Hollow fiber membrane and method for producing same

Abstract

A hollow fiber membrane. The hollow fiber membrane is made from a polymer blend comprising an aromatic sulfone polymer and a polyoxazoline, the hollow fiber membrane comprises an inner surface facing the lumen, an outer surface facing the exterior, and an intermediate wall having a wall thickness, and the hollow fiber membrane is a monolithic asymmetric permeable hollow fiber membrane.

Description

[Technical field]

[0001] The present disclosure relates to porous membranes. Further, the present disclosure relates to processes for producing such membranes. The present disclosure further relates to the use of such membranes for the filtration and purification of liquid media. [Background technology]

[0002] Hollow fiber membranes are used for microfiltration in a very wide range of different industrial, pharmaceutical or medical applications. In these applications, membrane separation processes are becoming increasingly important, since they have the advantage that the substances to be separated are not thermally burdened or even damaged. Ultrafiltration membranes can be used for the removal or separation of macromolecules. Many further applications of membrane separation processes are known in the beverage industry, in biotechnology, in water treatment or sewage technology. Such membranes are generally classified according to their retention capacity, i.e. according to the capacity to retain particles or molecules of a certain size, or with respect to the effective pore size, i.e. the size of the pores that determine the separation behavior. Ultrafiltration membranes thereby cover the size range of the pores that determine the separation behavior from roughly 0.01 μm to approximately 0.1 μm, and therefore can retain particles or molecules in the size range of more than 20,000 Daltons, or more than approximately 200,000 Daltons. There is a need for better polymeric membranes. Summary of the Invention

[0003] Thus, in one aspect, the present disclosure provides a hollow fiber membrane made from a polymer blend comprising an aromatic sulfone polymer and a polyoxazoline, the hollow fiber membrane comprising an inner surface facing the lumen, an outer surface facing the exterior, and an intermediate wall having a wall thickness, the hollow fiber membrane being an integral asymmetric permeable membrane.

[0004] In another aspect, the present disclosure provides a method including providing a spinning solution including an aromatic sulfone polymer and a polyoxazoline, and a bore fluid including water, a solvent, and a non-solvent, and spinning a hollow fiber with a dope spinneret outer diameter in the range of 300 μm to 1000 μm, a spinneret needle outer diameter in the range of 200 μm to 1000 μm, and a spinneret needle inner diameter in the range of 100 μm to 1000 μm.

[0005] Various aspects and advantages of exemplary embodiments of the present disclosure are summarized. The above summary is not intended to describe each illustrated embodiment or every implementation of the present disclosure. Additional features and advantages are disclosed in the following embodiments. The figures and the detailed description that follow more particularly illustrate specific embodiments that utilize the principles disclosed herein. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a schematic perspective view in partial cross-section of an exemplary hollow fiber membrane. [Diagram 2] 1 is a cross section of an exemplary hollow fiber membrane. [Diagram 3] 1 is a SEM photograph of a cross section of a hollow fiber membrane according to the present disclosure, magnified 4,000 times. [Figure 4] 1 is a SEM photograph of a cross section of a hollow fiber membrane according to the present disclosure, magnified 20,000 times. [Diagram 5] 1 is a SEM photograph of a cross section of a hollow fiber membrane according to the present disclosure, magnified 4,000 times. [Figure 6] 1 is a SEM photograph of a cross section of a hollow fiber membrane according to the present disclosure, magnified 20,000 times. [Figure 7] 1 is a SEM photograph of a cross section of a hollow fiber membrane according to the present disclosure, magnified 4,000 times. [Figure 8] 1 is a SEM photograph of a cross section of a hollow fiber membrane according to the present disclosure, magnified 20,000 times. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Before describing any embodiment of the present disclosure in detail, it is understood that the present invention is not limited in its application to the details of use, construction, and arrangement of components set forth in the following description. The present invention is capable of other embodiments and can be practiced or carried out in various ways that will be apparent to those skilled in the art upon reading this disclosure. It is also understood that the terms and terminology used herein are for descriptive purposes and should not be considered limiting. The use of "including," "comprising," or "having," and variations thereof, herein means to encompass the items listed thereafter and equivalents thereof, as well as additional items. It is understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present disclosure.

[0008] One embodiment of a hollow fiber membrane according to the present disclosure is shown in Figure 1. Figure 1 illustrates a perspective view of a partial cross section of a portion of an exemplary hollow fiber membrane 12. The hollow fiber membrane 12 may have a continuous hollow lumen 16 extending from one end of the fiber to the other, an exterior surface 18 facing the outside and forming the outside of the fiber, an interior surface 20 facing the hollow lumen 16 and defining the boundary of the continuous hollow lumen 16, and an intermediate wall 22 having a wall thickness 26. The hollow fiber membrane 12 may be made from a polymer blend including an aromatic sulfone polymer and a polyoxazoline. The hollow fiber membrane may be an integral asymmetric permeable hollow fiber membrane.

[0009] The wall thickness 26 is measured between the outer surface 18 and the inner surface 20 of the hollow fiber membrane 12 and can be in the range of 20 μm to 300 μm, 30 μm to 200 μm, or 40 μm to 80 μm.

[0010] Similarly, to achieve the desired flow through the lumen of the hollow fiber membrane according to the present disclosure, particularly the preferred pressure drop, the inner diameter of the hollow fiber membrane described herein is preferably in the range of 50 μm to 800 μm, 50 μm to 700 μm, 50 μm to 600 μm, 100 μm to 500 μm, 100 μm to 400 μm, or 100 μm to 300 μm. The wall thickness and diameter (i.e., inner diameter or lumen diameter, and outer diameter) of the membranes described herein are also determined by conventional inspection methods, for example, using scanning or transmission electron micrographs (scanning electron micrograph, SEM or transmission electron micrograph, TEM, respectively), for example, at magnifications up to 20,000:1. In some embodiments, the hollow fiber membrane can have a serpentine structure extending from the inner surface to the outer surface. The inner upstream side of the membrane is characterized by a porous surface, which is structured by an isotropic nodular structure. When the pore compartments are connected within the membrane and therefore have a tortuous morphology, high trans membrane flow (TMF) occurs.

[0011] In some embodiments, the hollow fiber membrane may have two zones: a zone having the smallest pore size and a zone having the largest pore size. In some embodiments, the zone having the smallest pore size is adjacent to the inner surface. In some of these embodiments, the zone having the largest pore size is adjacent to the outer surface. In other embodiments, the zone having the smallest pore size is adjacent to the outer surface. In some of these embodiments, the zone having the largest pore size is adjacent to the inner surface. By "adjacent" it is meant that the largest or smallest pore size zone is located at a distance in the range of 0 μm to 8 μm from the surface. In some embodiments, the size of the pores in the zone having the smallest pore size can be in the range of 10 nm to 100 nm, 10 nm to 90 nm, 10 nm to 80 nm, 10 nm to 70 nm, 10 nm to 60 nm, 20 nm to 80 nm, 20 nm to 70 nm, 20 nm to 60 nm, 20 nm to 50 nm, 30 nm to 70 nm, 30 nm to 60 nm, 30 nm to 50 nm, 30 nm to 40 nm, 40 nm to 90 nm, 40 nm to 80 nm, 40 nm to 70 nm, 40 nm to 60 nm, or 40 nm to 50 nm. In some embodiments, the size of the pores in the zone having the smallest pore size can be less than 100 nm, 90 nm, 80 nm, 70 nm, 60 nm, 50 nm, 40 nm, 30 nm, or 20 nm. In some embodiments, the size of the pores in the zone with the smallest pore size can be greater than 10 nm, 15 nm, 20 nm, 25 nm, 30 nm, or 40 nm. In some embodiments, the size of the pores in the zone with the largest pore size can be in the range of 0.05 μm to 10 μm. The average pore size of the zone with the largest pore size is greater than the average pore size of the zone with the smallest pore size. The zone with the smallest pore size can form a retaining layer. When the zone with the smallest pore size is adjacent to the outer surface, the retaining layer is adjacent to the outer surface of the membrane and can form a more conductive membrane structure for filtering liquids, such as biopharmaceuticals.In some embodiments, the hollow fiber membrane has a first zone of pores and a second zone of pores, the first zone of pores adjacent to the inner surface and the second zone of pores adjacent to the outer surface, and the density of pores in the first zone is greater than the density of pores in the second zone. In some embodiments, the hollow fiber membrane has a first zone of pores and a second zone of pores, the first zone of pores adjacent to the inner surface and the second zone of pores adjacent to the outer surface, and the density of pores in the second zone is greater than the density of pores in the first zone.

[0012] The average pore diameter or pore size of the pores can be determined, for example, by the method described in US Patent Application Publication No. 2017 / 0304780 (Asahi et al.). The average pore diameter or pore size of the pores can be determined by photographing the cross section of the hollow fiber with a scanning electron microscope (SEM). For example, the magnification is set to 50,000 times, and the field of view is set to a cross section perpendicular to the length direction of the hollow fiber, or a cross section parallel to the length direction, and horizontally passing through the center of the hollow part. After photographing the set field of view, the field of view to be photographed is moved horizontally in the film thickness direction, and the next field of view is photographed.

[0013] This photographing operation is repeated until a cross-sectional photograph of the membrane from the outer surface to the inner surface is taken without any gaps, and the obtained photographs are combined to obtain one membrane cross-sectional photograph. In this cross-sectional photograph, the average pore diameter of the pores in each region (2 μm in the circumferential direction of the membrane) × (1 μm from the outer surface to the inner surface) from the outer surface to the inner surface is calculated, and the gradient structure of the membrane cross section is quantified every 1 μm from the outer surface to the inner surface. By such quantification, it can be determined whether the membrane has a gradient type porous structure or not.

[0014] The average pore diameter or pore size can be calculated by a method using image analysis. The distinction between pores and solid parts is based on brightness, and non-distinguishing parts and noise are corrected by a freehand tool. The edges form the outline of the pores. After binarization, the diameter of the pores is calculated from the area value of the pores assuming that the pores are perfect circles. The calculation is performed for all pores, and the average pore diameter is calculated for each area of ​​1 μm x 2 μm. The pores located at the edge of the field of view and partially within the field of view are also counted (i.e., the area of ​​the pores partially within the field of view is calculated by assuming that the area of ​​one complete circle).

[0015] Another embodiment of a hollow fiber membrane according to the present disclosure is shown in Figure 2. Figure 2 illustrates a cross-sectional view of an exemplary hollow fiber membrane 112. The hollow fiber membrane 112 can have a continuous hollow lumen 116 extending from one end of the fiber to the other, an exterior surface 118 facing the exterior and forming the exterior of the fiber, an interior surface 120 facing the hollow lumen 116 and defining the boundary of the continuous hollow lumen 116, and an intermediate wall 122 having a wall thickness 126. The hollow fiber membrane 112 can have a first cross-sectional zone 128 that begins at the interior surface 120 and extends inwardly (and in some embodiments laterally) into the intermediate wall 122, terminating a distance into the intermediate wall 122. In the first cross-sectional zone 128, the pore size decreases as one progresses in the direction of the arrow over the distance midway between the inner and outer surfaces across the membrane wall (i.e., the pore size decreases as one progresses in the direction from the inner surface 120 to the outer surface 118 across the first cross-sectional zone (the pore size measurements are taken along a vector that defines the shortest cross-sectional distance from the inner surface of the membrane to the outer surface of the membrane).

[0016] The hollow fiber membrane 112 may have a second cross-sectional zone 130 that begins where the first cross-sectional zone ends and extends (in some embodiments, laterally) to the membrane's outer surface 118. In the second cross-sectional zone 130, the pore size increases as one progresses in the direction of the arrow (i.e., the pore size increases as one progresses between the ends of the second cross-sectional zone in the direction from the end of the first cross-sectional zone inside the wall to the outer surface). In some embodiments, the pore size at the outer surface 118 may be smaller than the pore size at the inner surface 112.

[0017] In some embodiments, in the first cross-sectional zone 128, the pore size decreases as one progresses in the direction of the arrow for about 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% of the distance across the membrane wall (i.e., the pore size decreases as one progresses in the direction from the inner surface 120 to the outer surface 118 across the first cross-sectional zone (the ... (Size measurements are taken along a vector defining the shortest cross-sectional distance from the membrane's inner surface to the membrane's outer surface.) In the second cross-sectional zone 130, the pore size increases as one progresses in the direction of the arrow (i.e., the pore size increases as one progresses between the ends of the second cross-sectional zone in a direction from the end of the first cross-sectional zone inside the wall to the outer surface). The pore size at the outer surface 118 may be smaller than the pore size at the inner surface 112.

[0018] In some embodiments, the pore size decreases as one progresses in the direction of the arrow over approximately 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% of the distance across the membrane wall (i.e., the pore size decreases as one progresses in the direction from the inner surface 120 to the outer surface 118 across the first cross-sectional zone (the pore size measurement defines the shortest cross-sectional distance from the inner surface of the membrane to the outer surface of the membrane). vector). In the second cross-sectional zone 130, the pore size increases as one progresses in the direction of the arrow (i.e., the pore size increases as one progresses from the end of the first cross-sectional zone interior to the outer surface, between the ends of the second cross-sectional zone). The pore size at the outer surface 118 may be between about 0.05 micrometers and 3 micrometers, and the pore size at the inner surface 112 may be between about 0.05 micrometers and 5 micrometers.

[0019] In some embodiments, the pore size decreases as one progresses in the direction of the arrow over approximately 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% of the distance across the membrane wall (i.e., the pore size decreases as one progresses in the direction from the inner surface 120 to the outer surface 118 across the first cross-sectional zone (the pore size measurements are taken along a vector that defines the shortest cross-sectional distance from the inner surface of the membrane to the outer surface of the membrane). In the second cross-sectional zone 130 (i.e., pore size increases as one progresses in the direction of the arrows between the ends of the second cross-sectional zone in the direction from the end of the first cross-sectional zone inside the wall to the outer surface.) The pore size at the outer surface 118 may be about 0.05 micrometers to 3 micrometers, the pore size at the inner surface 112 may be about 0.05 micrometers to 5 micrometers, and the pore size transition location may be about 0.015 micrometers to 0.035 micrometers.

[0020] The pore size transition location (i.e., the location where the first cross-sectional zone ends and transitions to the beginning of the second cross-sectional zone) may form at least a portion of the retention layer or retention zone in the hollow fiber membrane. The retention layer or retention zone is the section of the hollow fiber membrane that has the highest (i.e., the largest) ability or capacity to capture small contaminant components of the liquid sample when the liquid sample is filtered through the membrane. Typically, the liquid sample filtered through the hollow fiber membrane contains a desired component that is preferably collected in the filtrate after filtration, and a contaminant component that is preferably captured by the membrane. The retention layer or retention zone filters contaminants from the liquid sample primarily based on the size difference between the contaminant component and the desired component. The desired component(s) in the liquid sample are of a size that can pass through the retention layer or retention zone and can be collected in the filtrate, resulting in a purified liquid sample.

[0021] In some embodiments, the pore size decreases as one progresses in the direction of the arrows from the outer surface to a distance of 3 micrometers to 50 micrometers (i.e., the pore size decreases as one progresses from the inner surface 120 to the outer surface 118 between the ends of the first cross-sectional zone. (The pore size measurements are taken along a vector that defines the shortest cross-sectional distance from the inner surface of the membrane to the outer surface of the membrane). In the second cross-sectional zone 130, the pore size increases as one progresses in the direction of the arrows (i.e., the pore size increases as one progresses from the end of the first cross-sectional zone inside the wall to the outer surface between the ends of the second cross-sectional zone). The pore size at the outer surface 118 may be smaller than the pore size at the inner surface 112.

[0022] In some embodiments, the wall thickness of the hollow fiber membrane is 30 micrometers to 100 micrometers, 40 micrometers to 90 micrometers, or 50 micrometers to 65 micrometers, and the pore size of the membrane at the inner surface facing the lumen decreases as one progresses in the direction from the inner surface to the outer surface between the ends of the first cross-sectional zone to a distance of 3 micrometers to 50 micrometers from the outer surface. (The pore size measurement is taken along a vector that defines the shortest cross-sectional distance from the inner surface of the membrane to the outer surface of the membrane). In the second cross-sectional zone 130, the pore size increases as one progresses in the direction of the arrow (i.e., the pore size increases as one progresses in the direction from the end of the first cross-sectional zone inside the wall to the outer surface between the ends of the second cross-sectional zone). The pore size at the outer surface 118 may be smaller than the pore size at the inner surface 112.

[0023] In some embodiments, the pore size at the outer surface is between 0.05 micrometers and 3 micrometers, the pore size at the inner surface is between about 0.05 micrometers and 5 micrometers, and the pore size transition location is between about 0.015 micrometers and 0.035 micrometers.

[0024] In some embodiments, the wall thickness of the hollow fiber membrane is between 30 micrometers and 100 micrometers, the pore size at the outer surface is between 0.05 micrometers and 3 micrometers, the pore size at the inner surface is between about 0.05 micrometers and 5 micrometers, and the minimum or smallest pore size in the membrane is between 0.015 micrometers and 0.035 micrometers.

[0025] The aromatic sulfone polymers of the present disclosure can be used, such as polysulfone, polyethersulfone, polyphenylenesulfone, polyarylethersulfone, or copolymers or modifications of these polymers, or mixtures of these polymers. In a preferred embodiment, the aromatic sulfone polymer can be a polysulfone or polyethersulfone having repeating molecular units as shown in the following formulas (I) and (II): [ka]

[0026] More preferably, as aromatic sulfone polymer, polyethersulfone according to formula (II) is used, since it has a lower hydrophobicity than, for example, polysulfone. Polysulfone may have a molecular weight of about 72 kg / mol.

[0027] In some embodiments, the polyoxazoline of the present disclosure can be poly(2-oxazoline). Poly(2-oxazoline) can be prepared by cationic ring-opening polymerization of various 2-oxazoline monomers. Polymerization of 2-alkyl substituted 2-oxazoline monomers provides poly(2-alkyl-2-oxazoline).

[0028] In some embodiments, the poly(2-oxazoline) of the present disclosure can be poly(2-ethyl-2-oxazoline) (PEtOx). Poly(2-oxazoline) has high potential for protein repulsion. Residues of poly(2-oxazoline) can be altered to change the properties of the polymer, for example, from hydrophilic to hydrophobic. Poly(2-oxazoline) can have a molecular weight of about 25 kg / mol to about 500 kg / mol. Poly(2-oxazoline) can have a molecular weight from about 50 kg / mol.

[0029] Poly(2-ethyl-2-oxazoline) may have a molecular weight of about 25 kg / mol to about 500 kg / mol. Poly(2-ethyl-2-oxazoline) may have a molecular weight of about 25 kg / mol to about 100 kg / mol. Poly(2-ethyl-2-oxazoline) may have a molecular weight of about 50 kg / mol.

[0030] The poly(2-oxazoline) may be present in a concentration of 0.5% to 30%, 1% to 30%, 5% to 30%, or 10% to 30% by weight based on the weight of the membrane. The poly(2-oxazoline) may be present in a concentration of more than 0.5%, more than 1%, more than 2%, more than 3%, more than 4%, more than 5%, more than 6%, more than 7%, more than 8%, more than 9%, more than 10%, more than 15%, or more than 20% by weight based on the weight of the membrane. The poly(2-oxazoline) may be present in a concentration of less than 30%, less than 28%, less than 25%, less than 23%, less than 20%, less than 15%, or less than 10% by weight based on the weight of the membrane.

[0031] The aromatic sulfone polymer and poly(2-oxazoline) may be distributed throughout the membrane. The aromatic sulfone polymer and poly(2-oxazoline) may be uniformly distributed throughout the membrane. The aromatic sulfone polymer and poly(2-oxazoline) may be uniformly distributed throughout the membrane.

[0032] In some embodiments, the polyoxazoline may be distributed throughout the membrane. The poly(2-oxazoline) may be distributed throughout the membrane. The poly(2-oxazoline) may be uniformly distributed throughout the membrane. In some embodiments, the poly(2-oxazoline) may be uniformly distributed throughout the membrane. The poly(2-ethyl-2-oxazoline) may be distributed throughout the membrane. In some embodiments, the poly(2-ethyl-2-oxazoline may be uniformly distributed throughout the membrane. In some embodiments, the poly(2-oxazoline) may not be uniformly distributed throughout the membrane. In some embodiments, the poly(2-ethyl-2-oxazoline) may not be uniformly distributed throughout the membrane. For example, the concentration of poly(2-ethyl-2-oxazoline) adjacent to the exterior surface may be higher than the concentration of poly(2-ethyl-2-oxazoline) adjacent to the interior surface.

[0033] In some embodiments, the polymer blend may further include an additional hydrophilic polymer. Exemplary hydrophilic polymers may include polyvinylpyrrolidone, polyethylene glycol, glycerol, polyvinyl alcohol, polyglycol monoesters, polysorbitates, carboxymethylcellulose, polyacrylic acid, polyacrylates, or modifications or copolymers of these polymers. In some embodiments, the hydrophilic polymer may be polyethylene glycol. In some embodiments, the polymer blend does not include polyvinylpyrrolidone. In some embodiments, the polymer blend may be a hydrophobic polymer blend.

[0034] In some embodiments, the hydrophilic polymer may be present in a concentration of 1% to 75% by weight based on the weight of the membrane. In some embodiments, the polymer blend may include more than 7%, more than 10%, more than 20%, more than 30%, more than 40%, more than 50%, more than 60%, more than 70%, more than 80%, or more than 90% by weight of polyvinylpyrrolidone. In some embodiments, the polymer blend may include less than 3%, less than 2%, or less than 1% by weight of polyvinylpyrrolidone.

[0035] In some embodiments, the polymer blend may include a solvent and a non-solvent. Exemplary blends may include glycol, glycerol, butyrolactone, ε-caprolactam, N-methylpyrrolidone, water, or combinations thereof.

[0036] It is also preferred that the wall thickness of the hollow fiber membrane disclosed herein is in the range of 10 μm to 400 μm, 20 μm to 300 μm, 30 μm to 200 μm, or 40 μm to 80 μm. At wall thicknesses below 20 μm, the mechanical properties of the hollow fiber membrane may fall below a certain desired level, while at wall thicknesses above 400 μm, the flow rate through the membrane is reduced. Similarly, to achieve the desired flow through the lumen of the hollow fiber membrane according to the present disclosure, particularly the preferred pressure drop, the inner diameter of the hollow fiber membrane described herein is preferably in the range of 50 μm to 800 μm, 50 μm to 700 μm, 50 μm to 600 μm, 100 μm to 500 μm, 100 μm to 400 μm, or 100 μm to 300 μm.

[0037] The hollow fiber membrane according to the present invention preferably has a water permeability of at least 0.01 mL / (cm 2 ·min ·bar), preferably at least 0.1 mL / (cm 2 ·min ·bar), more preferably at least 0.15 mL / (cm 2 ·min ·bar), even more preferably at least 0.2 mL / (cm 2The hollow fiber membranes disclosed herein exhibit a transmembrane flux of 0.01 mL / (cm 2 ) for water. This ensures sufficient and stable filtration capacity for the application. 2 ·min·bar)~10mL / (cm 2 ·min ·bar), preferably 0.15 mL / (cm 2 ·min·bar)~5mL / (cm 2 ·min ·bar), more preferably 0.1 mL / (cm 2 ·min·bar)~3mL / (cm 2 It is further preferred that the membrane exhibits a flux within the range of 1000 sq. m.min.bar. Fluxes within these ranges provide sufficient and stable filtration capacity for the preferred application without compromising retention capacity or mechanical stability. The fluxes are preferably determined as described in the experimental section.

[0038] Hollow fiber membranes according to the present disclosure can be made by the methods disclosed in WO 2019 / 229667(A1) (Malek et al.), which is incorporated by reference in its entirety. In some embodiments, the hollow fiber membranes can be made from a homogenous spinning solution of aromatic sulfone polymer and poly(2-oxazoline) and a bore liquid. The bore liquid can include water, a solvent, and a non-solvent. Accordingly, the present disclosure further provides a method for producing a hollow fiber membrane, the method comprising the steps of providing a spinning solution comprising an aromatic sulfone polymer and a polyoxazoline, and a bore liquid comprising water, a solvent and a non-solvent, and spinning a hollow fiber of the aromatic sulfone polymer and poly(2-oxazoline) with an outer spinneret diameter in the range of 300 μm to 1000 μm, an outer spinneret needle diameter in the range of 200 μm to 1000 μm, and an inner spinneret needle diameter in the range of 100 μm to 1000 μm.

[0039] In some embodiments, the spinning solution may further comprise a hydrophilic polymer. A long-chain polymer is advantageously used as at least one hydrophilic polymer that exhibits compatibility with the hydrophobic aromatic sulfone polymer. The aromatic sulfone polymer has repeating polymer units that are hydrophilic in themselves. The hydrophilic polymer is preferably polyvinylpyrrolidone, polyethylene glycol, polyvinyl alcohol, polyglycol monoester, polysorbate such as polyoxyethylene sorbitan monooleate, carboxymethyl-cellulose, or modifications or copolymers of these polymers. Polyvinylpyrrolidone and polyethylene glycol are particularly preferred.

[0040] In some embodiments, the spinning solution includes polyethylene glycol (PEG). In some embodiments, the polyethylene glycol in the spinning solution can have a molecular weight (MW) of about 100 g / mol to about 1,800 g / mol. In some embodiments, the polyethylene glycol in the spinning solution can have a molecular weight (MW) of about 200, 400, 500, 600, 1000, 1200, or 1,500 g / mol.

[0041] In the context of the present disclosure, the at least one hydrophilic polymer may also comprise a mixture of different hydrophilic polymers. The hydrophilic polymer may be, for example, a mixture of chemically different hydrophilic polymers or hydrophilic polymers having different molecular weights, for example a mixture of polymers with molecular weights differing by a factor of 5 or more. Preferably, the at least one hydrophilic polymer comprises a mixture of polyvinylpyrrolidone or polyethylene glycol and a hydrophilically modified aromatic sulfone polymer. It is also preferred that the hydrophilically modified aromatic sulfone polymer is a sulfonated aromatic sulfone polymer, in particular a sulfonated modification of the hydrophobic aromatic sulfone polymer used in the membranes and methods according to the present disclosure. A mixture of polyethersulfone, sulfonated polyethersulfone, and polyvinylpyrrolidone may be particularly advantageously used. The presence of the hydrophilically modified aromatic sulfone polymer results in hollow fiber membranes with particularly stable hydrophilic properties in application. The hydrophilic polymer may be present in an amount of 5% to 50% by weight based on the weight of the solution.

[0042] After preferably degassing and filtering to remove gas and undissolved particles, the homogenous spinning solution is extruded through the annular gap of a conventional hollow fiber die, where, in combination with the bore fluid, hollow fibers are produced. The bore fluid, i.e., the coagulation medium for the aromatic sulfone polymer and at the same time an internal filler that stabilizes the lumen of the hollow fiber, is extruded through a central nozzle opening, located coaxially with the annular gap of the hollow fiber die. In this disclosure, the terms "hollow fiber die" and "spinneret" may be used interchangeably. The bore fluid may include water and glycerol, but may also include additional components and / or solvents, such as polyethylene glycol (PEG). Preferably, the bore fluid further includes a non-solvent for the membrane-forming polymer, such as water, a low molecular weight polyethylene glycol having an average molecular weight less than 1000 Daltons, or a low molecular weight alcohol, such as ethanol or isopropanol, and / or a protic solvent, such as ε-caprolactam. Preferably, the bore fluid comprises water, N-methylpyrrolidone, and polyethylene glycol. The solvent may be present in an amount of 5% to 70% by weight based on the weight of the solution.

[0043] The solvent system used must be compatible with the aromatic sulfone polymer and poly(2-oxazoline) used so that a homogeneous spinning solution can be produced. The solvent system preferably comprises a polar aprotic solvent such as dimethylformamide, dimethylacetamide, dimethylsulfoxide, N-methylpyrrolidone, or a mixture thereof, or a protic solvent such as ε-caprolactam. Furthermore, the solvent system may contain up to 70% by weight of a latent solvent, where in the context of the present invention a latent solvent is understood as a solvent in which the sulfone polymer dissolves poorly or only at high temperatures. If ε-caprolactam is used as the solvent, for example butyrolactone, propylene carbonate or polyalkylene glycols can be used. In addition, the solvent system may contain a non-solvent for the membrane-forming polymer, for example water, glycerin, low molecular weight polyethylene glycols with an average molecular weight of less than 1000 Daltons, or low molecular weight alcohols, for example ethanol or isopropanol. Preferably, the solvent system contains N-methylpyrrolidone.

[0044] In one embodiment, the spinning solution comprises an aromatic sulfone polymer, poly(2-oxazoline), polyethylene glycol, N-methylpyrrolidone, and water. In another embodiment, the spinning solution comprises polyethersulfone, poly(2-ethyl-2-oxazoline), polyethylene glycol, N-methylpyrrolidone, and water. In yet another embodiment, the spinning solution comprises polyethersulfone, poly(2-ethyl-2-oxazoline), PEG200 or PEG1500, N-methylpyrrolidone, and water.

[0045] The width of the annular gap and the inner diameter of the central nozzle opening were selected according to the desired characteristics of the hollow fiber membrane according to the present disclosure, i.e., the spinneret exhibits a dope spinneret outer diameter in the range of 300 μm to 1000 μm, a spinneret needle outer diameter in the range of 200 μm to 1000 μm, and a spinneret needle inner diameter in the range of 100 μm to 1000 μm.

[0046] After leaving the hollow fiber die (i.e. the spinneret) and before entering the coagulation medium, the hollow fibers preferably pass through an environmental control zone with defined environmental conditions. Here, the environmental control zone can take the form of, for example, an enclosed chamber. For technical reasons, it may be necessary for an air gap to exist between the hollow fiber die and the environmental control zone. However, this gap should advantageously be as small as possible, and the environmental control zone is preferably located immediately after the hollow fiber die.

[0047] In this regard, it is preferred that the hollow fibers have a retention time in the environmental control zone of 0.5 seconds to 10 seconds, the environmental control zone containing air having a relative humidity of 20% to 95% and a temperature of 25° C. to 75° C. The retention time of the hollow fibers in the environmental control zone is preferably 0.5 seconds to 5 seconds. To establish stable conditions in the environmental control zone, air is passed through the environmental control zone preferably at a speed of less than 0.5 m / s, particularly preferably at a speed in the range of 0.15 m / s to 0.35 m / s.

[0048] In one embodiment, the environmentally controlled zone contains air having a relative humidity of 20%-95% and a temperature of 25°C-75°C. In one embodiment, the environmentally controlled zone contains air having a relative humidity of 60%-75% and a temperature of 30°C-50°C. In one embodiment, the environmentally controlled zone contains air having a relative humidity of 75%-90% and a temperature of 30°C-50°C. In one embodiment, the environmentally controlled zone contains air having a relative humidity of 60%-75% and a temperature of 50°C-70°C. In one embodiment, the environmentally controlled zone contains air having a relative humidity of 75%-90% and a temperature of 50°C-70°C.

[0049] When the hollow fiber is guided through the environmental control zone, which is set to the environmental conditions preferred in the method according to the present disclosure, a pre-coagulation of the hollow fiber is induced on the outside of the hollow fiber by absorption of water vapor acting as a non-solvent, after which the hollow fiber coagulates. At the same time, the retention time should be set within the range preferred in the method according to the present disclosure. These measures influence the formation of the outer layer of the hollow fiber membrane according to the present disclosure, so that in some embodiments, the outer layer can obtain an essentially isotropic structure.

[0050] After passing through the environmental control zone, the pre-coagulated hollow fibers are guided through an aqueous coagulation medium, preferably adjusted to 20° C. to 90° C., to complete the formation of the membrane structure. The coagulation medium is preferably adjusted to a temperature within the range of 20° C. to 90° C. Preferably, the coagulation medium, e.g., precipitation bath, is water or a water bath.

[0051] In the coagulation medium, the membrane structure is first precipitated to the extent that it already has sufficient stability, and can be deflected in the coagulation medium, for example by deflection rollers or similar means. During the further course of the process, the coagulation is completed and the membrane structure is stabilized. The solvent system and the extraction of soluble substances are carried out here at the same time. Generally, most of the hydrophilic polymer is extracted from the membrane structure, and the coagulation bath simultaneously functions as a washing bath or extraction bath. Water is preferably used as the coagulation medium or washing medium in the coagulation bath or washing bath.

[0052] After extraction, the hollow fiber membranes may be dried. The dried membranes may then be wound into a coil. The hollow fiber membranes according to the present disclosure may then be textured (if necessary) to improve the exchange properties of the bundled hollow fiber membranes. Finally, the hollow fiber membranes may be processed using conventional methods, for example, wound onto a coil or directly formed into a bundle with a suitable thread count and length. To ensure the spacing of the hollow fiber membranes relative to each other and better flow around the individual hollow fiber membranes in the bundle, auxiliary threads, for example in the form of multifilament yarns, may be added to the hollow fiber membranes before the production of the bundle.

[0053] According to the present disclosure, the concentration of the sulfone polymer in the spinning solution is preferably in the range of 10% to 35% by weight. Below a concentration of 10% by weight, disadvantages may arise, especially with regard to the mechanical stability of the resulting hollow fiber membrane. The sulfone polymer may also contain additives, such as, for example, antioxidants, nucleating agents, UV absorbers, etc., to selectively modify the membrane properties. The concentration of poly(2-oxazoline) in the spinning solution may be in the range of 5% to 30% by weight.

[0054] In some embodiments, the spinning solution can have 10% to 35% by weight of the aromatic sulfone polymer by weight of the solution, 5% to 30% by weight of the poly(2-oxazoline) by weight of the solution, 25% to 70% by weight of the solvent by weight of the solution, 5% to 45% by weight of the hydrophilic polymer by weight of the solution, and 0% to 10% by weight of the sulfonated aromatic sulfone polymer. In some embodiments, the spinning solution can have 20% to 30% by weight of the aromatic sulfone polymer by weight of the solution, 7% to 15% by weight of the poly(2-oxazoline) by weight of the solution, 30% to 40% by weight of the solvent by weight of the solution, and 25% to 50% by weight of the hydrophilic polymer by weight of the solution.

[0055] In some embodiments, the spinning solution can have 10% to 35% by weight polyethersulfone by weight of the solution, 10% to 30% by weight poly(2-ethyl-2-oxazoline) by weight of the solution, and 50% to 70% by weight N-methylpyrrolidone by weight of the solution.

[0056] In some embodiments, the spinning solution can have 10% to 35% by weight of polyethersulfone by weight of the solution, 5% to 20% by weight of poly(2-ethyl-2-oxazoline) by weight of the solution, 20% to 70% by weight of N-methylpyrrolidone by weight of the solution, and 5% to 40% by weight of polyethylene glycol by weight of the solution.

[0057] In some embodiments, the spinning solution can have from 5% to 18% by weight of poly(2-ethyl-2-oxazoline) based on the weight of the solution.

[0058] In some embodiments, the spinning solution can have 25% to 75% by weight of N-methylpyrrolidone based on the weight of the solution. In some embodiments, the spinning solution can have 25% to 50% by weight of N-methylpyrrolidone based on the weight of the solution. In some embodiments, the spinning solution can have 50% to 75% by weight of N-methylpyrrolidone based on the weight of the solution.

[0059] In some embodiments, the polyethylene glycol component of the spinning solution can have a molecular weight of 200 g / mol (PEG200), 400 g / mol (PEG400), 600 g / mol (PEG600), 1000 g / mol (PEG1000), 1200 g / mol (PEG1200), or 1500 g / mol (PEG1500).

[0060] In some embodiments, the polyethylene glycol component of the spinning solution can have a molecular weight of 200 g / mol to 600 g / mol. In some embodiments, the polyethylene glycol component of the spinning solution can have a molecular weight of 500 g / mol to 1000 g / mol. In some embodiments, the polyethylene glycol component of the spinning solution can have a molecular weight of 1000 g / mol to 1500 g / mol.

[0061] The present invention provides polymer membranes with excellent protein repellency. Therefore, these membranes clog slower, exhibit higher throughput behavior, and therefore exhibit longer life. These membranes also exhibit asymmetric structure, which is promising for the preparation of highly selective membranes. The protein repellency of the membrane can provide better filtration properties due to less fouling and higher throughput.

[0062] In some embodiments, the hollow fiber membranes of the present disclosure can be used for multiple extracorporeal blood purification procedures, including dialysis. In some embodiments, the hollow fiber membranes of the present disclosure can be suitable for use in applications in the field of filtration. Due to the unique combination of properties of the hollow fiber membranes described herein, and preferably obtained from the methods described herein, the present disclosure further provides the use of the membranes described herein for the filtration of liquids, such as microfiltration, or ultrafiltration. "Microfiltration" and "ultrafiltration" have their common meanings in the art. Preferably, the uses described herein include the clarification and / or purification of liquid media, particularly aqueous liquids. In some embodiments, the liquid that can be filtered by the hollow fiber membranes of the present disclosure can include biological products selected from adeno-associated virus (AAV) capsids, viruses, and virus-like particles. The hollow fiber membranes can have a yield of adeno-associated virus (AAV) capsid of greater than 80%, 85%, 90%, 95%, or 96%, while removing contaminating bacteriophage or viruses of 35 nm to 40 nm or larger at a log reduction value (LRV) of greater than 4, and contaminating bacteriophage or viruses of 50 nm or larger, such as mammalian viruses, at a log reduction value (LRV) of 5, 6, or 7. The hollow fiber membranes can provide high permeability (yield) of AAV and can be operated at a variety of transmembrane pressures, for example, 7 psi to 30 psi. The hollow fiber membranes can be operated using either a constant flow rate or a constant pressure. These membrane attributes allow for faster processing times and greater versatility in the processing equipment used to perform the filtration, and can be operated under a variety of conditions.

[0063] The following examples are intended to illustrate, but not limit, the disclosure. EXAMPLES

[0064] Objects and advantages of this invention are further illustrated by the following examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this invention.

[0065] The following abbreviations are used herein: mL = milliliter, L = liter, kg = kilogram, g = gram, mg = milligram, m = meter, cm = centimeter, mm = millimeter, nm = nanometer, s = seconds, min = minutes, hr = hours, psi = pounds per square inch, and wt.% = weight percent.

[0066] Scanning electron microscopy (SEM) images were obtained using an FEI 250 scanning electron microscope (Thermo Fisher Scientific, Waltham, MA) equipped with xT Microscope Control operating software or a Coxem EM-30AX scanning electron microscope (Coxem Company, Daejeon, Korea) equipped with NanoStation operating software. [Table 1]

[0067] Method A: Method for determining transmembrane flux (TMF) A hollow fiber membrane test module was prepared by placing 10 hollow fiber membranes (10 cm long) into a straight cylindrical polycarbonate tube (8 mm inner diameter, 60 mm long). The tube had a side-located outlet located approximately halfway between the two ends of the cylinder. The hollow fiber membranes were embedded into the tube using hot melt adhesive on both ends of the tube. After solidification, the protruding ends of the hollow fiber membranes and excess adhesive were removed using a razor blade. The membrane openings were visually inspected, and only modules in which all of the hollow fiber membranes had open, unobstructed lumen portions were used. Each end of the polycarbonate tube was capped with a cap with an open port for attachment to flexible tubing. The completed test module was mounted on a stand, placed vertically, filled with water, and connected to a measurement system.

[0068] The measurement system included a pressure pot filled with water and connected to one end of the test module by flexible tubing, two pressure gauges (a first pressure gauge located between the pressure pot and the test module, and a second pressure gauge located downstream from the opposite end of the module), and a flush valve located downstream from the module and the second pressure gauge. The measurement system also included a heater located between the pressure pot and the first pressure gauge, through which the water passed. The heater warmed the water to 25°C.

[0069] The pressure pot was pressurized to 5.8 psi. At the start of the test, the air in the system was replaced by closing the side outlet and opening the flush valve. The flush valve was then closed and the side outlet was opened to operate the module in a dead-end filtration configuration. Water flowed from the pressure pot through the lumen of the membrane filtering through the membrane wall and exited the module through the side outlet into the first collection vessel. The module was flushed with water for 4 minutes and collected in the first collection vessel through the side outlet. After the 4-minute flush, the first collection vessel was replaced with a tared second collection vessel. Filtered water was collected in the second collection vessel for 60 seconds. The amount of water collected in the second vessel was determined using a digital balance. The differential pressure was determined by reading the difference between the two pressure gauges.

[0070] Based on the membrane dimensions, the differential pressure, and the weight of water, the transmembrane flux (TMF) was calculated according to Equation 1.

number

[0071] Method B: Method for determining the viscosity of the spinning solution (polymer blend) The viscosity of the casting solution was measured at 60 °C and 10 s using a HAAKE RheoStress 1 rheometer (Thermo Fisher Scientific, Waltham, MA) equipped with a Z20DIN sensor device (Thermo Fisher Scientific). -1 The measurements were performed at a shear rate of .

[0072] Method C: Method for determining protein throughput using Bovine Serum Albumin (BSA) A 5 mg / mL solution of bovine serum albumin (BSA) (MilliporeSigma, Burlington, MA) was prepared by vigorously mixing the protein with phosphate buffer (pH 7.4, 4 mS / cm). The solution was filtered through a 0.2 micron filter and used within 8 hours of preparation. The concentration of the BSA solution was examined using ultraviolet spectroscopy at 280 nm.

[0073] Hollow fiber membrane test modules were prepared and tested according to the following procedure. Polycarbonate tubes with a length of 50 mm and an internal diameter of 4 mm were used. A single hole was drilled in the side of each tube approximately 15 mm from one end. An open hole connector was attached to the hole using a UV / visible light curing adhesive to form a side port. Approximately 25-30 hollow fibers (15 cm long) were placed in each tube. The inserted hollow fibers were cut with a razor blade to provide approximately 15 mm of hollow fiber overhang at each end of the tube. The overhanging hollow fibers were sealed with wax and then potted in the tube using polyurethane resin. After curing for 24 hours, the overhanging ends were removed using a razor blade. The openings of the membranes were inspected using a microscope, and only tubes in which all of the hollow fiber membranes had open, unobstructed lumen portions were used. The total surface area of ​​the internal hollow fibers (i.e., the total surface area of ​​the lumens) was approximately 5 cm for the 50 mm tube. 2 ~6cm2 It was.

[0074] The membrane test module was mounted vertically, parallel to the vertically mounted pressure pot. A three-way valve was placed at the bottom of the pressure pot. MASTERFLEX tubing (size 14, Cole-Parmer, Vernon Hills, Ill.) was used to connect the three-way valve to the bottom of the vertically mounted membrane test module. The pressure pot was first filled with ultrapure water (obtained from MilliporeSigma's MILLI-Q water system), sealed, and pressurized to approximately 5 psi. The three-way valve between the pressure pot and the test module was opened to allow water to flow into the lumen of the hollow fibers and out the open top end of the tubing. Once the lumen of the hollow fibers was filled with water, the top of the test module was capped. The pressure was gradually increased to 30 psi. A side port on the test module was used to allow the filtrate to exit the module into the first collection vessel. Water was filtered through the hollow fiber module at 30 psi for a minimum of 10 minutes. After the initial water flushing period, the three-way valve at the bottom of the pressure pot was closed to remove any water remaining in the pressure pot.

[0075] The pressure pot was depressurized and filled with 5 mg / mL BSA solution. The pressure pot was then sealed and pressurized to 30 psi, and the three-way valve was opened. The filtrate was collected in a second collection vessel that was placed on a digital balance and tared. The BSA solution was filtered through the membrane for a minimum of 20 minutes. The amount of BSA solution that passed through the membrane during the filtration time was calculated as the mass of BSA solution (kg) filtered during a specific filtration time divided by the filtration area of ​​the hollow fiber (surface area of ​​the inner fiber wall) (kg / (m 2 The time course was recorded as 10 min.

[0076] Method D. Preparation of Phi-X174 phage cultures Phi-X174 bacteriophage (ATCC 13706-B1) was obtained from ATCC (Manassas, VA). Phage cultures were generated by growing 1 L cultures of E. coli (ATCC 13706) in CRITERION Nutrient Broth (Hardy Diagnostics, Santa Maria, CA) supplemented with 5% sodium chloride to an OD of 0.45 at 37°C with mixing at 210 revolutions per minute (rpm). The cultures were inoculated with approximately 1,000 plaque-forming units (pfu) of Phi-X174 phage. The inoculated cultures were grown for an additional 4 hours at 37°C with mixing at 210 rpm. The inoculated Phi-X174 cultures were then purified using anion exchange chromatography. The purified Phi-X174 was sterile filtered through a 0.2 micron syringe filter. Phage concentrations were determined according to method F and stored at 4°C.

[0077] Method E. Filtration of Phi-X174 phage solution Hollow fiber membrane test modules were prepared and tested according to the following procedure. Polycarbonate tubes with a length of 90 mm and an internal diameter of 4 mm were used. A single hole was drilled in the side of each tube approximately 15 mm from one end. An open hole connector was attached to the hole using a UV / visible light curing adhesive to form a side port. Approximately 25-30 hollow fibers (15 cm long) were placed in each tube. The inserted hollow fibers were cut with a razor blade to provide approximately 15 mm of hollow fiber overhang at each end of the tube. The overhanging hollow fibers were sealed with wax and then potted in the tube using polyurethane resin. After curing for 24 hours, the overhanging ends were removed using a razor blade. The openings of the membranes were inspected using a microscope, and only tubes in which all of the hollow fiber membranes had open, unobstructed lumen portions were used. The total surface area of ​​the internal hollow fibers (i.e., the total surface area of ​​the lumens) was approximately 13 cm for the 90 mm tube. 2 It was.

[0078] The membrane test module was mounted vertically parallel to the vertically mounted pressure pot. A three-way valve was placed at the bottom of the pressure pot. MASTERFLEX tubing (size 14, Cole-Parmer) was used to connect the three-way valve to the bottom of the vertically mounted membrane test module. The pressure pot was first filled with ultrapure water (obtained from MILLI-Q water purification system from EMD Millipore, Burlington, MA), sealed, and pressurized to approximately 5 psi. The three-way valve at the bottom of the pressure pot was opened to allow water to flow into the lumen of the hollow fibers and out the top of the tube. Once the lumen of the hollow fibers was filled with water, the top of the test module was capped and the pressure was gradually increased to 30 psi. A side port on the test module was used to allow the filtrate to exit the module. The filtrate was collected in a beaker that was placed on a balance. Ultrapure water was filtered through the test module at 30 psi for a minimum of 10 minutes. After the initial water flush, the three-way valve at the bottom of the pressure pot was closed to remove any water remaining in the pressure pot.

[0079] Phi-X174 phage, 10 7 Phage solution was added to phosphate buffer (pH 7.4, 4 mS / cm) at a concentration of pfu / mL and 150 mL of the phage solution was added to the pressure pot. The pressure pot was sealed, pressurized to 30 psi, and the three-way valve at the bottom of the pressure pot was opened. The filtrate was collected in a sterile container placed on a balance. At the end of the filtration, the filtrate container was capped and stored at 4° C. until the phage concentration could be determined.

[0080] Method F. Determination of Phi-X174 phage concentration Phage concentrations of filtrate samples, feed solutions, and Phi-X174 culture preparations were determined using the following procedure: Solutions of interest were serially diluted (10-fold). Top agar (CRITERION Nutrient Broth (Hardy Diagnostics) with 0.9% agar, 2.5 mL) was mixed with 50 microliters of E. coli (ATCC 13706) culture (grown at 37°C with shaking at 210 rpm overnight in CRITERION Nutrient Broth with 5% sodium chloride) and 100 microliters of diluted Phi-X174 phage. The mixture was poured onto standard nutrient agar plates (CRITERION Nutrient Broth with 1.5% agar) and incubated at 37°C for 3-4 hours. After incubation, plaque forming units (pfu) were counted. The number of pfu correlated with the number of phage particles. Phage particle concentrations (particles / mL) were calculated from pfu counts adjusted for dilution. Log reduction values ​​(LRVs) were determined by the difference between the number of plaques present in the feed solution and the number of plaques present in the filtrate (see Equation 1).

[0081] Method G. Preparation of T7 phage cultures T7 bacteriophage (ATCC BAA-1025-B2) was obtained from ATCC (Manassas, VA). Phage cultures were generated by growing 1 L cultures of E. coli BL21 (ATCC BAA-1025) in CRITERION tryptic soy broth (Hardy Diagnostics, Santa Maria, CA) supplemented with 5% sodium chloride at 37° C. to an OD (optical density) of 0.45 with mixing at 210 rpm. The cultures were inoculated with approximately 1,000 pfu of T7 phage. The inoculated cultures were grown for an additional 4 hours at 37° C. with mixing at 210 rpm. The inoculated T7 cultures were then filtered through a 0.2 micron PES filter and stored at 4° C. Phage concentrations were determined according to Method H.

[0082] Method H. Determination of T7 phage concentration Phage concentrations of filtrate samples, feed solutions, and T7 culture preparations were determined using the following procedure. Solutions of interest were serially diluted (10-fold). Top agar (CRITERION Tryptic Soy Broth with 0.9% agar (Hardy Diagnostics), 2.5 mL) was mixed with 50 microliters of E. coli BL21 (ATCC BAA-1025) culture (grown at 37°C with shaking at 210 rpm overnight in CRITERION Tryptic Soy Broth) and 100 microliters of diluted T7 phage solution. The mixture was poured onto a standard tryptic soy agar plate (CRITERION Tryptic Soy Broth with 1.5% agar) and incubated at 37°C for 3-4 hours. After incubation, pfu were counted. The number of pfu correlated with the number of phage particles. Phage particle concentration (particles / mL) was calculated from the pfu count adjusted for dilution. Log reduction values ​​(LRVs) were determined by the difference between the number of plaques present in the feed solution and the number of plaques present in the filtrate (see Equation 1). A ">" symbol for the reported LRVs indicates that no pfu were observed for any of the serially diluted samples of the filtrate.

number

[0083] Example 1 A spinning solution was prepared by vigorously mixing 19% by weight of polyethersulfone, 13% by weight of poly(2-ethyl-2-oxazoline), 63% by weight of N-methylpyrrolidone, and 5% by weight of water at a temperature of about 55° C. The resulting spinning solution was cooled to about 50° C., filtered, and then degassed. A temperature-controlled spinneret (35° C.) was used with a dope outer diameter of 0.41 mm, a needle outer diameter of 0.3 mm, and an inner diameter of the spinneret needle of 0.15 mm. The spinneret was fixed at a distance of 60 cm above the precipitation bath.

[0084] Hollow fibers were generated using the spinning solution described above and a mixture of NMP:water (53:47) as the bore fluid in the spinneret needle of the spinneret. The hollow fibers were moved through an environmental control zone, which was adjusted to a temperature of 25°C to 75°C and a relative humidity of 20% to 95%. The membrane structure was then fixed by moving the hollow fibers into an aqueous precipitation bath heated to about 71°C. Immediately after this coagulation and fixing step, the wet hollow fiber membranes were wound on a wheel and then assembled into a hollow fiber membrane bundle having a length of about 30 cm and containing about 1200 individual hollow fiber membranes. The hollow fiber membranes were extracted with hot water (about 90°C) for about 1 hour and then dried with air at about 90°C for 1 hour. The resulting hollow fiber membrane had an inner physical diameter of about 250 micrometers and a wall thickness of about 70 micrometers, with a zone with the smallest pore size located adjacent to the inner surface and a zone with the largest pore size located approximately in the center of the membrane. In addition, the pores on the outer surface were larger in size than the pores on the inner surface. The transmembrane flux (TMF) was 0.03 mL / (cm 2 The measured pressure was 1.5 bar (min·bar).

[0085] Example 2 The same procedure was followed as described in Example 1, except that the precipitation bath was adjusted to 60° C. The resulting hollow fiber membrane had an inner physical diameter of about 250 micrometers, a wall thickness of about 67 micrometers, a zone with the smallest pore size located adjacent to the inner surface, and a zone with the largest pore size located approximately in the center of the membrane. In addition, the pores on the outer surface were larger in size than the pores on the inner surface. The transmembrane flux (TMF) was 0.03 mL / (cm 2 The measured pressure was 1.5 bar (min·bar).

[0086] Scanning electron microscope (SEM) images of the cross section of the hollow fiber membrane are shown in FIG. 3 and FIG.

[0087] Example 3 The same procedure was followed as described in Example 1, except that the rotational speed of the polymer blend pump was reduced. The resulting hollow fiber membrane had an inner physical diameter of about 250 micrometers, a wall thickness of about 30 micrometers, a zone with the smallest pore size located adjacent to the inner surface, and a zone with the largest pore size located approximately in the center of the membrane. In addition, the pores on the outer surface were larger in size than the pores on the inner surface. The transmembrane flux (TMF) was 0.10 mL / (cm 2 The measured pressure was 1.5 bar (min·bar).

[0088] Example 4 The same procedure was followed as described in Example 1, except that the precipitation bath was adjusted to 50° C. and the rotational speed of the polymer blend pump was reduced. The resulting hollow fiber membrane had an inner physical diameter of about 250 micrometers, a wall thickness of about 30 micrometers, a zone with the smallest pore size located adjacent to the inner surface, and a gradient of increasing pore size toward the outer surface. The largest pore was located adjacent (less than 1 micrometer distance) to the outer surface. The transmembrane flux (TMF) was 0.18 mL / (cm 2 The measured pressure was 1.5 bar (min·bar).

[0089] Scanning electron microscope (SEM) images of the cross section of the hollow fiber membrane are shown in FIG. 5 and FIG.

[0090] Example 5 A spinning solution was prepared by vigorously mixing 21 wt% polyethersulfone, 9 wt% poly(2-ethyl-2-oxazoline), 36 wt% N-methylpyrrolidone, 32 wt% poly(ethylene glycol) 200 (PEG200) and 2% water at a temperature of about 55°C. The resulting spinning solution was cooled to about 50°C, filtered and degassed. A temperature-controlled spinneret (35°C) was used with a dope outer diameter of 0.41 mm, a needle outer diameter of 0.3 mm and an inner diameter of the spinneret needle of 0.15 mm. The spinneret was fixed at a distance of 25 cm above the precipitation bath.

[0091] The hollow fibers were generated using the above-mentioned spinning solution and a mixture of NMP:polyethylene glycol:water (50:30:20) as the bore fluid in the spinneret needle of the spinneret. The hollow fibers were then transferred to an aqueous precipitation bath heated to about 60° C. to fix the membrane structure with the smallest size pores in the outer surface area of ​​the membrane and the largest size pores on the inner (lumen) surface. Immediately after this coagulation and fixation step, the wet hollow fiber membrane was wound on a wheel and then assembled into a hollow fiber membrane bundle having a length of about 30 cm and containing about 1200 individual hollow fiber membranes. The hollow fiber membranes were extracted with hot water (about 90° C.) for about 1 hour and then dried with air at about 90° C. for about 1 hour. The resulting hollow fiber membranes had a physical inner diameter of about 300 micrometers and a wall thickness of about 50 micrometers.

[0092] Scanning electron microscope (SEM) images of the cross-section of a hollow fiber membrane are shown in Figures 7 and 8. In Figure 7, the zone with the smallest pore size is located adjacent to the outer surface, and the zone with the largest pore size is located adjacent to the inner surface. The image in Figure 8 shows the interconnected serpentine structure of the membrane wall.

[0093] The transmembrane flux (TMF) was 0.11 mL / (cm 2 When the membrane was evaluated according to methods E and F, an LRV of 1.5 was measured for the Phi-X174 phage.

[0094] Example 6 A spinning solution was prepared by vigorously mixing 19% by weight of polyethersulfone, 13% by weight of poly(2-ethyl-2-oxazoline), 63% by weight of N-methylpyrrolidone, and 5% of water at a temperature of about 55° C. The resulting spinning solution was cooled to about 50° C., filtered, and then degassed. A temperature-controlled spinneret (35° C.) was used with a dope outer diameter of 0.41 mm, a needle outer diameter of 0.3 mm, and an inner diameter of the spinneret needle of 0.15 mm. The spinneret was fixed at a distance of 60 cm above the precipitation bath.

[0095] Hollow fibers were generated using the spinning solution described above and a mixture of NMP:water (53:47) as the bore fluid in the spinneret needle of the spinneret. The hollow fibers were moved through an environmental control zone, which was adjusted to a temperature of 25°C to 75°C and a relative humidity of 20% to 95%. The hollow fibers were then moved into an aqueous precipitation bath heated to about 60°C to fix the membrane structure with the largest size pores in the outer surface area of ​​the membrane and the smallest pores on the inner (lumen) surface. Immediately after this coagulation and fixation step, the wet hollow fiber membrane was wound on a wheel and then assembled into a hollow fiber membrane bundle having a length of about 30 cm and containing about 1200 individual hollow fiber membranes. The hollow fiber membranes were extracted with hot water (about 90°C) for about 1 hour and then dried with air at about 90°C for about 1 hour. The resulting hollow fiber membrane had an inner physical diameter of about 250 micrometers, a wall thickness of about 70 micrometers, a zone with the smallest pore size located adjacent to the inner surface, and a gradient of increasing pore size toward the outer surface, with the largest size pores located adjacent (less than 1 micrometer away) to the outer surface.

[0096] The transmembrane flux (TMF) is 0.8 mL / (cm 2 ·min ·bar). The BSA throughput was measured to be 73 kg / (m 2 It was measured to be 10 hours.

[0097] Example 7 A spinning solution was prepared by vigorously mixing 19 wt. % polyethersulfone, 13 wt. % poly(2-ethyl-2-oxazoline), 63 wt. % N-methylpyrrolidone, and 5 wt. % water at a temperature of about 55° C. The resulting spinning solution was cooled to about 50° C., filtered, and degassed. A temperature-controlled spinneret (35° C.) was used with a dope outer diameter of 0.41 mm, a needle outer diameter of 0.3 mm, and a spinneret needle inner diameter of 0.15 mm. The spinneret was fixed at a distance of 25 cm above the precipitation bath.

[0098] The hollow fibers were generated using the spinning solution described above and a mixture of NMP:water (53:47) as the bore fluid in the spinneret needle of the spinneret. The hollow fibers were then transferred to an aqueous precipitation bath heated to about 71° C. to fix the membrane structure with the smallest pore size in the outer surface area of ​​the membrane and the largest pore size on the inner (lumen) surface. Immediately after this coagulation and fixation step, the wet hollow fiber membrane was wound on a wheel and then assembled into a hollow fiber membrane bundle having a length of about 30 cm and containing about 1200 individual hollow fiber membranes. The hollow fiber membrane was extracted with hot water (about 90° C.) for about 1 hour and then dried with air at about 90° C. for about 1 hour. The resulting hollow fiber membrane had a physical inner diameter of about 250 micrometers, a wall thickness of about 70 micrometers, a zone with the smallest pore size located adjacent to the outer surface of the hollow fiber membrane, and a zone with the largest pore size located adjacent to the inner surface.

[0099] The transmembrane flux (TMF) is 0.8 mL / (cm 2 The BSA throughput was measured to be 230 kg / (m 2 It was measured to be 10 hours.

[0100] Example 8 A spinning solution was prepared by vigorously mixing 19% by weight of polyethersulfone, 6.5% by weight of poly(2-ethyl-2-oxazoline), 6.5% by weight of PEG1500, 63% by weight of N-methylpyrrolidone, and 5% by weight of water at a temperature of about 55° C. The resulting spinning solution was cooled to about 50° C., filtered, and then degassed. A temperature-controlled spinneret (35° C.) was used with a dope outer diameter of 0.41 mm, a needle outer diameter of 0.3 mm, and an inner diameter of the spinneret needle of 0.15 mm. The spinneret was fixed at a distance of 25 cm above the precipitation bath.

[0101] The hollow fibers were generated using the above-mentioned spinning solution and a mixture of NMP:water (53:47) as the bore fluid in the spinneret needle of the spinneret. The hollow fibers were then transferred to an aqueous precipitation bath heated to about 71° C. to fix the membrane structure with the smallest pore size in the outer surface area of ​​the membrane and the largest pore size on the inner (lumen) surface. Immediately after this coagulation and fixation step, the wet hollow fiber membrane was wound on a wheel and then assembled into a hollow fiber membrane bundle having a length of about 30 cm and containing about 1200 individual hollow fiber membranes. The hollow fiber membrane was extracted with hot water (about 90° C.) for about 1 hour and then dried with air at a temperature of about 90° C. for about 1 hour. The resulting hollow fiber membrane had a physical inner diameter of about 250 micrometers, a wall thickness of about 70 micrometers, a zone with the smallest pore size located adjacent to the outer surface of the hollow fiber membrane, and a zone with the largest pore size located adjacent to the inner surface.

[0102] The membrane transmembrane flow rate (TMF) is 0.8 mL / (cm 2 ·min ·bar). The BSA throughput was measured to be 1046 kg / (m 2 It was measured to be 10 hours.

[0103] Example 9 A spinning solution was prepared by vigorously mixing 24 wt% polyethersulfone, 9 wt% poly(2-ethyl-2-oxazoline), 34 wt% N-methylpyrrolidone, 31 wt% poly(ethylene glycol) 200 (PEG200) and 2 wt% water at a temperature of about 55°C. The resulting spinning solution was cooled to about 50°C, filtered and degassed. A temperature-controlled spinneret (35°C) was used with a dope outer diameter of 0.41 mm, a needle outer diameter of 0.3 mm and an inner diameter of the spinneret needle of 0.15 mm. The spinneret was fixed at a distance of 25 cm above the precipitation bath.

[0104] Hollow fibers were generated using the above spinning solution and a mixture of NMP:polyethylene glycol (PEG200):water (50:45:5) as the bore fluid in the spinneret needle of the spinneret. The hollow fibers were then transferred to an aqueous precipitation bath heated to about 60°C. Immediately after this coagulation and fixation step, the wet hollow fiber membranes were wound on a wheel and then assembled into a hollow fiber membrane bundle having a length of about 30 cm and containing about 1200 individual hollow fiber membranes. The hollow fiber membranes were extracted with hot water (about 90°C) for about 1 hour and then dried with air at about 90°C for about 1 hour. The resulting hollow fiber membranes had a physical inner diameter of about 217 micrometers and a wall thickness of about 61 micrometers. The transmembrane flux (TMF) was 0.69 mL / (cm 2 The measured pressure was 1.5 bar (min·bar).

[0105] Cross sections of the membrane wall were examined using SEM (8,000x magnification). The membrane pore size at the inner surface facing the lumen was about 0.2 micrometers to 5 micrometers. The pore size decreased as one progressed from the inner membrane surface to the outer membrane surface over a distance of about 54 micrometers (89%) across the membrane wall (pore size measurements were taken along a vector defining the shortest cross-sectional distance from the inner membrane surface to the outer membrane surface). The pore size then transitioned to increasing in size as one progressed toward the outer surface (along the same vector direction), with the pore size at the outer membrane surface being about 0.2 micrometers to 3 micrometers. The pore size at the transition from increasing to decreasing pore size in the membrane wall was about 0.04 micrometers.

[0106] Example 10 Hollow fiber membranes were prepared according to the general procedure described in Example 9, except that the components of the spinning solution were added in different weight percentages. The spinning solution was prepared by vigorously mixing 25.5 wt% polyethersulfone, 9 wt% poly(2-ethyl-2-oxazoline), 33.2 wt% N-methylpyrrolidone, 30.3 wt% poly(ethylene glycol) 200 (PEG200), and 2 wt% water. The resulting hollow fiber membrane had an inner physical diameter of about 216 micrometers and a wall thickness of about 57 micrometers. The transmembrane flux (TMF) was 0.97 mL / (cm 2 The measured pressure was 1.5 bar (min·bar).

[0107] Cross sections of the membrane wall were examined using SEM (8,000x magnification). The membrane pore size at the inner surface facing the lumen was about 0.3 micrometers to 3 micrometers. The pore size decreased as one progressed from the inner membrane surface to the outer membrane surface over a distance of about 48 micrometers (84%) across the membrane wall (pore size measurements were taken along a vector defining the shortest cross-sectional distance from the inner membrane surface to the outer surface of the membrane). The pore size then transitioned to increasing in size as one progressed toward the outer surface (along the same vector direction), with the pore size at the outer membrane surface being about 0.4 micrometers to 1.3 micrometers. The pore size at the transition from increasing to decreasing pore size in the membrane wall was about 0.045 micrometers to 0.05 micrometers.

[0108] Example 11 Hollow fiber membranes were prepared according to the general procedure described in Example 9, except that the components of the spinning solution were added in different weight percentages. The spinning solution was prepared by vigorously mixing 26.5 wt% polyethersulfone, 9 wt% poly(2-ethyl-2-oxazoline), 32.7 wt% N-methylpyrrolidone, 29.8 wt% poly(ethylene glycol) 200 (PEG200), and 2 wt% water. The resulting hollow fiber membrane had an inner physical diameter of about 203 micrometers and a wall thickness of about 53 micrometers. The transmembrane flux (TMF) was 0.45 mL / (cm 2 The measured pressure was 1.5 bar (min·bar).

[0109] Cross sections of the membrane wall were examined using SEM (8,000x magnification). The membrane pore size at the inner surface facing the lumen was about 6.5 micrometers to 0.3 micrometers. The pore size decreased as one progressed from the inner membrane surface to the outer membrane surface over a distance of about 50 micrometers (94%) across the membrane wall (pore size measurements were taken along a vector defining the shortest cross-sectional distance from the inner membrane surface to the outer membrane surface). The pore size then transitioned to increasing size as one progressed toward the outer surface (along the same vector direction), with the pore size at the outer membrane surface being about 0.05 micrometers to 0.3 micrometers. The pore size at the transition from increasing to decreasing pore size in the membrane wall was less than 0.03 micrometers.

[0110] Example 12 Hollow fiber membrane test modules were prepared and tested according to the following procedure. Polycarbonate tubes with a length of 13 mm and an internal diameter of 4 mm were used. A single hole was drilled in the side of each tube. An open hole connector was attached to the hole using a UV / visible light curing adhesive to form a side port. Approximately 10-15 hollow fibers prepared according to Example 10 were placed in each tube. The inserted hollow fibers were cut with a razor blade to provide approximately 15 mm of hollow fiber overhang at each end of the tube. The overhanging hollow fibers were sealed with wax and then potted in the tube using polyurethane resin. After curing for 24 hours, the overhanging ends were removed using a razor blade. The openings of the membranes were inspected using a microscope, and only tubes in which all hollow fiber membranes had open, unobstructed lumen portions were used. The total surface area of ​​the internal hollow fibers (i.e., the total surface area of ​​the lumens) was approximately 1 cm. 2 Prior to challenge with the AAV solution, the test modules were sterilized using gamma irradiation (25 kGy to 45 kGy).

[0111] The membrane test module was connected to a three-way valve located at the bottom of a vertically mounted pressure pot. The pressure pot was first filled with ultrapure water (obtained from MilliporeSigma's MILLI-Q water purification system). The three-way valve between the pressure pot and the test module was opened to allow water to flow into the lumen of the hollow fibers and out the opposite end of the module. Once the lumen of the hollow fibers was filled with water, the end of the test module was capped. The pressure was gradually increased to 30 psi. A side port on the test module was used to allow the filtrate to exit the module and enter the first collection vessel. Water was filtered through the hollow fiber module at 30 psi for a minimum of 10 minutes. The three-way valve at the bottom of the pressure pot was then closed to remove any water remaining in the pressure pot.

[0112] The pressure pot was depressurized and approximately 1 x 10 9The pressure pot was then sealed, pressurized to 30 psi, and the three-way valve was opened. The filtrate was collected in a second collection vessel that was placed on a digital balance and tared. A minimum of 100 L / m 2 AAV2 solution was filtered through the membrane test module. AAV2 concentrations in the filtrate and feed were measured using a PROGEN Xpress AAV2 ELISA kit (PROGEN, Wayne, PA). The percent yield of AAV2 was calculated by dividing the concentration of AAV2 in the filtrate by the concentration of AAV2 in the feed and multiplying by 100. The calculated percent yield of AAV2 was 100%.

[0113] Example 13 Bacteriophage T7 was used to simulate viral contaminants, which are larger in size than AAV, to demonstrate the membrane's ability to remove large viral contaminants. T7 phage was injected at 1x10 7 A feed solution was prepared by adding phage to phosphate buffer (pH 7.4, 4 mS / cm) at a concentration of pfu / mL. Filtration of the phage-containing feed solution was performed using a constant flow rate during filtration.

[0114] Hollow fiber membrane test module (polycarbonate tube with a length of 13 mm and an inner diameter of 4 mm, 5 cm 2 ~6cm 2A membrane test module (having 10-15 fibers each for a total filtration area of ​​100 nm) was prepared as described in Method E (using hollow fibers prepared in Example 10) and sterilized using gamma irradiation (25 kGy-45 kGy). The membrane test module was mounted vertically. A pressure gauge was placed in-line at the inlet of the vertically mounted module. A peristaltic pump and MASTERFLEX tubing (size 14, Cole-Parmer) were used to pump the challenge solution from the container into the lumen of the hollow fibers. The pump was set at a flow rate that provided a transmembrane pressure of 20 psi to 30 psi. Ultrapure water (obtained from MilliporeSigma's MILLI-Q water purification system) was pumped into the module first while the cap at the opposite end of the module was removed to allow the water to completely fill the membrane lumen. Once the lumen was filled with water, the module was capped and the module was operated in dead-end filtration mode. A side port on the test module was used to allow the filtrate to exit the module. The filtrate was collected in a tared beaker placed on a digital balance. Ultrapure water was filtered through the test module for a minimum of 10 minutes and the transmembrane pressure was monitored. After the first water flush, the inlet feed was switched to T7 phage feed solution. The first filtrate, equivalent to the dead volume of the system, was collected and discarded. The water was drained from the inlet line. The T7 phage feed solution was pumped at a flow rate that provided a transmembrane pressure of 20 psi to 30 psi, the same as used for the water. Minimum 100 L / m 2 The membrane was challenged with 0.05 ml of feed solution. The filtrate was placed on a digital balance and collected in a tared sterile container. The transmembrane pressure was monitored throughout the experiment. The T7 phage concentration of the filtrate and the corresponding LRV value were determined according to method H. An LRV of >6 was measured for T7 phage.

[0115] All references and publications cited herein are expressly incorporated by reference in their entirety into this disclosure. Exemplary embodiments of the present invention have been discussed, and possible variations within the scope of the present invention have been mentioned. For example, features described in the context of one exemplary embodiment may be used in the context of other embodiments of the present invention. These and other variations and modifications of the present invention will be apparent to those skilled in the art without departing from the scope of the present invention, and it should be understood that the present invention is not limited to the exemplary embodiments described herein. Therefore, the present invention should be limited only by the claims provided below and their equivalents.

Claims

1. made from a polymer blend comprising an aromatic sulfone polymer and a polyoxazoline; an inner surface facing the lumen, an outer surface facing the exterior, and an intermediate wall having a wall thickness; A hollow fiber membrane is an integral asymmetric permeable hollow fiber membrane.

2. 10. The hollow fiber membrane of claim 1, wherein the polymer blend comprises more than 7 wt.% or less than 3 wt.% polyvinylpyrrolidone.

3. 3. The hollow fiber membrane according to claim 1, wherein the polymer blend does not contain polyvinylpyrrolidone.

4. The hollow fiber membrane according to any one of claims 1 to 3, comprising a serpentine structure extending from the inner surface toward the outer surface.

5. providing a spinning solution comprising an aromatic sulfone polymer and a polyoxazoline, and a bore fluid comprising water, a solvent, and a non-solvent; 1. A method comprising: spinning hollow fibers with a dope spinneret outer diameter in the range of 300 μm to 1000 μm, a spinneret needle outer diameter in the range of 200 μm to 1000 μm, and a spinneret needle inner diameter in the range of 100 μm to 1000 μm.

6. Use of the hollow fiber membrane according to any one of claims 1 to 4 for the filtration of liquids.

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