Stackable Planar Adsorptive Devices for Linear Chromatography Scaling
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Solution Overview
Problem
Existing chromatographic devices are not linearly scalable, requiring significant design and geometry alterations as the device size increases, leading to uncertainties and risks in pharmaceutical manufacturing processes, and they have limitations in capacity, scalability, and operational efficiency due to the use of bead-packed columns and membrane-based adsorbers.
Innovation Solution
The development of planarly cohesive, substantially isotropic adsorptive media in the form of web-based cassettes that can be stacked to create thick adsorptive blocks, allowing for easy scaling and self-supporting structures that resist hydraulic pressures, enabling the use of soft stationary phases and facilitating uniform lateral flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional bead-packed columns are used, then chromatographic separation can be achieved, but the devices are not linearly scalable and require significant design alterations as size increases
Solution Approach 1:
The adsorptive bed is segmented into multiple planar layers or sheets that can be stacked vertically. Each layer contains adsorptive media distributed across a planar support structure, allowing the system to be scaled by simply adding more layers rather than redesigning the entire column geometry.
Solution Approach 2:
The invention transitions from conventional cylindrical/columnar geometry to a planar layered geometry. By stacking multiple planar adsorptive layers vertically, the system achieves scalability in the vertical dimension while maintaining consistent planar flow paths, enabling linear scale-up without geometric redesign.
2Speed
If membrane-based adsorbers are used, then fast kinetics and short bed depths are achieved, but capacity is severely limited
Solution Approach 1:
The invention uses planar adsorptive layers with flow paths that traverse laterally across the plane rather than perpendicular to it. This dimensional change allows increased bed depth through vertical stacking while maintaining the fast kinetics characteristics of thin-planar structures, thereby increasing capacity without sacrificing speed.
Solution Approach 2:
The adsorptive bed is divided into multiple thin planar layers stacked vertically. Each layer maintains the thin-structure advantages for fast kinetics, while the cumulative effect of multiple layers provides increased total capacity through extended flow path length.
3Ease of operation
If planar adsorptive beds are made very thin, then capillary flow is sufficient without pumping, but the beds lack structural support under pressure
Solution Approach 1:
The thin planar adsorptive layers are segmented and stacked between rigid end plates. The end plates provide structural support and pressure containment, allowing the use of thin layers that rely on capillary flow while the overall assembly can withstand operating pressures.
Solution Approach 2:
Rigid end plates and support structures act as intermediaries between the thin planar adsorptive layers and the applied hydraulic pressure. These support elements distribute and contain the pressure, protecting the thin layers from structural failure while allowing capillary-driven flow.
4Stability of the object's composition
If stacked web-based structures are used, then planar cohesion is achieved, but the sidewalls require encapsulation to contain hydraulic pressure
Solution Approach 1:
A peripheral seal or encapsulating layer is introduced as an intermediary element that contains hydraulic pressure along the sidewalls of the stacked web structure. This seal allows the web-based structure to maintain its planar cohesive advantages while providing the necessary pressure containment for practical operation.
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
This solution enables linear scalability from laboratory to large-scale manufacturing, increases capacity, and reduces operational complexities by allowing easy loading and unloading, while maintaining performance and uniformity of fluid flow, thus addressing the limitations of conventional chromatographic devices.
Implementation Method 1
planarly cohesive, substantially isotropic adsorptive media
Implementation Method 2
induce substantially uniform lateral flow from the first end to the second end within the block
Implementation Method 3
a peripheral seal encapsulating the at least one sidewall
Implementation Method 4
The differential adsorptive interaction between the components and media leads them to traverse the column at different velocities, which results in a physical separation of the components
Data Source
AI summary
Stackable planar adsorption devices include a plurality of layers of adsorptive media provided in a web format. The layers are stacked in contiguous fashion, sealed and include fluid passageways to provide a range of scalable chromatography devices suitable for large scale manufacturing applications.