Sterilizing Filter Manufacturing with Large-Inner-Diameter Hollow Fibers

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Solution Overview

Problem

There is a lack of an industrial-scale manufacturing process for sterilizing filters comprising hollow fiber membranes with a large inner diameter suitable for dead-end filtration of medical liquids.

Innovation Solution

A process involving the preparation of a polymer solution, continuous solvent phase inversion spinning, cutting and sealing of hollow fiber membranes, and assembly into a housing to create a sterilizing filter with large inner diameter and specific pore size for effective filtration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If hollow fiber membranes with large inner diameter are used for sterilizing filters, then filtration efficiency and patient safety are improved, but no industrial-scale manufacturing process is available

Engineering Contradiction:

Improvefiltration efficiencyVSAvoidmanufacturing process availability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manufacturing process segments the production into distinct stages: spinning solution preparation, phase inversion in coagulation bath, drawing through tension, cutting into individual fibers, bundling, and final assembly. This segmentation enables industrial-scale production by making each step manageable and controllable

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The process maintains continuous production through continuous spinning solution extrusion, continuous phase inversion, and continuous drawing of fibers through tension. This continuity eliminates interruptions and enables scalable industrial manufacturing while maintaining consistent fiber quality

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If continuous solvent phase inversion spinning is used, then production efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveproduction efficiencyVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The spinning solution serves multiple functions: it provides the polymer matrix, contains the pore-forming agent (PVP), and acts as the medium for phase inversion. This multi-functionality reduces the number of separate processing steps and simplifies the overall manufacturing system

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The hollow fiber structure itself is nested - a continuous fiber is formed that is then cut into segments, which are bundled together. The manufacturing process nests multiple operations (spinning, cutting, bundling) in a compact sequence, reducing space and equipment requirements

Inventive Principle:

Principle #7Nested doll (Nesting)

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

Enables the production of high-quality sterilizing filters with large inner diameter and precise pore size for efficient filtration of medical liquids, ensuring patient safety by removing pyrogens and particulate matter.

Implementation Method 1

continuous solvent phase inversion spinning

Methodology Applied

Scientific EffectPhase inversion: Phase Change

Implementation Method 2

dead-end filtration of medical liquids

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentEP4084895B1Process for manufacturing a sterilizing filter

Publication Date: 2025.07.16 GAMBRO LUNDIA AB

Figure 1

AI summary

The present disclosure relates to a process for manufacturing a sterilizing filter comprising a plurality of hollow fiber membranes having a large inner diameter.