Potting manifold

Abstract

The present disclosure relates to devices for potting hollow fiber membranes in diffusion and / or filtration devices, such as ultrafilters or capillary dialyzers.

Description

Technical Field

[0001] This disclosure relates to an apparatus for filling hollow fiber membranes in diffusion and / or filtration devices (e.g., ultrafiltration or capillary dialyzers). Background Technology

[0002] Diffusion and / or filtration devices, including hollow fiber membranes, are widely used for the separation or purification of liquids. Examples include ultrafiltration devices for water purification; plasma filters for separating plasma from blood; capillary dialyzers for blood purification in patients with renal insufficiency (i.e., capillary dialyzers used to treat patients through hemodialysis, hemodiafiltration, or hemofiltration), and so on. Many different models of diffusion and / or filtration devices, including hollow fiber membranes, are available on the market.

[0003] These devices generally include a housing comprising tubular sections, the openings of which are sealed with end caps. Bundles of hollow fiber membranes are arranged within the housing in such a way that a seal is provided between a first flow space formed by the fiber cavities and a second flow space surrounding the membrane exterior. The seal is generally provided by end-wall devices within the housing, formed from polymer blocks embedded in the ends of the hollow fiber membranes.

[0004] Polyurethane resins are commonly used as potting compounds or curable liquid sealants. Isocyanates and polyols are metered into a mixer (e.g., a mixing head), and the reaction mixture is introduced into the housing of a diffusion and / or filtration device via a disposable manifold. Because small amounts of polyurethane resin remain in the mixing unit and on the surface of the manifold, forming scale after the resin cures, the mixing unit needs to be flushed periodically and the disposable manifold replaced.

[0005] GB2016358A describes a method for sealing the ends of a hollow fiber bundle in a hollow fiber dialyzer. The method includes: inserting the bundle into a tubular housing; sealing the ends of the housing using a sealing member; providing a curable liquid sealant within the housing; rotating the housing to spread the sealant around the ends of the hollow fibers; allowing the sealant to cure; then removing the sealing member and cutting through the fiber ends and the sealant; or, cutting through the sealing member instead of removing it.

[0006] WO1984 / 002486A1 discloses another method for manufacturing a hollow fiber separation device, comprising the steps of: forming an integral structure and an elongated chamber portion, the integral structure including at least one tubular shell portion, the elongated chamber portion extending elongated relative to the tubular shell portion and communicating with shell portions adjacent to its opposite ends. An orifice is provided in the central region of the elongated chamber. Hollow fibers for diffusion are introduced into the shell, and the ends of the shell portion are closed. The structure is rotated on an axis between the ends, and potting compound is added to the chamber portion through the orifice. The potting compound migrates radially outward through the chamber to the closed end of the shell portion, thereby encapsulating the ends of the hollow fibers in the potting compound. After the potting compound has cured, the ends of the tubular shell portion are laterally cut to expose the openings of the hollow fibers, and a manifold end cap member is applied to the cut ends of the tubular shell portion.

[0007] EP3620228A1 discloses a process for manufacturing a filtration and / or diffusion device comprising hollow fiber membrane bundles within a tubular housing. The process involves sealing the ends of the fibers and the openings of the tubular housing using a thermoplastic resin.

[0008] JPS63-296764A discloses a potting container having a cap that engages with a portion of the upper surface of a body. The body contains a potting compound, and a potting compound inlet port is disposed on the cap body. The sidewall portion of the body is inclined such that the angle defined by the sidewall portion and the bottom surface of the body forms an acute angle. The potting compound outlet port is disposed along the acute-angled sidewall portion.

[0009] JP2008-279374A discloses a container for injecting potting material, comprising: a body for storing potting material; and an injection nozzle for injecting potting material from a cylindrical liquid inflow / outflow nozzle disposed on the side of the body of a hollow fiber membrane module. The injection nozzle has a shape adapted to the liquid inflow / outflow nozzle, has one or more protrusions on its outer wall, and satisfies the following formulas (1) to (3): 0≦AB≦0.015 (1); 0.1≦C≦0.2 (2); -90≦D≦90 (3), where A represents the outer diameter (mm) of the portion of the protrusion excluding the nozzle, B represents the inner diameter of the nozzle, C represents the total height (mm) of each protrusion, and D represents the mounting position (°) of the protrusion on the circumference of the outer wall.

[0010] JP2009-131746A discloses a potting material injection container having a central dispenser with a bottom and opposing sidewalls protruding from the bottom, and an injection nozzle separate from the central dispenser. The injection nozzle is attached to an end of the opposing sidewall opposite to the central axis of the central dispenser and has a reservoir for potting material. The reservoir extends from an upstream side to a downstream side. The container has a conical shape and is inclined relative to the central axis of the central dispenser. The bottom has a conical or truncated cone shape.

[0011] The purpose of this disclosure is to provide an improved single-use potting manifold. Summary of the Invention

[0012] This disclosure provides a disposable manifold for potting hollow fiber membranes in diffusion and / or filtration equipment. This disclosure also provides a process for manufacturing the potted manifold and its intended use. Attached Figure Description

[0013] Figure 1 This is a schematic perspective view of the manifold disclosed herein.

[0014] Figure 2 yes Figure 1 A schematic side view of the manifold.

[0015] Figure 3 yes Figure 1 A schematic front view of the manifold.

[0016] Figure 4 yes Figure 1 A schematic bottom view of the manifold.

[0017] Figure 5 This is a schematic perspective view of the welding station used in the production of the manifold of this disclosure.

[0018] Figure 6 yes Figure 5 A schematic front view of the welding station. Detailed Implementation

[0019] This disclosure provides an apparatus for filling hollow fiber membranes in diffusion and / or filtration devices (e.g., hemodialyzers, plasma filters, or ultrafilters). The filling apparatus is a disposable manifold.

[0020] The filling manifold of this disclosure includes a four-fork container having a flat bottom and a circumferential outer wall extending upward from the bottom. At the end of each fork of the container, a tubular outlet nozzle extends downward from the bottom of the container. The height of the circumferential outer wall is greater than the height of the remaining outer wall in a region near the end of the fork, thereby forming a U-shaped tab extending upward from the top edge of the outer wall.

[0021] In some embodiments, the potting manifold is rectangular in shape. In some embodiments, the maximum length of the potting manifold is in the range of 230 to 240 mm, the maximum width is in the range of 85 to 90 mm, and the maximum height is in the range of 130 to 140 mm.

[0022] The four-forklift container has a flat bottom and a surrounding outer wall extending upward from the bottom. In some embodiments, the outer wall is perpendicular to the bottom, i.e., the angle between the bottom and the outer wall is 90°. In some embodiments, the height of the surrounding outer wall is in the range of 25 to 50 mm. The height of the surrounding outer wall is greater in the region near the ends of the forks than the height of the rest of the outer wall, which is uniform in height. In some embodiments, the height of the outer wall near the ends of the forks is in the range of 40 to 50 mm, while the height of the outer wall in the remaining region is in the range of 25 to 35 mm. At the ends of the forks, a U-shaped tab is formed extending upward from the top edge of the outer wall. In some embodiments, the height of the U-shaped tab is in the range of 10 to 20 mm, for example, the height of the U-shaped tab is 15 mm.

[0023] In some embodiments, the bottom of the container includes a central cruciform ridge that separates the forked arms from each other. In some embodiments, the width of the legs of the ridge is in the range of 9 to 10 mm. In some embodiments, the height of the ridge is in the range of 8 to 10 mm. In some embodiments, the apex angle of the cruciform ridge is in the range of 40° to 50°, for example, the apex angle of the cruciform ridge is 45°. The cruciform ridge allows the liquid potting resin poured into the container to be divided into four equal volumes.

[0024] At the end of each fork arm of the container, a tubular outlet nozzle extends downward from the bottom of the container. In some embodiments, the inner diameter of the tubular outlet nozzle is in the range of 4 to 6 mm. In some embodiments, the four tubular outlet nozzles of the manifold form two pairs of tubular outlet nozzles that are opposite in diameter and of different lengths. In some embodiments, one pair of outlet nozzles is longer than the other pair, with the difference ranging from 50 to 60 mm. The different lengths of the tubular outlet nozzle pairs allow for the simultaneous attachment of two filtration and / or filling devices to the manifold.

[0025] In some embodiments, a plurality of tongues are disposed on the outer side of the surrounding outer wall, at the top edge of the surrounding outer wall, and facing outward. These tongues increase the rigidity of the container wall, thereby reducing deformation of the container during use.

[0026] In some embodiments, the forks at the shorter face of the filling manifold are connected by horizontal plates attached to the top edge of the surrounding outer wall. These horizontal plates further increase the rigidity of the container wall, thereby preventing the container from deforming during use. The horizontal plates also facilitate handling of the filling manifold by automated tools, such as robotic grippers.

[0027] The potted manifold is made of a thermoplastic polymer. In some embodiments, the potted manifold is made of a polyolefin. In one embodiment, the polyolefin is polypropylene. In another embodiment, the polyolefin is polyethylene.

[0028] The filling manifold has a U-shaped tab extending upward from the top edge of the outer wall at the end of the fork arm. In embodiments of the filling manifold, the legs of the U-shaped tab are connected to each other, thereby forming a cap at the end of the container's fork arm. The cap prevents liquid filling resin from spilling out of the filling manifold during use, particularly when the manifold rotates about its central axis to dispense liquid filling resin into a filter and / or diffusion device attached to the filling manifold. The integrated cap at the end of the fork arm replaces the cap required in prior art filling manifolds, thereby eliminating the need for an additional component and reducing the amount of polymer material required to manufacture the manifold.

[0029] This disclosure also provides a process for manufacturing potted manifolds. Potted manifolds are generally produced by injection molding. Suitable equipment and processes for producing injection-molded parts from thermoplastic polymers are known in the art.

[0030] In some embodiments of the process, the legs of the U-shaped tabs located at the ends of the forks of the filling manifold are joined together in a subsequent step to form a cap at the ends of the forks of the container. In one embodiment of the process, the legs of the U-shaped tabs are joined together by welding. In another embodiment of the process, the legs of the U-shaped tabs are joined together by adhesive. Suitable adhesives are known in the art.

[0031] Figure 5 and Figure 6 The diagram illustrates suitable equipment for simultaneously welding all four U-shaped tabs. A heated fixture is used to weld the legs of each U-shaped tab together. The potting manifold is placed upside down on the welding station, and the U-shaped tabs are introduced into the heated fixture. The fixture is heated to melt the polymer material of the manifold, and then the fixture is closed to weld the legs of each U-shaped tab together, forming a closed cap.

[0032] This disclosure also provides the use of potting manifolds in the potting of filtration and / or diffusion devices. In some embodiments, the use involves simultaneously introducing a liquid potting resin (e.g., a reactive polyurethane blend) into two filtration and / or diffusion devices. Diffusion and / or filtration devices typically include a tubular housing in which hollow fiber membrane bundles are disposed and at least one tubular fluid port located on the outer wall surface of the tubular housing.

[0033] In a typical potting procedure, a reactive polyurethane mixture is metered into a disposable manifold that connects to the tubular fluid ports of the housings of two diffusion and / or filtration units. The reactive polyurethane mixture then enters the diffusion and / or filtration units through these tubular fluid ports.

[0034] Each diffusion and / or filtration device rotates about a central axis perpendicular to the longitudinal axis of the housing, thereby conveying the reactive polyurethane mixture toward the end of the housing, where the polyurethane mixture solidifies and forms an end wall.

[0035] The advantages of the potting manifold and its manufacturing process disclosed herein include reduced material and manufacturing costs because the potting manifold does not require a cap, and reduced equipment and investment required because the production of the potting manifold only requires an injection molding machine and an injection mold.

[0036] Exemplary embodiments of the apparatus and processes disclosed herein are shown in the accompanying drawings and are described below. Detailed description of the attached figures

[0037] Figure 1 This is a schematic perspective view of the filling manifold 10 of this disclosure. The filling manifold 10 includes a four-fork-arm container having a planar bottom 11 and a peripheral outer wall 12 extending upward from the bottom 11. The bottom 11 of the container includes a central cross-shaped ridge 16 that separates the forks from each other. The peripheral outer wall 12 is higher in a region near the ends of the forks than the rest of the outer wall, thereby forming a U-shaped tab 15 extending upward from the top edge of the outer wall 12. A plurality of tongues 17 are disposed on the outer side of the peripheral outer wall 12, at the top edge of the peripheral outer wall 12 and facing outward. A horizontal plate 18 is located at the short face of the filling manifold 10, between the forks, at the top edge of the peripheral outer wall 12 and connecting the forks. At the end of each fork of the container, tubular outlet nozzles 13, 14 extend downward from the bottom 11 of the container. As shown, the first pair of tubular outlet nozzles 13 is longer than the second pair of tubular outlet nozzles 14.

[0038] Figure 2 yes Figure 1 A schematic side view of the filling manifold. Figure 3 yes Figure 1 A schematic front view of the filling manifold. Figure 4 This is a schematic bottom view of the manifold disclosed herein. (As shown) Figure 2 and Figure 3 As shown, the apex angle of the cross-shaped ridge 16 is 45°, and its base width is 9.18 mm.

[0039] Figure 5 This is a schematic perspective view of a welding station 20 for producing the manifold 10 of this disclosure. The welding station 20 accommodates two potted manifolds 10. Two substrates 21 are provided, each substrate carrying four heatable clamps 22. The potted manifold 10 is secured to a support 23, and the U-shaped tabs 15 of the potted manifold 10 are introduced into the heatable clamps 22 for welding.

[0040] Figure 6 yes Figure 5A schematic front view of the welding station. List of reference numerals 10. Filling manifold 11 Bottom 12 outer wall 13 First tubular outlet nozzle 14 Second tubular outlet nozzle 15 U-shaped protrusions 16. Cross-shaped ridge 17 Horizontal tongue plate 18 Horizontal Plate 20 Welding Stations 21 substrate 22 Heated clamps 23 stents

Claims

1. A filling manifold (10) comprising a four-fork container having a flat bottom (11) and a surrounding outer wall (12) extending upward from the bottom (11), and at the end of each fork of the container, tubular outlet nozzles (13, 14) extending downward from the bottom (11) of the container, wherein, The height of the surrounding outer wall (12) in the region near the end of the fork arm is greater than the height of the rest of the outer wall (12), thereby forming a U-shaped protrusion (15) extending upward from the top edge of the outer wall (12).

2. The potting manifold (10) according to claim 1, wherein, The bottom (11) of the container includes a central cross-shaped ridge (16) that separates the forks from each other.

3. The potting manifold (10) according to claim 1 or 2, wherein, The manifold has four tubular outlet nozzles (13, 14) forming two pairs (13, 14) of tubular outlet nozzles with opposite diameters and different lengths.

4. The potting manifold (10) according to any one of claims 1 to 3, wherein the potting manifold (10) is made of polyolefin.

5. The potting manifold (10) according to any one of claims 1 to 4, wherein, The legs of the U-shaped tabs (15) are connected to each other, thereby forming a cap at the end of the fork arm of the container.

6. A process for manufacturing a potting manifold, comprising the following steps: The filling manifold (10) according to any one of claims 1 to 4 is formed by injection molding, and then the legs of each U-shaped tab (15) are connected to each other to form a cap at the end of the fork arm of the container.

7. The process according to claim 6, wherein, The legs of each U-shaped tab (15) are connected to each other by welding.

8. The process according to claim 6, wherein, The legs of each U-shaped tab (15) are connected to each other by adhesive.

9. Use of a potting manifold according to any one of claims 1 to 5 in the potting of a filtration and / or diffusion device.

10. The use according to claim 9, comprising simultaneously introducing liquid potting resin into two filtration and / or diffusion devices.

Images