High Throughput Membrane With Segmented Channels

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Solution Overview

Problem

Current polymeric membranes for fluid filtration lack high throughput performance due to limitations in pore structure design, which affects their efficiency in applications such as sterile filtration and industrial processes.

Innovation Solution

A polymeric microporous membrane with two distinct porous portions, where the first portion has a more open pore structure with channels created by removing introduced fibers, and the second portion has smaller controlled pore structures, allowing for optimized pore structures for specific applications like sterile filtration and high throughput.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a polymeric membrane uses a uniform pore structure, then it is easier to manufacture, but it cannot achieve both high throughput and effective filtration simultaneously

Engineering Contradiction:

ImprovethroughputVSAvoidpore structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The membrane is divided into multiple distinct porous portions (first porous portion with larger pores, second porous portion with smaller pores) that perform different functions. This segmentation allows each portion to be optimized independently - the first portion for high throughput and the second portion for effective filtration - thereby resolving the contradiction between productivity and device complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the membrane are given different pore structures tailored to their specific functions. The first porous portion has a more open pore structure with larger average pore size for high throughput, while the second porous portion has a denser structure with smaller average pore size for effective filtration. This local differentiation enables the membrane to achieve both high productivity and effective filtration simultaneously.

Inventive Principle:

Principle #3Local quality

2Productivity

If a membrane has larger pores for high throughput, then fluid flow increases, but filtration efficiency and retentive capabilities decrease

Engineering Contradiction:

Improvefluid flow rateVSAvoidfiltration efficiency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The membrane is segmented into functional zones: the first porous portion with larger pores handles high throughput fluid flow, while the second porous portion with smaller pores provides the filtration barrier. This segmentation allows the system to achieve both high fluid flow rate and high filtration efficiency by distributing these conflicting requirements to different portions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The membrane exhibits local quality variations where the first porous portion has optimized pore structures for maximum fluid flow, while the second porous portion has optimized pore structures for maximum filtration efficiency. This local differentiation in pore quality enables the membrane to simultaneously achieve high productivity and high reliability in filtration.

Inventive Principle:

Principle #3Local quality

3Productivity

If channels are created by removing introduced fibers, then pore structure control and throughput improve, but manufacturing complexity increases

Engineering Contradiction:

Improvechannel formation efficiencyVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Fibers are introduced into the membrane structure during the manufacturing process as a preliminary step, and then these fibers are selectively removed to create the desired channel structures. This preliminary action of fiber introduction simplifies the overall manufacturing process by using a straightforward incorporation step followed by a controlled removal step, rather than attempting to create complex channels directly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The introduced fibers serve as an intermediary structure during manufacturing. They are temporarily incorporated into the membrane to define the future channel locations and shapes, then selectively removed to create the final pore structure. This intermediary approach simplifies manufacturing by using the fibers as a template or mold for the channels, making the process more controllable and easier to execute.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 high throughput and efficient filtration by maintaining structural integrity and allowing lateral flow without blocking, while the smaller pore structures in the downstream portion ensure retentive capabilities for sterile filtration.

Implementation Method 1

a polymeric microporous membrane... comprising (a) a first microporous surface; (b) a second microporous surface; and (c) a bulk between the first surface and the second surface

Methodology Applied

Scientific EffectSize exclusion: Filter (physical)

Implementation Method 2

allowing lateral flow without blocking

Methodology Applied

Scientific EffectLateral flow: Advection

Implementation Method 3

the membrane provides for sterile filtration

Methodology Applied

Scientific EffectSterile filtration: Filter (physical)

Data Source

PatentUS9808770B2High throughput membrane with channels

Publication Date: 2017.11.07 CYTIVA US LLC

AI summary

Membranes having first and second porous portions, wherein the first portion has a more open pore structure than the second portion, wherein the first porous portion includes channels prepared by removing introduced fibers, as well as methods of making and using the membranes, are disclosed.