Flow Director Filter for High-Volume Cell Culture Harvest
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Solution Overview
Problem
Existing filter systems face challenges in efficiently filtering large volumes of cell culture harvests without clogging, particularly due to high levels of particulate matter, which requires frequent filter changes and often necessitates a labor-intensive centrifugation step to prevent clogging.
Innovation Solution
The use of filtration devices with a flow director that increases the filter surface area by displacing more internal space towards the bottom, allowing larger volumes of crude samples to be filtered without clogging, and optionally incorporating a center sleeve to improve recovery at the end of the filtration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional filter is used to filter cell culture harvest, then filtration is performed, but the filter clogs quickly due to high particulate matter, requiring frequent filter changes and centrifugation
Solution Approach 1:
The filter is divided into multiple filtration zones with different pore sizes arranged in sequence. The first zone has larger pores to capture bulk particulate matter, while subsequent zones have progressively smaller pores for finer filtration. This segmentation allows each zone to handle specific particle sizes, preventing rapid clogging of the entire filter and extending filtration capacity.
Solution Approach 2:
Different regions of the filter have different pore size characteristics tailored to local filtration needs. The upstream regions have larger pores optimized for capturing large cell debris, while downstream regions have smaller pores for sterilization-level filtration. This local quality variation optimizes the filtration process at each stage and delays overall filter clogging.
2Reliability
If centrifugation is performed before filtration to remove bulk cells and debris, then filter clogging is delayed, but the process becomes slow, expensive, and labor intensive
Solution Approach 1:
The invention combines multiple filtration functions into a single integrated filter assembly. The depth filter and surface filter are merged into one unit, eliminating the need for separate centrifugation and filtration steps. This unified design captures both bulk particulate matter and fine particles in one pass, simplifying the overall process while maintaining effective clogging resistance.
Solution Approach 2:
The depth filter acts as an intermediary layer between the crude harvest and the final surface filter. It pre-cleans the sample by capturing large particulate matter, thereby protecting the downstream surface filter from rapid clogging. This intermediary function eliminates the need for centrifugation while still providing effective protection to the final filter.
3Productivity
If filter surface area is increased to delay clogging, then more filtrate can pass through, but the filter volume increases and recovery efficiency decreases due to clogged bottom areas
Solution Approach 1:
The invention transitions from a conventional flat filter geometry to a three-dimensional depth filter structure. The depth filter provides additional filtration capacity in the vertical dimension rather than requiring increased horizontal surface area. This allows high filtration volume capacity while maintaining compact filter dimensions and improving sample recovery by utilizing the full filter surface area effectively.
Solution Approach 2:
The filter design nests multiple filtration functions within a compact structure. The depth filter media is nested within a support structure that maximizes surface area utilization. This nested arrangement allows high filtration capacity in a small volume while ensuring all filter surfaces remain accessible and functional, preventing the bottom-clogging issues seen in conventional designs.
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
These devices enable high-volume filtration with lower pressure differentials and higher overall recoveries, reducing the need for centrifugation and delaying clogging, thus enhancing the efficiency and effectiveness of the filtration process.
Implementation Method 1
a flow director positioned within the filter and configured to direct sample flows to the filter
Implementation Method 2
The filtration devices of the inventions provide, e.g., high volume filtration flows, at lower pressure differentials, and with higher overall recoveries
Implementation Method 3
high volume filtration flows, at lower pressure differentials
Data Source
AI summary
Filter devices with a flow director surrounded by a filter element providing a large filter surface area and low fluid volumes for efficient filtration and high recovery of sample fluids. The filter device can be configured with dimensions and sealing surfaces to functionally interact as a pre-filter for common usage disposable filter flasks.