Composite Membrane with Macroporous Gel for High-Throughput Filtration
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Solution Overview
Problem
Current membrane filtration technologies face challenges with high contaminant feed streams, leading to rapid membrane plugging and reduced efficiency in separating target biomolecules from viscous and contaminated solutions, such as egg white, due to issues like concentration polarization and turbulence, which result in decreased throughput and increased operational costs.
Innovation Solution
A fluid treatment device featuring a composite material with a support member and a non-self-supporting macroporous cross-linked gel, where the macropores are smaller than the support member pores, arranged in configurations like coplanar stacks, tubular, or spiral wound, allowing for tangential flow and selective capture of target molecules with high binding capacity and reduced fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional direct flow filtration (DFF) is used to separate biomolecules from viscous and contaminated feed streams, then the membrane provides initial separation capability, but rapid membrane plugging occurs leading to decreased throughput and reduced efficiency
Solution Approach 1:
The invention employs a porous support structure with controlled pore size distribution that allows selective passage of molecules while preventing fouling. The porous architecture provides channels for fluid flow that reduce concentration polarization and prevent plugging by maintaining appropriate flow dynamics through the membrane matrix.
Solution Approach 2:
The membrane comprises a composite structure combining a porous support layer with a gel layer containing functional groups for biomolecule capture. This composite design integrates the mechanical strength and flow properties of the porous support with the selective binding capabilities of the gel, achieving both high throughput and effective separation.
2Productivity
If conventional filtration membranes are used with highly flocculating dispersions, then filtration separation is achieved, but floc formation near the membrane surface causes plugging and significant downtime
Solution Approach 1:
The invention converts the harmful effect of floc formation into a beneficial process by designing the membrane surface and flow regime to control floc deposition. The tangential flow component prevents excessive floc accumulation while the functional groups on the membrane selectively capture target molecules, transforming what would be a plugging problem into a controlled separation mechanism.
Solution Approach 2:
The invention modifies flow parameters by implementing tangential flow filtration mode with controlled shear rates that prevent excessive floc formation. The membrane surface properties are also adjusted through functional group selection to control interaction with flocs, changing the physical and chemical parameters of the filtration process to eliminate plugging.
3Productivity
If high pressure is applied to maintain reasonable flux in DFF separation, then permeate flux is maintained, but membrane blinding with solute occurs and operational costs increase
Solution Approach 1:
The invention utilizes hydraulic principles of tangential flow where the feed stream flows parallel to the membrane surface rather than directly through it. This hydrodynamic approach creates a sweeping effect that prevents solute accumulation and membrane blinding while maintaining appropriate flux levels without requiring excessive pressure.
Solution Approach 2:
The invention implements dynamic flow conditions with controlled cross-flow velocities that adapt to prevent solute deposition. The tangential flow regime creates continuous movement along the membrane surface, dynamically preventing static accumulation of solutes that would lead to blinding, while maintaining efficient mass transfer.
4Productivity
If conventional single-stage filtration is used for biomolecule separation, then the process is simple and reliable, but separation power and purification efficiency are insufficient for highly contaminated streams
Solution Approach 1:
The membrane is designed with multiple functional groups that provide both size-based filtration and specific biomolecule capture capabilities in a single stage. The functional groups (such as ion-exchange, affinity, or adsorption sites) enable the membrane to perform multiple separation functions simultaneously, achieving high purification efficiency without requiring complex multi-step processes.
Solution Approach 2:
The invention combines conventional filtration mechanisms with specific biomolecule capture functionality in a single integrated membrane structure. The porous support provides mechanical filtration while the gel layer with functional groups provides selective binding, merging size exclusion and affinity-based separation into one unified process that maintains simplicity while enhancing purification efficiency.
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 device achieves superior performance with up to 25× higher binding capacity and 10× to 100× higher throughput than existing systems, enabling efficient separation and purification of biomolecules from highly viscous feed streams with reduced operational costs and simplified process operations.
Implementation Method 1
a non-self-supporting macroporous cross-linked gel comprising macropores having an average size of 10 nm to 3000 nm
Implementation Method 2
a support member comprising a plurality of pores extending through the support member; and a non-self-supporting macroporous cross-linked gel comprising macropores
Data Source
AI summary
Described herein are fluid treatment devices for use in tangential flow filtration, comprising a housing unit and a composite material, wherein the composite material comprises: a support member comprising a plurality of pores extending through the support member; and a non-self-supporting macroporous cross-linked gel comprising macropores having an average size of 10 nm to 3000 nm, said macroporous gel being located in the pores of the support member. The invention also relates to a method of separating a substance from a fluid, comprising the step of placing the fluid in contact with an inventive device, thereby adsorbing or absorbing the substance to the composite material contained therein.