiments, the first housing member 122 can have a fluid inlet port 132 at the first axial end 112 of the filter. In various embodiments, the second housing member 124 can have a fluid outlet port 134 at the second axial end 114 of the filter 100. In various embodiments, at least one of the fluid inlet port 132 or the fluid outlet port 134 can include a bore, a sleeve, a nozzle, or any known variation as is conventionally known in the art for feeding fluid into the filter 100. As Figure 2AAs best shown, the fluid inlet port 132 or the fluid outlet port 134 may be connected to a conduit suitable for containing fluid and moving fluid into and out of the filter 100. In several embodiments, such as Figure 2C As best shown, the fluid inlet port 132 may include a fluid conduit attachment feature 133 that includes surface texture modifications. These surface texture modifications may be barbs, lips, struts, bevels, protrusions, textured / gripable surfaces, clips, nuts, bolts, bearings, slats, hooks, flanges, swivels, grommets, hook-eyes, latches, bolts, nails, rivets, tongue-and-groove joints, screw anchors, snaps, stitching, threaded fasteners, ties, toggle bolts, wedge anchors, screws, clamps, buckles, pins, or combinations thereof. In several embodiments, the fluid conduit attachment feature 133 may attach a filter to the conduit. In several embodiments, the fluid outlet port 134 may include a fluid conduit attachment feature 135 that includes surface texture modifications. This surface texture modification can be a barb, lip, strut, bevel, protrusion, textured / gripable surface, clip, nut, bolt, bearing, slat, hook, flange, swivel, sling, hook-eye, latch, bolt, nail, rivet, tongue-groove, screw anchor, snap, stitch, threaded fastener, tie, toggle bolt, wedge anchor, screw, clamp, snap ring, pin, or combination thereof. In several embodiments, the fluid conduit attachment feature 135 can attach a filter to the conduit.

[0058] like Figures 2B to 2C As best illustrated, in several embodiments, the first housing 122 and the second housing 124 may be fused or bonded into an integral filter 100 by means of a thermoplastic overmolding member 108. In several embodiments, the thermoplastic overmolding member 108 may be molded onto the periphery of the housing members 122, 124, thereby sealing the periphery of the housing members together to form an internal volume V for accommodating the porous filter element 102. F In several embodiments, the thermoplastic overmolding member 108 may contact the first housing member 122 or the second housing member 124 along at least 1% (such as at least 5%, at least 10%, at least 20%, at least 25%, at least 50%, at least 60%, at least 75%, at least 80%, at least 90%, at least 95%, or at least 99%) of its surface area. In several embodiments, the thermoplastic overmolding member 108 may completely surround and fill the joint 109 to form a monolithic housing 120. In several embodiments, the overmolding member 108 axially covers the axial outer surfaces of the sidewalls 123, 125 of each of the first housing member 122 and the second housing member 124. In several embodiments, the overmolding member 108 molds the first housing member 122 to the second housing member 124 along the entire periphery of the filter 100.

[0059] Still refer toFigures 2A to 2C In various embodiments, the two housing members can enclose a porous filter element or septum 102, which can be disposed between the first housing member 122 and the second housing member 124. For example, in intravenous applications, the porous filter element or septum 102 can be composed of nylon, cellulose ester, or other equivalent stable inert materials. In various embodiments, the porous filter element 102 can have an average pore size between 0.005 pm and 1200 pm, such as between 0.50 pm and 1000 pm, such as between 1 pm and 500 pm, or such as between 1.5 pm and 250 pm. The pore size can range from 0.1 pm to 15 pm. A variety of such filter elements are available, and these are well known to those skilled in the art. In various embodiments, the porous filter element 102 can be molded into at least one of the first housing member 122 or the second housing member 124, or the overmold 108. In various embodiments, the porous filter element 102 can contact the first housing member 122 or the second housing member 124 along at least 1% of its surface area, such as at least 5%, at least 10%, at least 20%, at least 25%, at least 50%, at least 60%, at least 75%, at least 80%, at least 90%, at least 95%, or at least 99%.

[0060] For illustrative purposes, Figure 2E A perspective top view of a first housing member of a filter according to various embodiments of the present disclosure is shown. For illustrative purposes, Figure 2F A perspective top view of a second housing member of a filter according to various embodiments of the present disclosure is shown. Reference is made to Figures 2E to 2FIn embodiments, at least one of the first housing member 122 or the second housing member 124 can include at least one radial rib 142. In embodiments, the at least one radial rib 142 can protrude inside the first housing member 122 or the second housing member 124 to form a portion of the internal volume of the filter 100. In embodiments, the at least one radial rib 142 can help support the septum 102 within the internal volume of the filter 100. As shown, the at least one radial rib 142 can be continuous or discrete. In embodiments, at least one of the first housing member 122 or the second housing member 124 can include a plurality of radial ribs 142. In embodiments, at least 1% (such as at least 5%, at least 10%, at least 20%, at least 25%, at least 50%, at least 60%, at least 75%, at least 80%, at least 90%, at least 95%, or at least 99%) of the surface area of the first housing member 122 or the second housing member 124 has radial ribs 142. In embodiments, at least one of the first housing member 122 or the second housing member 124 can include at least one circumferential rib 144. In embodiments, the at least one circumferential rib 144 can protrude inside the first housing member 122 or the second housing member 124 to form a portion of the internal volume of the filter 100. In embodiments, the at least one circumferential rib 144 can help support the septum 102 within the internal volume of the filter 100. As shown, the at least one circumferential rib 144 can be continuous or discrete. In embodiments, at least one of the first housing member 122 or the second housing member 124 can include a plurality of circumferential ribs 144. In embodiments, at least 1% (such as at least 5%, at least 10%, at least 20%, at least 25%, at least 50%, at least 60%, at least 75%, at least 80%, at least 90%, at least 95%, or at least 99%) of the surface area of the first housing member 122 or the second housing member 124 has circumferential ribs 144.

[0061] The filter 100, or any component thereof listed herein, can be formed from any suitable material in the sealing arts. In one particular embodiment, the filter 100, or any component thereof listed herein, can include at least in part a polymer. The polymer can be a thermoplastic polymer or a thermoset polymer. The polymer can be selected from a polyketone, a polyaramid, a polyphenylene sulfide, a polyether sulfone, a polyphenyl sulfone, a polyamide-imide, an ultra-high molecular weight polyethylene, a fluoropolymer, a polybenzimidazole, a polyformaldehyde, a polybutylene terephthalate (PBT), a polypropylene (PP), a rubber modified polypropylene (EPDM / PP), a polycarbonate (PC), an acrylonitrile butadiene styrene (ABS), a polyethylene terephthalate (PET), a polyimide (PI), a polyetherimide, a polyether ether ketone (PEEK), a polyaryletherketone (PAEK), a polyethylene (PE), a high-density polyethylene (HDPE), a polysulfone, a polyamide (PA), a thermoplastic polyurethane (TPU), a polyphenylene ether, a polyphenylene sulfide (PPS), a polyurethane, a polyester, a liquid crystal polymer (LCP), an elastomer, or any combination thereof. In one embodiment, the filter 100, or any component thereof listed herein, can include a fluoropolymer or even consist essentially of a fluoropolymer. Exemplary fluoropolymers include polytetrafluoroethylene (PTFE), modified PTFE (TFM), fluorinated ethylene propylene (FEP), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE), ethylene-chlorotrifluoroethylene copolymer (ECTFE), or any combination thereof. Other fluoropolymers, polymers, and blends can be included in the composition of the filter 100, or any component thereof listed herein. In another particular embodiment, the filter 100, or any component thereof listed herein, can include at least in part, or even consist essentially of, a polyethylene (PE), such as an ultra-high molecular weight polyethylene (UHMWPE). In another particular embodiment, the filter 100, or any component thereof listed herein, can include a thermoplastic elastomer hydrocarbon block copolymer, a polyether-ester block copolymer, a thermoplastic polyamide elastomer, a thermoplastic polyurethane elastomer, a thermoplastic polyolefin elastomer, a thermoplastic vulcanizate, an olefin-based copolymer, an olefin-based terpolymer, a polyolefin plastomer, or a combination thereof. In one embodiment, the filter 100, or any component thereof listed herein, can include a styrene-based block copolymer, such as a styrene-butadiene, a styrene-isoprene, a blend or mixture thereof, or the like.Exemplary styrenic thermoplastic elastomers include triblock styrenic block copolymers (SBCs) such as styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-ethylene butylene-styrene (SEBS), styrene-ethylene propylene-styrene (SEPS), styrene-ethylene-ethylene-butadiene-styrene (SEEBS), styrene-ethylene-ethylene-propylene-styrene (SEEPS), styrene-isoprene-butadiene-styrene (SIBS), or combinations thereof. Commercial examples include some grades of Kraton. TM and Hybrar TM resins. In one embodiment, the filter 100 or any component thereof listed herein can include an elastomer including at least one of acrylonitrile-butadiene (NBR) carboxylated nitrile (XNBR) ethylene propenoate (AEM, ), ethylene propylene rubber (EPR, EPDM), butyl rubber (IIR), chlorobutyl rubber (CR), fluorocarbon (FKM, FPM), fluorosilicone (FVMQ), hydrogenated nitrile (HNBR), perfluoroelastomers (FFKM), polyacrylate (ACM), polyurethane (AU, EU), silicone rubber (Q, MQ, VMQ, PVMQ), tetrafluoroethylene-propylene (FEPM). In various embodiments, the filter 100 or any component thereof listed herein can be formed by any conventional method known for polymer fabrication such as injection molding, open-die, cutting / slicing, hot or cold pressing, direct shaping, extrusion, skiving, machining, or CNC machining.

[0062] In one embodiment, the filter 100 or any component thereof listed herein can include at least in part a rigid material such as, but not limited to, a metal. According to certain embodiments, the metal can include iron, copper, titanium, tin, aluminum, alloys thereof, or can be another type of metal. In one embodiment, the filter 100 or any component thereof listed herein can include a metal such as aluminum, zinc, copper, magnesium, tin, platinum, titanium, tungsten, iron, bronze, steel, energy- enhanced steel, stainless steel, metal alloys including the listed metals, anodized metals including the listed metals, or any combination thereof.

[0063] In an embodiment, the filter 100 or any component thereof listed herein can be treated, impregnated, filled, or coated with a lubricious material or filler. Exemplary lubricious materials or fillers include molybdenum disulfide, tungsten disulfide, graphite, graphene, expanded graphite, boron nitride, talc, calcium fluoride, or any combination thereof. Additionally, the lubricious material or filler can include a ceramic such as alumina, silica, titania, calcium fluoride, boron nitride, mica, wollastonite, glass fiber, silicon carbide, silicon nitride, zirconia, carbon black, pigments, or any combination thereof. In an embodiment, the filter 100 or any component thereof listed herein can be an oxygen, hydrogen, hydroxide, or temperature resistant material. In embodiments, the filter 100 or any component thereof listed herein can be monolithic. In alternative embodiments, the filter 100 or any component thereof listed herein can not be monolithic and can include multiple pieces.

[0064] In an embodiment, the filter 100 or any component thereof listed herein can advantageously be subjected to a sterilization process. In an embodiment, the filter 100 or any component thereof listed herein can be sterilized by any method contemplated. For example, the polymer of the filter 100 is sterilized after the filter 100 is formed. Exemplary sterilization methods include radiation (such as X-ray radiation), electron beam, or e-beam sterilization techniques, combinations thereof, and the like. In a particular embodiment, the polymer or polymer blend is sterilized by vaporized hydrogen peroxide sterilization (VHP). In a particular embodiment, the filter 100 or any component thereof listed herein is sterilized by gamma radiation. For example, the filter 100 or any component thereof listed herein can be gamma sterilized between about 25 kGy to about 50 kGy.

[0065] In embodiments, the filter 100 or any component thereof listed herein can have additional desirable physical and mechanical properties. For example, the filter 100 or any component thereof listed herein can appear transparent or at least translucent. For example, the filter 100 or any component thereof listed herein can have a light transmittance greater than about 2% or greater than about 5% in the visible light wavelength range. In particular, the resulting article has a desirable transparency or translucency. Further, the filter 100 or any component thereof listed herein can have a favorable balance of any one or more of the physical properties such as hardness, flexibility, surface lubricity, tensile strength, elongation, Shore A hardness, gamma resistance, weld strength, and seal integrity to optimal levels.

[0066] In one embodiment, the filter 100 or any component thereof listed herein can have desirable thermal stability properties. There are many applications for polymers or polymer blends. In particular, the filter 100 or any component thereof listed herein can be non-toxic such that the material can be used in any application where toxicity is not desired. For example, the filter 100 or any component thereof listed herein can be substantially free of plasticizers or other low molecular weight extenders that can leach into a fluid to which it is transferred. As used herein, "substantially free" means a polymer mixture having a total organic content (TOC) (measured according to ISO 15705 and EPA 410.4) of less than about 100 ppm. Further, the filter 100 or any component thereof listed herein has biocompatibility and formulation ingredients that are free of animal-derived components. For example, the filter 100 or any component thereof listed herein can have potential for FDA, USP, EP, ISO, and other regulatory approval. In exemplary embodiments, the filter 100 or any component thereof listed herein can be used in applications such as industrial, medical, health care, biopharmaceutical, pharmaceutical, drinking water, food and beverage, laboratory, dairy, and the like. In one embodiment, the filter 100 or any component thereof listed herein can be used in applications where low temperature resistance is desired. In one embodiment, the filter 100 or any component thereof listed herein can also be safely disposed of because it does not substantially produce toxic gases when incinerated and does not leach plasticizers into the environment if landfilled.

[0067] In some embodiments, the filter 100 can be configured to contain and filter a product. The product can be a medical, biological, or pharmaceutical fluid. In various embodiments, the product can include a biomedical fluid for use in a medical, biological, or pharmaceutical application. In various embodiments, the product can include a biological agent. In various embodiments, the product can include a fluid for use in a medical, biological, or pharmaceutical application.

[0068] A method can be used to form a filter according to the various embodiments. The method can include a first step comprising providing a fluid inlet conduit. The method can include a second step of providing a fluid outlet conduit. The method can include a third step of providing a filter coupling the fluid inlet conduit to the fluid outlet conduit, wherein the filter comprises: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element sandwiched between the first housing member and the second housing member; and a thermoplastic overmold that can be molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an internal volume containing the porous filter element, wherein the first housing member comprises a radial sidewall comprising at least one axial step, and wherein the second housing member comprises a substantially straight radial sidewall. The method can include a fourth step of flowing a fluid through the fluid inlet conduit into the filter and into the fluid outlet conduit.

[0069] The use of filters according to the embodiments herein can provide increased benefits in several applications or other types of applications in fields such as, but not limited to, industrial, medical, healthcare, biopharmaceutical, pharmaceutical, drinking water, food and beverage, laboratory, dairy. Notably, the use of filters according to the embodiments herein can provide improved flow uniformity, lower flow resistance, and more adequate burst strength across a wide range of fluids of different flow rates and characteristics, increasing filter life and performance efficiency compared to existing filters.

[0070] Example

[0071] In various embodiments, filters according to the embodiments herein can exhibit improved burst strength compared to existing filters. Figure 3 A plot of pressure (bar) applied on the filter versus maximum principal strain (mm / mm) is shown for a conventional filter (A) versus a filter according to the embodiments herein (B).

[0072] As shown in Figure 3 , filters according to the embodiments herein have higher burst strength (i.e., maximum principal strain) as pressure increases compared to existing filters. In various embodiments, filters according to the embodiments herein can have a relative burst strength (strength per unit of filter area) of at least 40 Pa / mm2through the filter. 2

[0073] In various embodiments, filters according to the embodiments herein can exhibit improved velocity resistance compared to existing filters. Table 1 shows the standard deviation of velocity across the cross-section for evaluating flow uniformity and flow resistance of filters according to the embodiments herein compared to conventional filters.​

[0074] Housing design Standard deviation (cm / s) Prior art 1 6.31E-02 Prior art 2 4.20E-03 Filter 3 2.54E-02

[0075] Table 1

[0076] As shown in Table 1, filters according to embodiments herein have better flow uniformity and velocity resistance compared to existing filters. In various embodiments, when water is used as the fluid, and the cross-membrane flow of the porous filtration element, which is defined as the flow rate per surface area per pressure drop, is 4 ml / (min cm 2 ·bar), and the inner diameter of the porous filtration element is measured as 57 mm through the inner diameter of the disc filter, filters according to embodiments herein can define a pressure drop of no more than 29,000 Pa at a fluid flow rate of 2.94 ml / (min cm 2 ) through the filter. It is expected that other sizes of porous filtration elements will similarly function. The pressure drop of the filter can be measured by the pressure difference between pressure gauges tightly installed upstream and downstream of the filter, and the flow rate can be measured by a flow meter along the system. In various embodiments, when water is used as the fluid, and the cross-membrane flow of the porous filtration element, which is defined as the flow rate per surface area per pressure drop, is 4 ml / (min cm 2 ·bar), and the diameter of the porous filtration element is 57 mm, filters according to embodiments herein can define a standard deviation of the velocity across the surface upstream of the porous filtration element of no more than 0.04 cm / s, and in other embodiments no more than 0.026 cm / s, at a fluid flow rate of 2.94 ml / (min cm 2 ) through the filter. The standard deviation (σ) is defined as the following equation (u i is the local velocity, u is the average velocity across the surface, n is the number of mesh openings in the cross-sectional area defined for the test (i.e., the cross-filament mesh opening size is 0.2 mm, and for a 57 mm diameter filter, the number of mesh openings in the cross-section is approximately 63,800):

[0077]

[0078] This value can be obtained using commercially available CFD software ANSYS-Fluent. In detail, to input the given filter housing geometry, membrane properties, fluid properties, and a given fluid flow rate, the standard deviation can be obtained from the post-processing of the CFD results.

[0079] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described below. Those skilled in the art will appreciate that those aspects and embodiments are illustrative only and do not limit the scope of the present application.

[0080] Embodiment 1. A filter comprising: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an interior volume containing the porous filter element, wherein the first housing member comprises a radial sidewall comprising at least one axial step, and wherein the second housing member comprises a substantially straight radial sidewall.

[0081] Embodiment 2. A filter comprising: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an interior volume containing the porous filter element, wherein at least one of: 1) the first housing member comprises a radial sidewall comprising at least one axial step, provides a relative burst strength of at least 40 Pa / mm^2 (strength per unit filter area), or 2) the second housing member comprises a substantially straight radial sidewall, defines a pressure drop of no greater than 29,000 Pa at a fluid flow rate through the filter of 75 ml / min.

[0082] Embodiment 3. An assembly comprising: a fluid inlet conduit; a fluid outlet conduit; and a filter coupling the fluid inlet conduit to the fluid outlet conduit, wherein the filter comprises: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an interior volume containing the porous filter element, wherein the first housing member comprises a radial sidewall comprising at least one axial step, and wherein the second housing member comprises a substantially straight radial sidewall.

[0083] Embodiment 4. A method comprising: providing a fluid inlet conduit; providing a fluid outlet conduit; providing a filter coupling the fluid inlet conduit to the fluid outlet conduit, wherein the filter comprises: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first housing member and the second housing member; and a thermoplastic overmold molded on a periphery of the housing members, sealing the periphery of the housing members together to form an interior volume containing the porous filter element, wherein the first housing member comprises a radial sidewall comprising at least one axial step, and wherein the second housing member comprises a substantially straight radial sidewall; and flowing a fluid through the fluid inlet conduit into the filter and into the fluid outlet conduit.

[0084] Embodiment 5. The filter, assembly, or method of any of the preceding embodiments, wherein at least one of the first housing member or the second housing member comprises a thermoplastic material.

[0085] Embodiment 6. The filter, assembly, or method of any of the preceding embodiments, wherein at least one of the first housing member or the second housing member comprises at least one circumferential rib.

[0086] Embodiment 7. The filter, assembly, or method of any of the preceding embodiments, wherein at least one of the first housing member or the second housing member comprises at least one radial rib.

[0087] Embodiment 8. The filter, assembly, or method of any of the preceding embodiments, wherein the first housing member has a generally frustoconical cross-sectional profile.

[0088] Embodiment 9. The filter, assembly, or method of any of the preceding embodiments, wherein the second housing member has a circular cross-sectional profile.

[0089] Embodiment 10. The filter, assembly, or method of any of the preceding embodiments, wherein the second housing member, wherein the substantially straight radial sidewall is perpendicular to a central axis of the filter.

[0090] Embodiment 11. The filter, assembly, or method of any of the preceding embodiments, wherein the filter defines a relative burst strength (strength per unit of filter area) of at least 40 Pa / mm 2 of filter area.

[0091] Embodiment 12. The filter, assembly, or method of any of the preceding embodiments, wherein the filter defines a pressure drop of no greater than 29,000 Pa at a fluid flow rate through the filter of 75 ml / min.

[0092] Embodiment 13. The filter, assembly, or method of any of the preceding embodiments, wherein the first housing member further defines a vent.

[0093] Embodiment 14. The filter, assembly, or method of any of the preceding embodiments, wherein the overmold member molds the first housing member to the second housing member along an entire perimeter of the filter.

[0094] Embodiment 15. The filter, assembly, or method of any of the preceding embodiments, wherein the overmold member axially covers an axial outer surface of a sidewall of each of the first and second housing members.

[0095] Embodiment 16. The filter, assembly, or method of any of the preceding embodiments, wherein the fluid inlet port includes a fluid conduit attachment feature comprising a surface structure modification.

[0096] Embodiment 17. The filter, assembly, or method of embodiment 16, wherein the surface structure modification comprises at least one barb.

[0097] Embodiment 18. The filter, assembly, or method of any of the preceding embodiments, wherein the fluid outlet port includes a fluid conduit attachment feature comprising a surface structure modification.

[0098] Embodiment 19. The filter, assembly, or method of embodiment 18, wherein the surface structure modification comprises at least one barb.

[0099] Embodiment 20. The filter, assembly, or method of any of the preceding embodiments, wherein the radial sidewall of the first housing member comprises a plurality of axial steps.

[0100] Embodiment 21. The filter, assembly, or method of any of the preceding embodiments, wherein at least one of the first or second housing members comprises a plurality of circumferential ribs.

[0101] Embodiment 22. The filter, assembly, or method of any of the preceding embodiments, wherein at least one of the first or second housing members comprises a plurality of radial ribs.

[0102] Embodiment 23. The filter, assembly, or method of any of the preceding embodiments, wherein the porous filter element comprises a thermoplastic.

[0103] Embodiment 24. The filter, assembly, or method of any of the preceding embodiments, wherein the porous filter element comprises a metal.

[0104] Embodiment 25. The filter, assembly, or method of any of the preceding embodiments, wherein a peripheral edge of the porous filter element is molded to at least one of the first housing member, the second housing member, or the overmold.

[0105] Embodiment 26. The filter, assembly, or method of any of the preceding embodiments, wherein at least one of the first housing member, the second housing member, or the overmold comprises a monolithic piece.

[0106] Embodiment 27. The filter, assembly, or method of any of the preceding embodiments, wherein the porous filter element has an average pore size of between 5 nm and 1200 pm.

[0107] Embodiment 28. The filter, assembly, or method of any of the preceding embodiments, wherein the filter has an axial length of greater than 15 mm.

[0108] Embodiment 29. The filter, assembly, or method of any of the preceding embodiments, wherein the filter has an outer radius of greater than 25 mm.

[0109] Embodiment 30. The filter, assembly, or method of any of the preceding embodiments, wherein the filter is sterilizable.

[0110] Embodiment 31. The filter, assembly, or method of any of the preceding embodiments, wherein the filter defines a standard deviation of velocity across a surface upstream of the porous filter element of no greater than 0.04 m / s at a fluid flow rate of 75 ml / min through the filter.

[0111] Embodiment 32. The filter, assembly, or method of any of the preceding embodiments, wherein the second housing member contacts the porous filter element along at least 1% of a surface area of the porous filter element.

[0112] Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity can not be required, and that one or more further activities can be provided in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which activities are performed.

[0113] The benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0114] The specification and drawings are, at step, intended to provide a general understanding of the structure of various embodiments. The specification and drawings are not intended to serve as an exhaustive and comprehensive description of all the elements and features of apparatus and systems utilizing the structures or methods described herein. Separate embodiments can also be provided in combination in a single embodiment, and vice versa, for brevity, the various features of the embodiments will be described in the context constructed with individual embodiments, however, these features can also be provided alone or in any sub-combination. In addition, references to values stated in a range include each and every value within that range. Numerous other embodiments will become apparent to those skilled in the art upon reading this specification and drawings and the embodiments can be applied to other uses and embodiments without departing from the scope of the present disclosure. The disclosed embodiments are to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.

[0115] Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity can not be required, and that one or more further activities can be provided in addition to those described. Still further, the order in which activities are listed are not necessarily the order in which activities are performed.

[0116] The benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that can cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0117] Upon reading the specification, those skilled in the art will recognize that, for clarity, purposes some of the features described herein in the context of separate embodiments can also be provided in combination in a single embodiment. Conversely, for brevity, the various features described in the context of a single embodiment can also be provided separately or in any sub-combination. In addition, references to values stated in a range include each and every value within that range.

Claims

1. A filter, comprising: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an internal volume containing the porous filter element, wherein the first housing member includes a radial sidewall including at least one axial step, and wherein the second housing member includes a substantially straight radial sidewall.

2. A filter, comprising: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an internal volume containing the porous filter element, wherein at least one of: 1) the first housing member includes a radial sidewall including at least one axial step, provides a relative burst strength of at least 40 Pa / mm^2 (strength per unit filter area), or 2) the second housing member includes a substantially straight radial sidewall, defines a pressure drop of no greater than 29,000 Pa at a fluid flow rate of 75 ml / min through the filter.

3. An assembly, comprising: a fluid inlet conduit; a fluid outlet conduit; and a filter coupling the fluid inlet conduit to the fluid outlet conduit, wherein the filter comprises: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an internal volume containing the porous filter element, wherein the first housing member includes a radial sidewall including at least one axial step, and wherein the second housing member includes a substantially straight radial sidewall.

4. A method, comprising: providing a fluid inlet conduit; providing a fluid outlet conduit; providing a filter coupling the fluid inlet conduit to the fluid outlet conduit, wherein the filter comprises: a first housing member having a fluid inlet port; and a second housing member axially positioned below the first housing member, the second housing member having a fluid outlet port; a porous filter element disposed between the first and second housing members; and a thermoplastic overmold molded on the perimeters of the housing members, sealing the perimeters of the housing members together to form an internal volume containing the porous filter element, wherein the first housing member includes a radial sidewall including at least one axial step, and wherein the second housing member includes a substantially straight radial sidewall. ​ ​ a thermoplastic overmold molded on the perimeters of the shell members, sealing the perimeters of the shell members together to form an interior volume containing the porous filter element, wherein the first shell member comprises a radial sidewall comprising at least one axial step, and wherein the second shell member comprises a substantially straight radial sidewall; and flowing a fluid through the fluid inlet conduit into the filter and into the fluid outlet conduit.

5. The filter, assembly, or method of any of the preceding claims, wherein at least one of the first shell member or the second shell member comprises a thermoplastic material.

6. The filter, assembly, or method of any of the preceding claims, wherein at least one of the first shell member or the second shell member comprises at least one circumferential rib.

7. The filter, assembly, or method of any of claims 1-6, wherein at least one of the first shell member or the second shell member comprises at least one radial rib.

8. The filter, assembly, or method of any of claims 1-6, wherein the first shell member has a generally frustoconical cross-sectional profile.

9. The filter, assembly, or method of any of claims 1-6, wherein the second shell member has a circular cross-sectional profile.

10. The filter, assembly, or method of any of claims 1-6, wherein the second shell member, wherein the substantially straight radial sidewall is perpendicular to a central axis of the filter.

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