Disposable Filter Element With Bonded Media Layers
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Solution Overview
Problem
Current filtration technologies for biopharmaceutical applications face challenges such as high residual volumes, inconsistent results, high capital costs, and cumbersome cleaning processes, particularly in chromatography, due to the use of packed columns and traditional filtration methods.
Innovation Solution
The development of filter elements with media layers bonded directly to a separator element, forming a concentric structure that allows for hermetic seals and integrity testing, enabling the creation of simpler, less costly, and disposable filtration cells that replace traditional packed columns and stainless steel vessels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional packed columns are used for chromatography, then separation capability is achieved, but capital cost and device complexity increase
Solution Approach 1:
The patent employs disposable filter elements made from bonded media layers that replace expensive, reusable packed columns. These single-use elements eliminate the need for costly capital equipment while maintaining separation capability through their integrated media and separator element design.
Solution Approach 2:
The patent combines multiple functions into a single integrated filter element structure. The media layers are directly bonded to the separator element, merging the filtration media, support structure, and sealing components into one unit that performs separation while reducing overall device complexity.
2Reliability
If traditional packed columns are used for chromatography, then separation capability is achieved, but manufacturing consistency decreases
Solution Approach 1:
The patent segments the filtration system into pre-bonded media layers that are manufactured with consistent specifications before assembly. This segmentation allows each layer to be produced with controlled precision and then reliably assembled to the separator element, ensuring manufacturing consistency across batches.
Solution Approach 2:
The media layers are pre-bonded to the separator element during manufacturing with controlled adhesive application and curing processes. This preliminary bonding action ensures consistent alignment and positioning before the filter element is installed, eliminating variability that would occur during field assembly.
3Reliability
If traditional filtration methods are used, then filtration is achieved, but residual volume increases
Solution Approach 1:
The patent uses thin media layers bonded directly to the separator element, creating a compact filtration structure. The thin-film design reduces the volume of fluid that can be trapped in the filtration bed, minimizing residual volume while maintaining effective filtration capability.
Solution Approach 2:
The patent transitions from traditional three-dimensional packed beds to a more compact, layered structure where media are arranged in thin bonds. This dimensional change from bulk packing to layered configuration reduces the overall volume occupied by the filtration media and decreases residual fluid retention.
4Reliability
If traditional filtration methods are used, then filtration is achieved, but cleaning complexity increases
Solution Approach 1:
The patent employs disposable filter elements that eliminate the need for cleaning and maintenance. After use, the entire filter element is discarded rather than cleaned, simplifying the operational process and eliminating cleaning complexity entirely. This is economically viable because the filter elements are inexpensive single-use components.
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
This solution minimizes residual volumes, reduces costs, and improves handling and manufacturing consistency, providing efficient and cost-effective filtration solutions for biopharmaceutical applications by forming filter elements with bonded media layers and a separator element, which can be easily integrated into filtration assemblies.
Implementation Method 1
wherein the inner edge periphery and optionally the outer edge periphery comprises a bond directly to a portion of the separator element
Implementation Method 2
The bond of the present application comprises an adhesive or a weld
Implementation Method 3
filter elements for purifying fluids used during various biopharmaceutical applications, for example, chromatography or depth filtration
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
AI summary
Provided are filter elements or cells and filtration assemblies or capsules for purifying and/or clarifying fluids used during various biopharmaceutical applications, for example, chromatography or depth filtration, and processes for making and using the same. A filter element comprises a media pack comprising two sides and a separator element located between the two sides, at least one side comprising a filtration media, wherein an inner edge periphery and/or an outer edge periphery of the filtration media comprise a bond directly to a portion of the separator element.