Membrane Surface Channels for Virus Removal and Protein Capacity
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Solution Overview
Problem
Existing membranes have limitations in protein capacity and virus removal efficiency, requiring improved designs for enhanced filtration performance.
Innovation Solution
A microporous membrane with parallel channels on its surface, featuring rough side walls and a substrate with machine direction abrasions, which reduces skin formation and allows for increased pore availability, resulting in improved virus removal and protein filtration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional membranes are used, then virus removal capability is achieved, but protein capacity is limited
Solution Approach 1:
The membrane surface is segmented into distinct regions: smooth areas for virus removal and rough channel regions for protein capacity enhancement. The surface channels create separate pathways that segment the flow, allowing simultaneous optimization for different functions.
Solution Approach 2:
Different regions of the membrane surface have different qualities - smooth regions maintain virus removal efficiency while rough channel regions with Ra 0.1-0.5 μm provide enhanced protein capacity. This local differentiation allows the membrane to excel at both functions in different areas.
2Productivity
If membrane thickness is reduced to improve flow, then filtration efficiency may decrease, but the invention achieves both reduced thickness and maintained efficiency
Solution Approach 1:
The membrane incorporates surface channels with rough surfaces that create enhanced pore structures. The rough surfaces within channels (Ra 0.1-0.5 μm) provide increased surface area and improved mass transfer, maintaining filtration efficiency even in thinner membranes.
Solution Approach 2:
The invention adds a surface dimension feature (channels with rough walls) rather than simply increasing thickness. The channels extend along the surface plane, providing enhanced filtration capability without compromising the thin-profile advantage.
3Quantity of substance
If smooth surface membranes are used, then manufacturing is simple, but protein capacity is reduced
Solution Approach 1:
A substrate with pre-formed parallel abrasions serves as an intermediary tool to create the rough channel surfaces. The substrate's abrasion pattern transfers to the membrane during formation, providing controlled surface complexity without requiring complex direct manufacturing processes.
4Strength
If membrane thickness is increased to improve strength, then pleating becomes difficult, but the invention achieves robustness for pleating with reduced thickness
Solution Approach 1:
The porous structure with surface channels and rough surfaces provides mechanical interlocking and structural reinforcement. The channel walls with Ra 0.1-0.5 μm roughness create friction and mechanical engagement that enhance strength without requiring increased thickness.
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 comparable or better virus removal efficiency with reduced thickness and cost, and increased protein filtration capacity compared to conventional membranes, while being robust enough for pleating.
Implementation Method 1
the channels have side walls comprising rough surfaces, the rough surfaces having an Ra in the range of from about 0.1 μm (4.5 μin) to about 0.5 μm (19.0 μin)
Implementation Method 2
the rough surfaces having an Ra in the range of from about 0.1 μm (4.5 μin) to about 0.5 μm (19.0 μin)
Implementation Method 3
A microporous membrane with parallel channels on its surface
Implementation Method 4
exposing the solution to a phase inversion solution and forming a microporous membrane
Data Source
Figure 1A~1B
Figure 2~3B
Figure 4
AI summary
Membranes having parallel channels in a surface of the membranes, wherein the channels have side walls having rough surfaces; filters and devices including at least one membrane, and methods of making and using the membranes, are disclosed.