Biocompatible Polymeric Membrane With Uniform Pores for Fouling Control
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Solution Overview
Problem
Existing tangential flow filtration devices suffer from variability in pore size due to manual processes and material limitations, leading to fouling and inefficiencies, particularly in bioprocess applications.
Innovation Solution
A biocompatible polymeric filtration membrane with uniformly controlled pores is created using photolithography and mask technology, utilizing a sacrificial layer to define precise pore dimensions, ensuring consistent performance and resistance to pressure-induced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard microprocessor technology and semiconductor materials are used to create particulate filters, then pore size can be precisely controlled, but the device becomes brittle and cannot withstand typical membrane filter conditions
Solution Approach 1:
The patent changes the material parameters from brittle semiconductor materials to flexible polyimide polymers, while maintaining precise pore size control through the relationship between membrane thickness and pore diameter. This allows the membrane to withstand mechanical stress while preserving manufacturing precision.
Solution Approach 2:
The patent creates a composite structure where a porous polyimide membrane is combined with a metal support screen. This composite provides both the mechanical strength of metal and the filtration properties of the polymer, resolving the contradiction between strength and precision.
2Ease of manufacture
If horizontal passages are used in the membrane structure, then manufacturing is simplified, but the passages become deformed upon application of pressure
Solution Approach 1:
The patent transitions from horizontal passages to vertically extending cylindrical pores. The curved cylindrical geometry provides structural stability under pressure while maintaining manufacturing feasibility through controlled phase separation during membrane formation.
Solution Approach 2:
The patent changes the pore orientation from horizontal to vertical, extending through the entire thickness of the membrane. This dimensional change allows the pores to resist deformation under pressure while simplifying the manufacturing process through bulk phase separation.
3Manufacturing precision
If very small pores are used in hollow fiber devices, then filtration precision is improved, but the pores foul easily
Solution Approach 1:
The patent extracts the retentate stream containing suspended solids from the filtration path by directing it along the outer surface of the membrane. This tangential flow prevents solids from entering and blocking the small pores, maintaining both precision and reliability.
Solution Approach 2:
The patent uses hydraulic flow dynamics, specifically tangential flow filtration, where the feed stream flows parallel to the membrane surface. This creates a sweeping effect that prevents fouling of small pores while maintaining high filtration precision.
4Ease of manufacture
If manual processes are used to embed hollow fibers into tubes, then device assembly is simplified, but variability in effectiveness increases
Solution Approach 1:
The patent replaces manual mechanical assembly with a automated casting process. The membrane is formed in situ within the tube using controlled phase separation, eliminating variability introduced by manual embedding while maintaining assembly simplicity.
Solution Approach 2:
The patent performs preliminary action by forming the porous membrane structure within the tube before final assembly. This ensures consistent pore distribution and effective area from the start, eliminating variability that would arise from post-assembly adjustments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The membrane achieves uniform pore sizes with tight control over the entire surface, reducing fouling and enhancing filtration efficiency in both tangential and dead-end filtration applications.
Implementation Method 1
The membranes are made using photolithography and mask technology
Implementation Method 2
utilizing a sacrificial layer to define precise pore dimensions
Implementation Method 3
tangential flow filtration is widely used in bioprocess technology to remove liquid from a mixture of particulate and liquid
Implementation Method 4
ensuring consistent performance and resistance to pressure-induced deformation
Data Source
AI summary
A biocompatible polymeric membrane includes pores defined between two material layers, where the first membrane material layer includes strips, and the second membrane material binds to each of the plurality of first membrane material layer strips includes a plurality of windows exposing each of the first membrane material strips. The biocompatible polymeric filtration membrane comprises pores defined by uniform passages defined by the first membrane material layer strips and the second membrane material layer within each window.