Filtration device and components thereof

Abstract

A feed screen for a tangential flow filtration system is provided including a body having a screen, a flange surrounding the screen, at least one feed inlet port, and at least one feed outlet port. The feed inlet port is in fluid communication with the screen. The feed outlet port is in fluid communication with the screen. The screen is spaced a distance from an outer perimeter of the body by the flange.

Description

FILTRATION DEVICE AND COMPONENTS THEREOF BACKGROUNDTechnical Field.

[0001] Examples of the subject matter herein relate generally to filtration and more specifically to a feed screen, filtration module, and method of making a feed screen for use in a tangential flow filtration device for bioprocessing.Discussion of Art.

[0002] In the purification of biological streams, the goal is to capture one or more desired components (e.g., proteins) from a liquid stream that contains a variety of components such as proteins, lipids, aggregated proteins from cells, carbohydrates, DNA, and the like. A number of purification steps may be utilized including filtration.

[0003] Liquids, primarily aqueous liquids, have been filtered by tangential flow modules with a plurality of filters stacked between manifolds, one at the bottom of the stack and one at the top of the stack. The filters are separated by screens and liquid-impervious layers to permit liquid flow as well as filtrate and retentate flow into and from the stack. Flow holes are provided through the layers within the stack. The holes are sealed with a material to prevent mixture of filtrate with incoming liquid feed or retentate.

[0004] Prior to the present invention, tangential flow filtration cassettes have been overmolded and contain feed screens that extend outwardly throughout and beyond an overmolded area (also referred to as the “overmold”). The overmolded area seals against a permeate packet and defines the flow channel and height. Manufacturing the overmold is technically challenging and requires an expensive and complicated mold design. Further, compressing and sealing to the permeate packet is difficult due to its surface nonuniformity and thickness variation caused by the presence of the feed screen within the overmolded area. The overmold also defines a channel height that is thicker than is optimal, limited by necessity to fill around the screen.

[0005] It may be desirable to have improvements in design, arrangement, and alignment of the feed screen in order to facilitate a more compliant sealing surface and create a simpler design to manufacture / mold. It may be desirable to have a system and method that differs from those that are currently available.BRIEF DESCRIPTION

[0006] In accordance with an aspect of the invention, a feed screen for a tangential flow filtration system is described. The feed screen for the tangential flow filtration system includes a body having a screen, a flange, at least one feed inlet port, and at least one feed outlet port. The flange is positioned to surround the screen. The at least one feed inlet port is in fluid communication with the screen. The at least one feed outlet port is in fluid communication with the screen. The screen is spaced inward a distance from an outer perimeter of the body by the flange.

[0007] In an embodiment, the feed screen may extend into the flange a distance less than or equal to 0.3 inches.

[0008] In an embodiment, the screen does not extend past an outer periphery of the flange.

[0009] In an embodiment, the flange provides a sealing surface for sealing a membrane member around the feed screen.

[0010] In an embodiment, the body includes at least one permeate port, the at least one permeate port being fluidly isolated from the feed screen and / or the feed channel.

[0011] In an embodiment, the body may further include a first permeate port adjacent to the feed inlet port, and a second permeate port adjacent to the feed outlet port.

[0012] In an embodiment, the first permeate port and the second permeate port are fluidly isolated from the screen.

[0013] In an embodiment, the flange may be formed from one of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate.

[0014] In accordance with another aspect of the invention, a filtration module for a tangential flow filtration system is described. The filtration module includes a membrane and a feed screen. The feed screen is in contact with the membrane. The feed screen includes a body having a screen and a flange surrounding the screen. The screen does not extend past an outer periphery of the flange.

[0015] In an embodiment, the membrane is affixed to a first side of the flange forming a first seal and wherein the first seal does not overlap the screen.

[0016] In an embodiment, the filtration module further includes a permeate screen heat sealed to the membrane.

[0017] In an embodiment, the permeate screen includes at least one permeate port, the at least one permeate port being fluidly isolated from the screen.

[0018] In an embodiment, the body of the feed screen includes at least one feed inlet in fluid communication with the screen, and at least one feed outlet in fluid communication with the screen, and at least one permeate port fluidly isolated from the screen.

[0019] In an embodiment, the permeate screen and the flange of the body of the feed screen are formed from the same material.

[0020] In an embodiment, the flange may be made of at least one of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate.

[0021] In accordance with yet another aspect of the invention, a method of manufacturing a feed screen is described. The method includes providing a screen and forming a flange around a periphery of the screen such that the flange defines a uniform sealing surface, and such that the screen does not extend to an outer periphery of the flange.

[0022] In an embodiment, the flange is formed via overmolding.

[0023] In an embodiment, the screen includes an inlet aperture and an outlet aperture.

[0024] In an embodiment, the method further includes sealing a permeate screen to a membrane.

[0025] In an embodiment, the screen does not overlap the seal between the flange and the membrane.

[0026] In an embodiment, forming the flange includes forming first and second permeate ports in the flange, the first and second permeate ports being fluidly isolated from the screen.BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The subject matter may be understood from reading the following description of non-limiting examples, with reference to the attached drawings, wherein below:

[0028] Fig. l is a perspective view of a feed screen of a filtration module, according to an embodiment of the invention;

[0029] Fig. 2 is a top view of a feed screen of a filtration module and a membrane packet of a filtration module according to an embodiment of the invention;

[0030] Fig. 3 is a top view of a feed screen and membrane packet, according to an embodiment of the invention;

[0031] Fig. 4 is a top view of a portion of a feed screen of a filtration module, according to an embodiment of the invention;

[0032] Fig. 5 is a perspective view of a feed screen of a filtration module, according to one example;

[0033] Fig. 6 is a detailed view of a portion of a feed screen of a filtration module, according to one example; and

[0034] Fig. 7 is a cross-sectional view of a feed screen of a filtration module, according to one example.DETAILED DESCRIPTION

[0035] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0036] “TFF assembly,” “TFF system” and “TFF apparatus” are used interchangeably herein to refer to a tangential flow filtration system that is configured for operation in a recirculation mode where at least a portion of the retentate is returned to the system as feed. These terms include, but are not limited to, single pass tangential fluid flow systems as well as TFF systems that utilize recirculation loops.

[0037] The terms “feed,” “feed sample” and “feed stream” refer to the solution that is delivered to a filtration module to be filtered. The feed that is delivered to a filtration module for filtration can be, for example, feed from a feed container (e.g., vessel, tank) external to the system, or retentate from a preceding filtration module in the same system.

[0038] The term “filtration” generally refers to the act of separating the feed sample into two streams, a permeate and a retentate, using membranes.

[0039] The terms “permeate” and “filtrate” refer to that portion of the feed that has permeated through the membrane.

[0040] The term “retentate” refers to the portion of the solution that has been retained by the membrane, and the retentate is the stream enriched in a retained species.

[0041] “Feed line” or “feed channel” refers to a conduit for conveying a feed from a feed source (e.g., a feed container) to one or more processing units in a filtration assembly.

[0042] The expression “flow path” refers to a channel supporting the flow of a liquid (e.g., feed, retentate, permeate) through all or part of a TFF system. Thus, a TFF system can have multiple flow paths, including a flow path through the entire system from the feed inlet to the retentate outlet, a flow path within a filtration module (e.g., a flow path through TFF cassettes and / or a manifold segment in a filtration module) and a flow path between two or more adjacent filtration modules (e.g., a flow path between manifold segments in adjacent filtration modules). The flow path can have any topology which supports tangential flow (e.g., straight, coiled, arranged in zigzag fashion).

[0043] A “filtration module” refers to a cassette in a TFF system or to one or more cassettes fluidly connected to a manifold segment.

[0044] A “manifold segment” refers to a block having a plurality of manifolds, including a manifold for carrying a feed, a manifold for carrying a retentate and a manifold for carrying a permeate. Each manifold segment is fluidly connected to one or more cassettes.

[0045] A “TFF cassette” or “cassette” refers to a plate-and-frame structure including a filtration membrane (e.g., an ultrafiltration membrane, a microfiltration membrane) and separate feed / retentate and permeate flow channels suitable for TFF processes.

[0046] “Filtration membrane” refers to a selectively permeable membrane for separating a feed into a permeate stream and a retentate stream using a TFF process. Filtration membranes include, but are not limited to, ultrafiltration (UF) membranes, microfiltration (MF) membranes, reverse osmosis (RO) membranes, and nanofiltration (NF) membranes.

[0047] The term “plurality,” when used herein to describe processing units, refers to two or more processing units.

[0048] “Fluidly connected” refers to two or more components of a TFF system (e.g., two or more manifold segments, two or more TFF cassettes, a manifold segment and one or more TFF cassettes), that are connected by one or more conduits (e.g., a feed channel, aretentate channel, a permeate channel) such that a liquid can flow from one component to the other.

[0049] Embodiments of the subject matter described herein may relate to a filtration module, e.g., a cassette, for use in a TFF system. Specifically, a feed screen, a filtration module, and a method for making or using a feed screen of a TFF system. The feed screen and filtration module utilize a feed screen that has a body with a screen, a flange surrounding the screen, wherein the screen is spaced a distance from an outer perimeter of the body by the flange. Embodiments are not limited to a specific size or configuration of screen, filtration module, or TFF system. Indeed, certain embodiments, may be generally suitable for use where filtration is accomplished via one or more molded screens regardless of whether the screens are incorporated into a cassette or a TFF system, or are for bioprocessing. Likewise, embodiments are not limited to the filtration of any specific type or volume of fluid or flow rate, and are not limited to the removal of any specific component or product from a fluid.

[0050] The system and method may include a filtration module, also referred to as a TFF cassette. The filtration module may include various placements and functions of feed screens within the filtration module. As will be appreciated, however, while certain embodiments may be suitable for use with the filtration module, embodiments are not so limited. Indeed, embodiments may be suited for use with cassettes / fluid filtering assemblies such as those depicted and described in U.S. 10,350,550 and 10,183,108, both of which are incorporated by reference in their entirety, as well as those commercially available under the trademarks CENTRAMATE™ and CENTRASETTE™ (Pall Corporation, Port Washington, N.Y.).

[0051] More specifically, the filtration module may include a top end plate, a bottom end plate, one or more membranes, and one or more ports, for example a feed inlet, a retentate outlet, a permeate outlet, and a filtrate outlet. The permeate outlet may also be referred to as a permeate passthrough aperture, a permeate hole, or the like. The one or more membranes may include a membrane plate. The membrane plate may be made of one ormore of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate.

[0052] Other suitable materials include but are not limited to thermoplastics, such as polyethylene, polypropylene, EVA copolymers, alpha olefins and metallocene copolymers, PF A, MFA, polycarbonate, vinyl copolymers such as PVC, polyamides such as nylon, polyesters, acrylonitrile-butadienestyrene(ABS), poly sulphone, polyethersulphone, poly aryl sulphone, polyphenyl sulphone, polyacrylonitrile, polyvinylidene fluoride (PVDF), and blends thereof, thermoplastic elastomers which can be formed of styrenic block copolymers, blends of EPDM and polypropylene and the like and which are sold under brand names such as Santoprene® polymer, Kraton® thermoplastic elastomer and Dynaflex® elastomer, EPDM rubber, thermosets such as closed cell foamed urethanes, and rubbers, either natural or synthetic.

[0053] The filtration module may include membranes having filtrate screens and feed screens forming channels. In embodiments, the feed screens may be surrounded by a flange. The screens may serve as spacer materials and / or perforate materials for the feed / retentate channels and permeate channels. The screens can have any suitable size openings, e.g., fine, medium, or coarse size openings. A cross-fluid treatment subassembly can have any number of membranes, feed channel s / retentate channels, and permeate channels. The top end plate and the bottom end plate and those components therebetween, e.g., the membranes, are pressed together to form the filtration assembly, i.e., cassette.

[0054] In use, the feed enters the through feed inlet and flows over a feed screen to a permeate outlet, the screen filtering the feed to filter desired, or undesired, components from the feed stream.

[0055] Figs. 1 and 2 illustrate a feed screen 200, according to one embodiment. The feed screen 200 includes a body 202 having a screen 204, a flange 206, at least one feed inlet port 208 in fluid communication with the screen 204, and at least one feed outlet port 210 in fluid communication with the screen 204. The flange 206 is positioned to surround the screen 204. The screen 204 is spaced a distance from an outer perimeter 212 of the bodyby the flange 206. The screen 204 may extend minimally into the flange 206. In one example, the screen 204 extends into the flange 206 a distance less than or equal to 1 inch, for example, 0.3 inches. The distance may be approximately 0.03125 inches to about 0.125 inches. The distance may be measured as a percentage of a width of the feed screen. The distance may be between 1% and 50% of the width of the feed screen, more particularly between about 12% and 25%. The distance the screen extends into the flange may be uniform throughout the feed screen or may vary. Where the distance varies, the distance may be a greatest distance, an average distance, a smallest distance, or a distance at a given point.

[0056] The feed screen 200 may be formed from silicone, synthetic polymers, or the like. In one example, the feed screen may be formed via injection molding. The durometer of the feed screen may be adjusted based on desired use characteristics. For example, a higher durometer, for example a Shore D30 elastomer, may be used to provide a more consistent shape for the feed screen. However, a lower durometer may be used which may be more flexible and may provide better sealing. The greater flexibility has benefits of better sealing but may be more easily misshapen compared to higher durometer materials. Based on desired use, a lower or higher durometer may be used. The flange 206 may be formed from one of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate. In one example, the flange 206 and the screen 204 may be made of the same material.

[0057] The screen 204 has openings and creates a feed channel. The size and density of the openings of the screen 204 may be adjusted based on the feed and desired filtration characteristics. The flange 206 extending around the screen 204 creates a critical seal area around the ports. The flange 206 provides a sealing surface 251 for sealing a membrane 250, shown in Fig. 2, to the feed screen 200 to form a membrane packet. Specifically, the sealing surface 251 may be a heat seal area configured to be coupled with the flange 206 of the feed screen 200. Having no screen in the flange area improves the integrity and moldability of the feed screen. The flange area may be sized to be approximately the length and width as the sealing surface. Additionally, the feed screen may be made from anelastomeric material which further enhances the sealing integrity. In one example, the flange and the membrane are made of the same or like materials to enhance the bonding of the flange and the membrane. For example, the materials may be different but may be made from the same base resin. Bonding at each layer of the filtration device helps to segregate any fluid which could leak past the flange seal so that it cannot travel to other layers of the filtration device.

[0058] The feed screen 200 may include at least one permeate port or permeate pass-through aperture, for example a first permeate port 208 and a second permeate port 242. In one example, the first permeate port may be positioned adjacent to the feed inlet port 240 and the second permeate port may be positioned adjacent to the feed outlet port 210. The first permeate port 208 and the second permeate port 242 may be fluidly isolated from the screen 204. For example, the permeate port 208 and the feed inlet port 240 may be spaced apart by an area 230 without any screen, as illustrated in Figs. 3 and 4. While first and second permeate ports are described, it is understood that there may be more or less than two permeate ports without deviating from the inventive concept.

[0059] In prior filtration devices, leakage between the feed inlet port and the permeate port was among the most common points of failure. Without the area 230, a leak can more easily spread over the existing screen between the feed port and the permeate port. However, the area 230 having no screen reduces leaks and enhances the reliability and consistency of the filtration device.

[0060] In embodiments, a membrane 250 may be coupled to a first side of the flange 206 of a feed screen 200 forming a first seal (FIG. 3) and a membrane packet. The first seal does not overlap the screen, but rather is designed to seal entirely in the space of the flange 206. By not sealing over the screen, or minimally sealing over the screen, the coupling of the membrane and the feed screen 200 has greater sealing integrity, consistency, and repeatability. As will be appreciated, when sealing over a screened area, the compression of sealing creates an uneven surface and increases sealing difficulty against the membrane surface. Additionally, the screen may reduce the surface area for bonding, resulting in a weaker bond and seal. The flange, without screen, facilitates a smoother and morecompliant sealing surface due to its geometry and material characteristics. Additionally, this creates a simpler design to mold and reduces cost and material waste. Further, the channel height may be reduced.

[0061] In embodiments, a permeate screen (not shown) may be heat sealed to the membrane 250. The permeate screen may be formed from the same material as the feed screen 200. The permeate screen may be made from polyethylene (PE), low-density polyethylene (LDPE), high-density polyethylene (HDPE), thermoplastic elastomer (TPE) or thermoplastic vulcanizates of PE, polypropylene (PP), polyethylene terephthalate (PET), or the like. The permeate screen may be include an overmolded portion and / or a woven screen portion. The overmolded portion and woven screen portion may be made of different materials or like materials.

[0062] Referring now to FIG. 5, a perspective view of a feed screen 600 is illustrated. The feed screen 600 may be generally rectangular or I-shaped (having enlarged opposing ends). The feed screen 600 includes, at a first end thereof, a feed inlet region 640 and a first pass-through aperture 608 adjacent to the inlet port 640, and at the opposing end, a feed outlet port or opening region 642 and a second pass-through aperture 610 adjacent to the outlet port 642. A feed channel 688 extends between the inlet port 840 and the outlet port 810. When assembled, the feed channel 688 is located between a first membrane of a top end plate, and a second membrane of a bottom end plate. In an embodiment, the feed screen 600 is an over-molded feed screen which acts both as a gasket seal and as the screen to hold the membrane layers apart and create the necessary cleaning action to prevent buildup and fouling. In an embodiment, the feed screen 600 includes a feed screen formed from polypropylene with a thermoplastic elastomer overmold. In one embodiment, the feed screen 600 is manufactured by die-cutting a polypropylene screen and placing it into a mold (using, for example, feed and retentate holes for alignment). Thermoplastic elastomer (TPE) or silicone is then injection molded around the screen (although other material may also be utilized without departing from the broader aspects of the invention). The use of TPE or silicone for the overmold area of the feed screen provides a fluid seal when compressed between the membranes of the end plates during assembly, helping to ensurethe overall integrity of the device. In an embodiment the feed screen 600 is an edgeless feed screen, having a flat flange surrounding the peripheral edge of the screen portion of the feed screen.

[0063] A method of manufacturing a feed screen is also provided. The method includes providing a screen and forming a flange around a periphery of the screen such that the flange defines a uniform sealing surface, and such that the screen does not extend to an outer periphery of the flange. In one example, the flange is formed via overmolding. The screen may include an inlet aperture and an outlet aperture.

[0064] The method may include providing a screen pinch to stop the intrusion of material, e.g., plastic or polymer, into the screen material. The pinch may be a metal ridge machined into a mold which, when the mold halves are closed together, has less space between the metal ridges than the thickness of the screen. The ridge must have some minimum width to be strong enough not to wear out over time. The taller the ridge from the surface of the mold, the more it will pinch into the screen when the mold halves are closed. The interference between the ridge and the screen causes the screen to squish outwardly and permanently deform. For example, FIG. 6 shows a microscope image of the screen pinch area. The screen pinch 750 is positioned between the screen 700 and the flange 760. The deeper the interference, or the wider the ridge, the more pressure from the molten material can be withstood without flashing during the injection molding process.

[0065] FIG. 7 shows a cross-sectional view of a feed screen, for example, the feed screen of FIG. 5. As discussed above, the screen 700 is spaced from the flange 760 by the screen pinch 750. When the screen intrudes minimally into the flange, the material pressure to fill the mold during injection molding is substantially lower and more uniform than the pressure would be when filling through a feed screen where the screen extends fully to the periphery of the flange or past the outside of the flange. The lower pressure afforded by using the present feed screen allows for the width and depth of the pinch to be less substantial. The ability to reduce the width and depth of the pinch enables greater scalability, increases reliability, and increases longevity of the mold while simultaneouslyoffering a larger processing window for the molding process. For example, allowing a wider range of temperature, pressure, and other molding parameters.

[0066] The dimensions of the pinch may vary based on the feed screen size and characteristics. The dimensions of the pinch may be between about 0.0125 inches in depth and about 0.02 inches to 0.125 inches in width on each side of the feed screen. The pinch may have a width measured as a percentage relative to an overall width of the feed screen. For example, the percentage may be determined by dividing the width of the pinch by the overall width of the feed screen, and multiplying by 100%. The pinch may be between about 10% and about 40% of the width of the feed screen.

[0067] In one embodiment, a feed screen for a tangential flow filtration system is described. The feed screen for the filtration system includes a body. The body includes a screen, a flange, at least one feed inlet port, and at least one feed outlet port. The flange surrounds the screen. The at least one feed inlet port is in fluid communication with the screen. The at least one feed outlet port is in fluid communication with the screen. The screen is spaced inward a distance from an outer perimeter of the body by the flange.

[0068] In one example, the screen extends into the flange a distance less than or equal to 0.3 inches. The flange may provide a sealing surface for sealing a membrane member around the feed screen. The body may include at least one permeate port, the at least one permeate port being fluidly isolated from the screen. In one example, the screen does not extend past an outer periphery of the flange.

[0069] In one example, the body may further include a first permeate port adjacent to the feed inlet port and a second permeate port adjacent to the feed outlet port. The first permeate port and the second permeate port may be fluidly isolated from the screen. The flange may be formed from one of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate.

[0070] In one embodiment, a filtration module for a tangential flow filtration system is described. The filtration module includes a membrane and a feed screen. The feed screen is in contact with the membrane. The feed screen includes a body having a screen and aflange surrounding the screen. The screen does not extend past an outer periphery of the flange.

[0071] In one example, the membrane may be affixed to a first side of the flange forming a first seal. The first seal does not overlap the screen. The filtration module may include a permeate screen heat sealed to the membrane. The body of the feed screen may include at least one feed inlet in fluid communication with the screen and at least one feed outlet in fluid communication with the screen. At least one permeate port is fluidly isolated from the screen.

[0072] In one example, the permeate screen and the flange of the body of the feed screen are formed from the same material. The flange is made of at least one of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate.

[0073] In one embodiment, a method of manufacturing a feed screen is described. The method includes providing a screen and forming a flange around a periphery of the screen such that the flange defines a uniform sealing surface, and such that the screen does not extend to an outer periphery of the flange.

[0074] In one example, the flange is formed via overmolding. The method may include forming the flange via overmolding. The screen may include an inlet aperture and an outlet aperture. The method may include sealing a permeate screen to a membrane. The screen does not overlap the seal between the flange and the membrane. The step of forming the flange includes forming first and second permeate ports in the flange. The first and second permeate ports being fluidly isolated from the screen.

[0075] As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” do not exclude the plural of said elements or operations, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the invention do not exclude the existence of additional embodiments that incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising,” “comprises,” “including,” “includes,” “having,” or “has” an element or aplurality of elements having a particular property may include additional such elements not having that property. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and do not impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function devoid of further structure.

[0076] The above description is illustrative, and not restrictive. For example, the abovedescribed embodiments (and / or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the inventive subject matter without departing from its scope. While the dimensions and types of materials described herein define the parameters of the inventive subject matter, they are exemplary embodiments. Other embodiments will be apparent to one of ordinary skill in the art upon reviewing the above description. The scope of the inventive subject matter should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0077] Use of phrases such as “one or more of ... and,” “one or more of ... or,” “at least one of ... and,” and “at least one of ... or” are meant to encompass including only a single one of the items used in connection with the phrase, at least one of each one of the items used in connection with the phrase, or multiple ones of any or each of the items used in connection with the phrase. For example, “one or more of A, B, and C,” “one or more of A, B, or C,” “at least one of A, B, and C,” and “at least one of A, B, or C” each can mean (1) at least one A, (2) at least one B, (3) at least one C, (4) at least one A and at least one B, (5) at least one A, at least one B, and at least one C, (6) at least one B and at least one C, or (7) at least one A and at least one C.

[0078] This written description uses examples to disclose several embodiments of the inventive subject matter, including the best mode, and to enable one of ordinary skill in theart to practice the embodiments of inventive subject matter, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the inventive subject matter is defined by the claims, and may include other examples that occur to one of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.

Claims

WHAT IS CLAIMED IS:

1. A feed screen for a tangential flow filtration system, comprising:a body having:a screen;a flange surrounding the screen;at least one feed inlet port in fluid communication with the screen; and at least one feed outlet port in fluid communication with the screen; wherein the screen is spaced inward a distance from an outer perimeter of the body by the flange.

2. The feed screen of claim 1, wherein:the screen extends into the flange a distance less than or equal to 0.3 inches.

3. The feed screen of claim 2, wherein:the screen does not extend past an outer periphery of the flange.

4. The feed screen of claim 1, wherein:the flange provides a sealing surface for sealing a membrane member around the feed screen.

5. The feed screen of claim 1, wherein:the body includes at least one permeate port, the at least one permeate port being fluidly isolated from the screen.

6. The feed screen of claim 1, wherein:the body further includes a first permeate port adjacent to the feed inlet port, and a second permeate port adjacent to the feed outlet port;wherein the first permeate port and the second permeate port are fluidly isolated from the screen.

7. The feed screen of claim 1, wherein:the flange is formed from one of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate.

8. A filtration module for use in a tangential flow filtration system, comprising: a membrane; anda feed screen in contact with the membrane, the feed screen including a body having a screen and a flange surrounding the screen;wherein the screen does not extend past an outer periphery of the flange.

9. The filtration module of claim 8, wherein:the membrane is affixed to a first side of the flange forming a first seal; wherein at least a portion of the first seal does not overlap the screen.

10. The filtration module of claim 9, further comprising a permeate screen heat sealed to the membrane.

11. The filtration module of claim 10, wherein the permeate screen includes at least one permeate port, the at least one permeate port being fluidly isolated from the screen.

12. The filtration module of claim 11, wherein:the body of the feed screen includes at least one feed inlet in fluid communication with the screen, and at least one feed outlet in fluid communication with the screen, and at least one permeate port fluidly isolated from the screen.

13. The filtration module of claim 11, wherein:the permeate screen and the flange of the body of the feed screen are formed from a like material.

14. The filtration module of claim 8, wherein:the flange is made of at least one of a polyolefin, silicone, urethane, a thermoplastic elastomer, a thermoplastic urethane, and a thermoplastic vulcanizate.

15. A method of manufacturing a feed screen, comprising:providing a screen; andforming a flange around a periphery of the screen such that the flange defines a uniform sealing surface, and such that the screen does not extend to an outer periphery of the flange.

16. The method according to claim 15, wherein:the flange is formed via overmolding.

17. The method according to claim 15, wherein:the screen includes an inlet aperture and an outlet aperture.

18. The method according to claim 15, further comprising the step of:sealing a permeate screen to a membrane.

19. The method according to claim 18, wherein:the screen does not overlap the seal between the flange and the membrane.

20. The method according to claim 15, wherein:forming the flange includes forming first and second permeate ports in the flange, the first and second permeate ports being fluidly isolated from the screen.

21. The method according to claim 15, further comprising: positioning a screen pinch between the screen and the flange.20

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