Tubular Membrane Filter Design for Uniform Transmembrane Pressure
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Solution Overview
Problem
Current tangential flow filtration technologies face challenges in achieving high surface area packing density, reduced recirculation rates, and consistent transmembrane pressure, particularly in large-scale applications for cultivated meats and precision fermentation, leading to inefficiencies and increased costs.
Innovation Solution
The development of innovative tubular membrane filter designs featuring a tube housing with a narrow gap and strategically placed holes or orifices to regulate permeate flow, along with the use of non-circular membrane tubes and internal cores to control flow resistance and turbulence, enhancing filtration efficiency and surface area utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hollow fiber or flat sheet cassettes are used for cell separation, then the membrane configuration is compact, but the separation flux is low (typically 20 LMH or less)
Solution Approach 1:
The patent changes the pore size parameter from conventional small pores (20 LMH flux) to large pores (2-5 μm) achieving 400 LMH or higher flux, directly resolving the contradiction between productivity and membrane area requirements
Solution Approach 2:
The patent transitions from flat sheet or hollow fiber configurations to tubular membrane geometry with large lumens, creating a three-dimensional structure that enables higher flux while maintaining compact footprint
2Productivity
If tubular membranes with large lumens are used, then the separation flux is high (400 LMH or higher), but the recirculation rate is high (2 L/min/tube or more)
Solution Approach 1:
The patent places multiple tubular membrane elements inside a single housing, nesting several high-flux tubes together to achieve the required total separation capacity while keeping individual tube recirculation rates manageable
Solution Approach 2:
The patent divides the filtration system into multiple separate tubular membrane elements rather than using a single large tube, allowing parallel operation that reduces recirculation rate per tube while maintaining high overall productivity
3Productivity
If the length of fibers is extended to enhance concentration ratio, then the concentration ratio improves, but the transmembrane pressure control becomes difficult due to substantial pressure differentials
Solution Approach 1:
The patent uses multiple shorter tubular membrane elements instead of one long fiber, segmenting the total filtration path to maintain uniform transmembrane pressure across all elements while achieving the required concentration ratio through parallel configuration
Solution Approach 2:
The patent optimizes each tubular membrane element's length to achieve local pressure uniformity, with each tube operating at optimal transmembrane pressure while the system as a whole achieves high concentration ratio through multiple parallel elements
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 designs achieve a more uniform transmembrane pressure profile, reduce recirculation rates, and increase filtration surface area, thereby improving separation efficiency and reducing operational costs in large-scale applications.
Implementation Method 1
Two key technologies used for cell separation in perfusion applications are Alternative Tangential Flow (ATF) and Tangential Flow Filtration (TFF). These approaches leverage semi-permeable membranes to separate cells from the culture medium.
Implementation Method 2
These approaches leverage semi-permeable membranes to separate cells from the culture medium.
Implementation Method 3
Filters capable of delivering consistent transmembrane pressure are highly sought after.
Data Source
AI summary
In some embodiments thereof, the present invention describes TFF (Tangential Flow Filtration) filtration devices that utilize tubular membranes for the separation of cells and particles. These devices encompass several innovative features, including the use of membrane tubes with either circular or non-circular cross-sections. These tubes are closely surrounded by both tube housing and filter housing to regulate the pressure of the liquid exiting the filter housing. Additionally, the membrane tubes may feature internal cores within their lumens and/or structures along their inner walls. These internal features serve to regulate flow patterns and pressures within the tubes. One notable aspect of this invention is the inclusion of features on the tube housing or tube core that effectively regulate pressure resistance and feed flow patterns. These features lead to a reduction in the required recirculation rate and contribute to improved transmembrane pressure profiles, making these membrane filters highly effective for cell retention in cell culture and other applications. The patent also introduces various filter designs that incorporate tubular membranes into TFF filtration devices to achieve multiple goals, including a more consistent TMP (Transmembrane Pressure) profile for efficient separation, reduced recirculation rates to generate adequate shear rates, higher packing densities of membrane surface areas within the same filter design, and enhanced manufacturability and recyclability of the filters. Overall, this invention represents a significant advancement in the field of TFF filtration, offering innovative solutions for a wide range of applications in the separation of cells and particles.