Disposable Filter Flow Reducer for Membrane Wetting
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Solution Overview
Problem
Disposable filtration devices face challenges in efficiently wetting filter membranes during integrity tests due to the complexity of integrating control valves and pressure sensors, which also result in excessive water usage.
Innovation Solution
A disposable filtration device with an integrated flow reducer that can switch between two volume flow rates, allowing for effective back pressure during flushing while remaining sterilizable and simplifying handling, significantly reducing water usage by up to 95%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a controllable valve and pressure sensor are integrated into disposable filtration devices to enable back pressure control during flushing, then the wetting efficiency of the filter membrane is improved, but the device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent applies the disposable principle by integrating a simple, sterilizable flow reducer directly into the single-use filtration device. This eliminates the need for complex control valves and pressure sensors that would need to be integrated into disposable components. The flow reducer is designed as a simple mechanical component with defined flow cross-sections that can be easily manufactured, sterilized, and discarded with the filter unit, thereby maintaining wetting efficiency without increasing device complexity.
Solution Approach 2:
The patent extracts the back pressure control function from complex active components (control valves and pressure sensors) and implements it through a passive flow reducer with predefined flow characteristics. By removing the need for active control mechanisms in disposable devices, the solution simplifies the device architecture while preserving the essential function of generating back pressure during flushing operations.
2Reliability
If sterile water is provided in bags for flushing disposable filters, then the filter membrane can be wetted for integrity testing, but the water consumption becomes excessively high and costly
Solution Approach 1:
The patent applies parameter changes by modifying the flow characteristics through the flow reducer, which creates defined back pressure conditions during flushing. This changes the pressure parameter in the flushing process, enabling more efficient water utilization. The back pressure generated by the flow reducer improves wetting efficiency and facilitates bubble removal, allowing integrity testing to be performed with significantly reduced water consumption while maintaining test reliability.
3Measurement precision
If control valves and pressure sensors are integrated into disposable filtration devices, then back pressure can be precisely controlled during flushing, but additional connections and sterilization complexity are required
Solution Approach 1:
The patent replaces precision control instruments (control valves and pressure sensors) with a simple, disposable flow reducer that provides sufficient back pressure control for flushing operations. The flow reducer is designed as a straightforward mechanical component with defined flow cross-sections that can be manufactured using standard processes, easily assembled into the filter unit, and sterilized using conventional methods, thereby improving ease of manufacture while providing adequate pressure control.
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 integrated flow reducer ensures reliable wetting of filter membranes with reduced water consumption, enhancing the efficiency and cost-effectiveness of the filtration process, particularly in single-use applications.
Implementation Method 1
The back pressure ensures that any trapped gas is dissolved better and/or bubbles are reduced in size and can migrate through the filter membrane. Since the back pressure reduces the transmembrane pressure
Implementation Method 2
The back pressure ensures that any trapped gas is dissolved better
Implementation Method 3
a filter means and a preferably integrated flow reducer are arranged one behind the other
Data Source
AI summary
A filtration device, in particular a disposable filtration device, has a flow path in which a filter element and an integrated flow reducer are arranged one behind the other. The flow reducer is adapted to be brought to a first operating position, which permits a defined first volume flow rate, and at least to a second operating position, which permits a defined second volume flow rate which is smaller than the first volume flow rate.