U.S. patent application number 12/809194 was filed with the patent office on 2011-09-22 for filter device.
Invention is credited to Jeffrey A. Lucas.
Application Number | 20110226691 12/809194 |
Document ID | / |
Family ID | 40824645 |
Filed Date | 2011-09-22 |
United States Patent
Application |
20110226691 |
Kind Code |
A1 |
Lucas; Jeffrey A. |
September 22, 2011 |
FILTER DEVICE
Abstract
A filter device is disclosed. The device includes at least one
substantially flat filter media that may be encapsulated between
non-permeable films. Some embodiments comprise ports for
introducing a fluid to be filtered and for evacuating the filtered
fluid. Various substrates may be employed therein in cooperation
with the at least one filter media to enhance device performance.
Also disclosed are various apparatuses configured to contain at
least one filter device.
Inventors: |
Lucas; Jeffrey A.; (Clinton,
CT) |
Family ID: |
40824645 |
Appl. No.: |
12/809194 |
Filed: |
December 16, 2008 |
PCT Filed: |
December 16, 2008 |
PCT NO: |
PCT/US08/86923 |
371 Date: |
June 18, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61016149 |
Dec 21, 2007 |
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Current U.S.
Class: |
210/493.5 |
Current CPC
Class: |
B01D 29/05 20130101;
B01D 2201/02 20130101; B01D 29/52 20130101; B01D 29/016 20130101;
B01D 29/031 20130101; B01D 25/26 20130101; B01D 29/213 20130101;
B01D 29/50 20130101; B01D 35/1573 20130101 |
Class at
Publication: |
210/493.5 |
International
Class: |
B01D 27/06 20060101
B01D027/06 |
Claims
1-59. (canceled)
60. A filter device comprising: a first non-permeable film; a
second non-permeable film; a filter element planarly encapsulated
by the first and second non-permeable films, the filter element
comprising a filter media having a plurality of planarly disposed
pleats.
61. The filter device of claim 60 wherein the filter media
comprises a first surface, a second surface, a first end, and a
second end; wherein the first surface of the first end is attached
to the first non-permeable film, and the second surface of the
second end is attached to the second non-permeable film.
62. The filter device of claim 60 wherein the filter media
comprises a width defined by two substantially parallel edges, the
first end and second end being substantially perpendicular to the
two parallel edges; wherein the first and second non-permeable
films and the filter element are further attached together along
the two parallel edges.
63. The filter device of claim 62, wherein at least one of the two
parallel edges is further attached to at least one substrate.
64. The filter device of claim 62, wherein the two parallel edges
and the first and second ends of the filter media define a
rectangular periphery, wherein the interior of the rectangular
periphery defines an operative filtration area.
65. The filter device of claim 64, wherein the filter element is
further attached to a framing substrate, the framing substrate
being attached along the rectangular periphery and having one or
more apertures permitting fluid communication with the operative
filtration area.
66. The filter device of claim 60, wherein at least one of the
first and second non-permeable films comprise a fluid communication
port.
67. The filter device of claim 66, wherein at least one of the
first non-permeable film or second non-permeable film comprises
multiple fluid communication ports.
68. The filter device of claim 66, wherein the first non-permeable
film comprises a first fluid communication port to create a fluid
connection to a first chamber.
69. The filter device of claim 66, wherein the second non-permeable
film comprises a second fluid communication port to create a fluid
connection to a second chamber.
70. The filter device of claim 69, wherein the first non-permeable
film further comprises a fluid communication port to create a fluid
connection to the second chamber.
71. The filter device of claim 70, wherein the second non-permeable
film further comprises a fluid communication port to create a fluid
connection to the first chamber.
72. The filter device of claim 60, wherein the first and second
non-permeable films each have a first end and a second end, and
wherein the first ends and the second ends of the first and second
non-permeable films are attached together.
73. The filter device of claim 60, wherein at least one of the
first end or second end of the filter media is further attached to
at least one substrate.
74. The filter device of claim 61 further comprising a drainage
substrate in contact with at least a portion of one of the first
surface or the second surface.
75. A filter device comprising: a first non-permeable film; a
second non-permeable film; a filter element planarly encapsulated
by the first and second non-permeable films, the filter element
comprising a filter media having a plurality of planarly disposed
pleats, a first surface, and a second surface; and a drainage
substrate in contact with at least a portion of one of the first
surface or the second surface.
76. The filter device of claim 75 wherein at least one of the first
and second non-permeable films comprise a fluid communication
port.
77. The filter device of claim 76, wherein the first non-permeable
film comprises a first fluid communication port to create a fluid
connection to a first chamber.
78. The filter device of claim 77, wherein the second non-permeable
film comprises a second fluid communication port to create a fluid
connection to a second chamber.
79. The filter device of claim 78, wherein the first non-permeable
film further comprises a fluid communication port to create a fluid
connection to the second chamber.
Description
FIELD OF THE INVENTION
[0001] The present disclosure relates generally to a fluid filter
device and methods of making and using the same. More particularly,
the present disclosure relates to a disposable fluid filter device
comprising a polymeric film.
BACKGROUND
[0002] There are currently a number of fluid filter products
available for use in research, development, and manufacturing. Some
of these products comprise some type of disposable filter media
designed to decontaminate or sterilize a fluid source. The
disposable filter media is typically disposed in a reusable metal
housing. The metal housing contacts the fluid being processed and
is typically cleaned or sanitized during filter media replacement.
In order to reduce the risk of contamination between filter changes
and product batch changes, disposable filter cartridges that
eliminate fluid contact with a reusable housing have been
developed. Such products are often relatively bulky and heavy,
making them less desirable for handling. The relatively large size
can also result in increased waste upon disposal of the product.
Such products may also have hold up volumes (i.e., the fluid
contained within the cartridge assembly during operation) that are
difficult to reclaim upon completion of the filtering process.
[0003] Accordingly, there is a continuing need for disposable
filter products that are easy to handle, cost effective, and reduce
waste both directly (e.g., reduced filter media waste) and
indirectly (e.g., reduced hold up volumes).
SUMMARY
[0004] The present disclosure relates generally to a fluid filter
device and methods of making and using the same. More particularly,
the present disclosure relates to a disposable fluid filter device
comprising a polymeric film. The filter device of the present
disclosure can reduce the size and amount of material used and
disposed of in a filtering operation by replacing larger and less
efficient filter elements with smaller and thinner filter
elements.
[0005] The present application discloses a filter device having at
least one filter media and at least first and second non-permeable
films attached thereto. Some embodiments of further comprise at
least one drainage substrate configured to enhance performance of
the device. In some embodiments, at least one of the non permeable
films further comprises at least one fluid communication port
configured to allow fluid to enter or leave the filter device. The
non-permeable films may be attached together to substantially
planarly encapsulate the filter device. In some embodiments, the at
least one filter media may be further attached to at least one
substrate configured to provide support, further attachment area,
or filtration, flow or drainage enhancement. In some embodiments,
the filter media comprises planarly disposed pleats, although it is
envisioned that a multitude of filter media configurations, for
example, flat sheet media, could be successfully employed.
Embodiments comprising multiple filter elements may be employed to
further increase filtration surface area while maintaining a
substantially flat configuration. Also disclosed are various
apparatuses configured to contain and facilitate the use of
embodiments of the disclosed filter device, although it is
envisioned some embodiments of the disclosed filter device may be
independently employed. It is to be understood that, while the
disclosed filter device may be employed in a substantially flat
configuration, some embodiments are of a flexible nature that may
be manipulated to conform to a variety of alternatively shaped
configurations.
[0006] These and other aspects of the disclosure will be apparent
from the detailed description below. In no event, however, should
the above summaries be construed as limitations to the claimed
subject matter, which subject matter is defined solely by the
attached claims, as may be amended during prosecution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Throughout the specification, reference is made to the
appended drawings, where like reference numerals designate like
elements, and wherein:
[0008] FIG. 1 is a partial cutaway view of a filter element
comprising a filter media having planarly disposed pleats having
folds that are welded along parallel edges;
[0009] FIG. 1a is a non-rectangular filter element having planarly
disposed pleats having folds that are welded along an edge;
[0010] FIG. 1b is a cross-sectional view detailing one possible
configuration of planarly disposed pleats;
[0011] FIG. 2 is a partial cutaway view of a filter element
comprising a filter media having planarly disposed pleats having
folds that are welded along each edge, wherein each edge is further
attached to a substrate;
[0012] FIG. 2a is a partial cutaway view of a filter element
comprising a filter media having planarly disposed pleats having
folds that are welded along each edge, wherein each edge is further
attached to a substrate that extends beyond the width of the filter
media;
[0013] FIG. 3 is a partial cutaway view of a filter element
comprising a filter media having planarly disposed pleats having
folds that are welded along each parallel edge, wherein each
parallel edge is further attached to at least one substrate that
extends beyond the width of the filter media, the at least one
substrate in this case comprising a first and second substrate
attached along the parallel edges of the filter media, along with a
third substrate attached to the first and second substrates;
[0014] FIGS. 4-4b are a partial cutaway views of a filter element
comprising a filter media having planarly disposed pleats having
folds that are welded along each parallel edge and further along a
first end and a second end, wherein the parallel edges and the
first and second ends define a rectangular periphery that surrounds
an operative filtration, wherein at least a portion of the
rectangular periphery is further attached to a framing substrate,
the framing substrate having one or more apertures permitting fluid
communication with the operative filtration area;
[0015] FIG. 5 is a partial cutaway view of a filter device showing
how first and second non-permeable films may be positioned with
respect to a filter element before being assembled to substantially
planarly encapsulate the filter element;
[0016] FIG. 6 is an exploded view of a filter device showing a
possible disposition of first and second non-permeable films, a
filter media, a framing substrate and a drainage substrate;
[0017] FIG. 7 is a cross-sectional view of a filter device having
fluid communication ports and a filter media comprising planarly
disposed pleats;
[0018] FIG. 7a is a cross-sectional view of a filter device having
fluid communication ports and a filter media comprising planarly
disposed pleats, wherein the filter media is further attached to a
framing substrate;
[0019] FIG. 8 is an isometric cutaway view of a filter device
having fluid communication ports and a filter media comprising
planarly disposed pleats;
[0020] FIGS. 9 and 9a are cross-sectional representations of filter
devices having fluid communication ports, two filter elements, and
a drainage substrate disposed between the filter elements;
[0021] FIG. 10 shows perpendicular views of an exemplary filter
device;
[0022] FIG. 11 is an exploded view of an apparatus comprising
stackable members configured to contain at least one filter
device;
[0023] FIGS. 12 and 12a show an overhead view and a partial
cross-section of one example of a stackable member configured for
use, for example, in the apparatus shown in FIG. 11; and
[0024] FIG. 13 is a detailed cross-section of one embodiment of an
apparatus configured to contain at least one filter device.
DETAILED DESCRIPTION
[0025] FIG. 1 shows a substantially flat filter element 10
comprising at least one filter media 12 having planarly disposed
pleats 14 having folds 14a. The filter media 12 may be formed of a
single material or a composite of multiple materials that are
suitable alone or in combination to meet various filtration,
structural support, drainage, and flow requirements of a chosen
application. Such materials may include, for example, membranes
(e.g., nylon, polyethersulfone, polytetrafluoroethylene,
polypropylene, and the like), non-wovens, polymeric meshes,
apertured films, fibrous media (typically made by a wet laid paper
making type operation with materials such as, for example, glass
fibers, diatomaceous earth, perlite, cellulose, and binder resins),
non-fibrous media, depth filter media, adsorptive media, charge
modified media, or any other material found to have beneficial
characteristics for a given application and that can be configured
in a substantially flat filter element.
[0026] For example, the at least one filter media 12 may be formed
of a single material. In other embodiments, the filter media 12 may
be formed of multiple materials. In some cases, it may be desirable
to form the filter media 12 of a composite of materials configured
to provide improved pressure drop characteristics, such as by
employing multiple materials having different degrees of porosity
to selectively capture particulates and prevent premature loading
or clogging of the filter media 12. In other embodiments, the at
least one filter media 12 may be formed of multiple materials.
[0027] In FIG. 1a, the filter element 10 is formed in a
non-rectangular configuration. It is envisioned that various shapes
of filter elements 10 may be desired, depending on the needs of a
particular application. Such varying shapes may be formed, for
example, by punching or otherwise cutting them out of a larger
article of filter media 12 or by pleating pre-shaped filter media
12. Although the shape shown in FIG. 1a is circular, other shapes
can also be utilized.
[0028] FIG. 1b is a detailed view of one possible configuration for
planarly disposed pleats 14. The planarly disposed pleats 14 may be
configured such that the crown 14c of a given pleat rests at or
near the root 14b of a corresponding pleat. The planarly disposed
pleats 14 may also be configured such that the crown 14c of a given
pleat rests substantially against the leg 14d of a corresponding
pleat in no specific relation to the root 14b of a corresponding
pleat. It is envisioned that, in some embodiments, the planarly
disposed pleats 14 may exhibit a combination of the above
configurations or even a random assortment of pleat sizes. In such
configurations, the resulting pleated filter element 10 may have
one, three, five, seven, nine, eleven, thirteen or even fifteen
layers of filter media at any given cross-section, each layer of
filter media comprising either a single filter material or a
composite of multiple filter materials.
[0029] As used in the present disclosure, the term "pleat" refers
to successive folds in a filter media forming first pleat legs
having a first length and second pleat legs having a second length.
Pleats may be formed with similar or dissimilar first and second
leg lengths. Further, similar pleats may be uniformly distributed
throughout a filter media or dissimilar pleats may be distributed
in a repeating pattern or in an irregular or random pattern such
that varying leg lengths are produced. The use of pleats in the
filter media increases the amount of available surface area of the
filter media in the filter device, and generally improves filter
flow and throughput.
[0030] It is envisioned that the substantially flat filter element
10 could be manufactured either in discrete lengths for
incorporation into a filtration application, wherein the at least
one filter media 12 has a first end 12a and a second end 12b as
shown in FIG. 4, or in an essentially continuous form that be cut
to length in a secondary operation. In some embodiments, it is
envisioned that the substantially flat filter element 10 is welded
along at least one edge 18a, 18b, each edge 18a, 18b being
substantially parallel to the other and being substantially
perpendicular to the folds 14a of the planarly disposed pleats 14.
As used in the present disclosure, the term "weld" shall mean
secured by any of various known polymer welding methods including,
but not limited to, ultrasonic, high-frequency, vibration,
friction, laser, solvent, contact, hot plate, plastic rod, speed
tip, hot gas, and free hand.
[0031] In other embodiments, the folds 14a need not be
perpendicular to edges 18a, 18b, such as where the filter element
10 is formed in a non-rectangular configuration. Where edges are
welded, such welds may be substantially continuous, i.e.,
uninterrupted along the at least one edge 18a, 18b, or may be, for
example, discrete tacks sufficient to hold each planarly disposed
pleat 14 in a substantially flat configuration.
[0032] In FIG. 2, the filter element 10 further comprises at least
one substrate 20a that is further attached to the pleated filter
media 12. Such at least one substrate 20a may be attached to the
pleated filter media 12, for example, by welding, adhesives,
stitching or any other attachment means defined in this application
or suitable for the combination of materials employed. Such
attachment may be continuous or intermittent along the length of
the attachment, or may even consist of a single attachment point.
The at least one substrate 20a may comprise a polymeric material
that can be welded to the filter media 12. In some embodiments, the
substrate 20a is non-permeable and is characterized as having a low
water vapor transmission rate. The term "non-permeable" refers to a
material that does not allow fluids to diffuse or pass through
during reasonably expected operating conditions. The term "water
vapor transmission rate" refers to the rate of water vapor
transmission through the multilayer barrier composite as measured
using the test described in ASTM F1249-01, (Standard Test Method
for Water Vapor Transmission Rate Through Plastic Film and Sheeting
Using a Modulated Infrared Sensor, Published December 2001),
incorporated herein by reference. The substrate may comprise a
single layer of material or may comprise multiple components, such
as, for example, multilayer barrier composites. The term
"multilayer barrier composite" refers to any combination of metal,
plastic, or cellulosic layers (e.g., foils, films, and paper). The
combination of metal, plastic, or cellulosic layers can include
multiple layers of different materials, such as, for example, a
metal combined with a plastic layer. The combination of metal,
plastic, or cellulosic layers can also include multiple layers of
similar materials, such as, for example, two layers of plastic. The
layers can be combined substantially permanently using any
processes known in the art, including, for example, coating,
laminating, coextrusion, and deposition. Multilayer barrier films
useful in the can comprise layers of low-density polyethylene,
high-density polyethylene, polypropylene, polyester, and nylon. In
some embodiments, a multilayer barrier film having a layer of
metal, such as, for example, aluminum is used.
[0033] In some embodiments, such as in FIG. 2a, an edge of the at
least one substrate 20a extends beyond an edge 18a of the pleated
filter media 12. In other embodiments, such as in FIG. 2, an edge
of the at least one substrate 20a is flush with an edge 18a of the
pleated filter media 12. In embodiments where the at least one
substrate 20a extends beyond an edge 18a of the pleated filter
media 12, a non-porous material for the at least one substrate 20a
can be employed. It is envisioned that a second at least one
substrate 20b may be attached to an opposite edge 18b of the
pleated filter media 12, as shown in FIGS. 2 and 2a. In such
embodiments comprising multiple substrates 20a, 20b, such
substrates 20a, 20b may be attached by same or different means, may
comprise same or different materials, may each comprise an edge
that is flush with an edge 18a, 18b of the pleated filter media 12,
and may extend beyond an edge 18a, 18b of the pleated filter media
12 by same or different amounts, including embodiments where one
substrate 20a or 20b is flush with an edge 18a, 18b of the pleated
filter media 12 and a second substrate 20a or 20b extends beyond an
edge 18a, 18b of the pleated filter media 12.
[0034] As shown in FIG. 3, a third substrate 20c may be further
attached to one or both of the at least first and second substrates
20a, 20b. In some embodiments, the third substrate 20c, if
employed, can be composed of a non-porous material. In other
embodiments, the third substrate 20c may be composed of a porous
material configured to permit fluid flow therethrough. The third
substrate 20c, when employed, may be attached to the filter element
10 by any means discussed in this disclosure, or any other
reasonable means known to those in the art consistent with the
materials chosen and the applications desired. Such attachment
means may be the same or different from any attachment means
employed to secure substrates 20a and 20b to the filter element
10.
[0035] As shown in FIG. 4, the pleated filter media 12 may further,
or alternatively, be provided with a framing substrate 34. The
framing substrate 34, when provided, may allow for more robust
attachment of the filter element 10 to another substrate or another
article than would otherwise be attained when, for example,
employing very porous or relatively fragile materials in filter
media 12. Further, or alternatively, the framing substrate 34 may
provide varying degrees of rigidity to the filter element 10 for
applications where a certain degree of structural stiffness is
desired. In other embodiments, the framing substrate 34 may be
configured to allow a high degree of flexibility of the filter
element 10.
[0036] In some embodiments, at least a portion of the framing
substrate 34 is attached directly to at least a portion of the
pleated filter media 12. In other embodiments, at least a portion
of the framing substrate 34 is attached to at least a portion of at
least one substrate 20a, 20b, which may be directly attached to at
least a portion of the pleated filter media 12. In still other
embodiments, at least a portion of the framing substrate 34 is
attached to at least a portion of a third substrate 20c, which is
attached to at least one first or second substrate 20a, 20b, which
may be directly attached to at least a portion of the pleated
filter media 12. In appropriate applications and embodiments, the
framing substrate 34 may be continuously or intermittently attached
about a periphery 30 surrounding an operative filtration area
32.
[0037] In some embodiments, the framing substrate 34 may be
composed of a single, continuous member. In other embodiments, a
framing substrate 34 may be constructed of multiple members and
subsequently assembled in a suitable framing configuration. Such a
multiple-member framing substrate 34 may be, for example, easier or
more efficient to manufacture, depending upon the capabilities of
the fabrication means employed.
[0038] In the framing substrate 34, within the periphery 30, there
may be a single aperture 36 or multiple apertures 36' enabling
fluid communication through the framing substrate 34 to the pleated
filter media 12. Such apertures 36 or 36' may be configured in a
manner similar to a typical picture frame as in FIG. 4, wherein
four sides surround a single rectangular opening 36. In some
embodiments, the opening or openings in the framing substrate 34
may be, for example, circular in shape as in FIG. 4a or rectangular
in shape as in FIG. 4b. It is also envisioned that there may be
multiple openings of similar or different shapes in the framing
substrate 34. In one embodiment, openings in the framing substrate
34 comprise a mesh, for example, as may be provided with an
extruded polymer mesh or an apertured film. Such mesh, or any
combination of aperture or apertures, may be configured with any
reasonable porosity calculated or believed to provide suitable flow
characteristics for the desired application.
[0039] FIG. 5 is a partial cutaway view of a filter device before
being assembled to encapsulate the filter element. In some
embodiments, such as that shown in FIG. 5, the filter element 10
comprises at least one filter media 12 having planarly disposed
pleats 14. The filter element 10 may be further attached to a
framing substrate 34 and encapsulated between first and second
non-permeable films 40, 42, respectively. The non-permeable films
40,42 shown in FIG. 5 are transparent, in other embodiments the
films may be opaque. The non-permeable films may comprise a
polymeric material that can be welded to other components of the
filter device. In some embodiments, the non-permeable film is
characterized as having a low water vapor transmission rate. The
non-permeable film may comprise a single layer of material or may
comprise multiple components, such as, for example, multilayer
barrier composites. The term "multilayer barrier composite" refers
to any combination of metal, plastic, or cellulosic layers (e.g.,
foils, films, and paper). The combination of metal, plastic, or
cellulosic layers can include multiple layers of different
materials, such as, for example, a metal combined with a plastic
layer. The combination of metal, plastic, or cellulosic layers can
also include multiple layers of similar materials, such as, for
example, two layers of plastic. The layers can be combined
substantially permanently using any processes known in the art,
including, for example, coating, laminating, coextrusion, and
deposition. Multilayer barrier films useful in the can comprise
layers of low-density polyethylene, high-density polyethylene,
polypropylene, polyester, and nylon. In some embodiments, a
multilayer barrier film having a layer of metal, such as, for
example, aluminum is used. In some embodiments, at least one
drainage substrate may further be provided. In such cases, the
drainage substrate may be disposed in substantial contacting
relation to either the filter media 12, the framing substrate 34,
or both, though the drainage substrate need not be in contact with
either to maintain function.
[0040] In FIG. 6, an exploded view of a filter device 8 illustrates
one possible relative disposition of first non-permeable film 40,
filter element 10 having a framing substrate 34, drainage substrate
52, and second non-permeable film 42. Dashes witness lines therein
illustrate an example of desired attachment locations of the
various components of the filter device 8. For example, in some
embodiments, portions of the first non-permeable film 40 labeled
"S" will attach to portions of the second non-permeable film 42
that are also labeled "S", and so on. It is to be understood that
the exemplary attachment locations as illustrated in FIG. 7
represent only one possible assembly configuration for a filter
device 8. The actual components selected, the physical disposition
of those components, and relative attachment locations may vary
depending on the materials selected and the desired
application.
[0041] FIG. 7 is a cross-sectional view of a filter device 8 having
fluid communication ports 54, 56, and a filter element 10
comprising planarly disposed pleats 14. As shown in FIG. 7, the
filter element 10 is attached on one end to a first non-permeable
film 40 and at the opposite end to a second non-permeable film 42.
The first and second non-permeable films are sealed at their
peripheries to create two chambers 44, 46 divided by the filter
element 10. The first fluid communication port 54 is attached to
the first non-permeable film 40 to create a fluid connection to the
first chamber 44. The second fluid communication port 56 is
attached to the second non-permeable film 42 to create a fluid
connection to the second chamber 46. During use, a source fluid
enters the first fluid communication port 54, enters first chamber
44, passes through filter media 12 where it is filtered. The
filtrate then enters second chamber 46 and exits the filter device
8 through the second communication port 56. The communication ports
54, 56 can be any design known in the art, and can be designed to
allow multiple filter devices 8 to be connected directly to one
another. In other embodiments, the communication ports are
configured to connect to tubing. In some embodiments, the first and
second communication ports are different and provide an operator
aid in identifying which communication port is to be used as an
inlet and which is an outlet. In some embodiments, the filter
device 8 is designed to operate with either communication port
being an inlet or outlet.
[0042] FIG. 7a is a cross-sectional view of a filter device 8
having fluid communication ports 54, 56 and a filter element 10
comprising planarly disposed pleats 14 of filter media 12 attached
to a framing substrate 34. As shown in FIG. 7a, the framing
substrate 34 may be used to attach the filter element 10 to the
first and second non-permeable films 40, 42. The use of a framing
substrate 34 may facilitate handling of the filter media 12. The
use of a framing substrate 34 may also assist in attaching the
filter media 12 to the first and second non-permeable films 40, 42.
If, for example, a filter media 12 is used that has multiple
components, one surface of the filter media 12 may provide a better
attachment anchor than the other. As shown in FIG. 7a, the framing
substrate 34 is attached to one surface of the filter media 12. The
framing substrate 34 shown in FIG. 7a also allows for the
attachment interface of the filter element 10 to be in a
compressive state during use. For example, if first fluid
communication port 54 is used as an inlet, the first chamber 44
will operate at a higher pressure than the second chamber 46
because of the pressure drop caused by the filter media 10.
Accordingly, the higher pressure of first chamber 44 will cause the
filter media 10 to be compress against the framing substrate
34.
[0043] FIG. 8 is an isometric cutaway view of a filter device
having fluid communication ports 54, 56, and a filter element 10
comprising a filter media 12 with planarly disposed pleats 14. As
shown in FIG. 8, the first and second non-permeable films 40, 42
are sealed at their peripheries to create two chambers 44, 46
divided by the filter element 10.
[0044] FIGS. 9 and 9a are cross-sectional representations of filter
devices having multiple fluid communication ports 54, 54', 56, 56',
two filter elements 10, 10', and a drainage substrate 52 disposed
between the filter elements 10, 10'. A shown in FIG. 9, the filter
element 10 can comprise filter media 12 with planarly disposed
pleats 14. As shown in FIG. 9a, the filter element can comprise
planar filter media 12. The planar filter media 12 can comprise
multiple pieces joined together as shown in FIG. 9a, or a single
folded piece. As shown in FIGS. 9 and 9a, two communication ports
can be used to connect to each of the chambers 44, 46 to facilitate
parallel filtration if multiple filter devices are employed.
[0045] FIG. 10 shows a front and cross-sectional side view of an
exemplary filter device 8. As shown in FIG. 10, the filter device 8
comprises fluid communication ports 54 54', 56, 56' and a filter
element 10 comprising planarly disposed pleats of filter media
attached to a framing substrate 34. As configured in FIG. 10, fluid
communications ports 54 and 54' function as inlet ports, and fluid
communication ports 56 and 56' function as outlet ports, relative
to the filter element 10. The first and second non-permeable films
are sealed at their peripheries to create two chambers 44, 46
divided by the filter element 10. A drainage substrate 52 is
positioned in chamber 46 between the filter element 10 and the
second non-permeable film 42. As chamber 46 is downstream of
chamber 44, the differential pressure created by the filter element
10 may force the filter element 10 toward the second non-permeable
film 42. The drainage substrate 52 is positioned between the filter
element 10 and the second non-permeable film to help promote fluid
flow from the filter element 10 toward the fluid communication
ports 56, 56'.
[0046] As shown in FIG. 10, the fluid communication ports 54 may be
configured to allow connection to additional filter devices 8. The
fluid communication ports 54 may be designed to be male and female
mating parts with integral seals, such as shown in FIG. 10. In some
embodiments, the fluid communication ports 54 connected to one
chamber form a single rigid body that extends from the first
non-permeable film 40 to the second non-permeable film 42. In such
embodiments, the fluid communication port may comprise multiple
pieces that are joined together with at least one fluid passage 48
that allow fluid flow from the fluid communication port 54 to the
chambers 44. The use of a single rigid body may provide additional
integrity in affixing the communication ports 54 to the first and
second non-permeable films 40, 42. The use of a single rigid body
may also provide improved handling capabilities when configuring
the filter device for operation (e.g., connecting the communication
ports).
[0047] FIG. 11 is an exploded view of an apparatus 70 comprising
stackable members 72 configured to contain at least one filter
device 8. As shown in FIG. 11, the apparatus 70 comprises a
clamping device 76 having a first end wall 76a, a second end wall
76b, and clamping members 76c configured to draw the end walls 70a,
70b toward one another. The stackable members 72 have hangers 82
configured to accept the clamping members 76c to help support and
locate the stackable members 72. Other clamping devices and
stackable member positioning devices and methods may be employed,
including for example, other known plate and frame assemblies. The
clamping device can be any apparatus configured to hold a member
and apply a compressive force thereto. Examples of suitable
compressive forces include, but are not limited to, those provided
by screws, hydraulic cylinders, pneumatic cylinders, cam levers,
magnets, and gravity. The embodiment shown in FIG. 11, includes
three filter devices 8 (similar to that shown in FIG. 10) located
between four stackable members 72.
[0048] The stackable members 72 are generally configured with a
depressed area that provides a cavity when two stackable members
are placed in intimate contact. The stackable member cavity is
configured to provide mechanical support for the filter device 8.
In some embodiments, the stackable member cavity is configured to
be slightly smaller than the outer geometry of the filter device 8
to eliminate any unsupported areas for the first and second
non-permeable films 40, 42. The stackable members 72 can all be
identical as shown in FIG. 11, or can vary to accommodate different
filter device 8 geometries.
[0049] FIGS. 12 and 12a show an overhead view and a partial
cross-section of one example of a stackable member 72 configured
for use, for example, in the apparatus 70 shown in FIG. 11. The
stackable member 72 has a handle 84, hangers 82, a pressure port
88, a sealing member 78, and a cavity 86. The cavity 86 has
apertures 90, 92 that are configured to accommodate the fluid
communication ports of the filter device.
[0050] The pressure port 88 is in fluid communication with cavity
86 and allows pressure and/or vacuum to be applied to the exterior
of the filter device 8 within the cavity 86. The application of
pressure to the exterior of the filter device can be used to
promote evacuation of the filter device. Likewise, the application
of vacuum to the exterior of the filter device can be used to
promote filling of the filter device. The sealing member 78 along
with pressure port seal 96 create a fluid seal between the exterior
surface of the filter device and atmosphere The pressure applied to
the exterior of the filter device through pressure port 88 can be
created with liquid or gas. In some embodiments, the liquid or gas
can be introduced at a desired temperature.
[0051] The stackable members can be made from any materials that
can withstand the expected operating pressures, including metal in
high pressure operations, and plastic in lower pressure operations.
Since the stackable members are predominantly in a compressive
state within the clamping device, plastic is suitable for many
applications. In some embodiments, the stackable members are made
from a transparent plastic that allows the operator to visually
inspect the filter devices and related connections during
operation.
[0052] FIG. 13 is a detailed cross-section of one embodiment of an
apparatus 70 configured to contain three filter devices 8 with
arrows showing the general direction of fluid flow. As shown in
FIG. 13, the first end stackable member 72a has a first aperture 90
and a pressure port 88. A connection device 94 is used to extend
the fluid communication port of the filter device beyond the
stackable member 172a. Opposite the first end stackable member 72a,
is the second end stackable member 72b. The second end stackable
member 72b also has a connection device 94 associated with the
opposite fluid communication port of the filter device. Between the
first and second end stackable members, are two middle stackable
members 72c. Any number of middle stackable members can be used to
accommodate the desired number of filter devices.
[0053] As shown in FIG. 13, the filter devices can be configured
for parallel flow. In other embodiments, the fluid communication
ports of the filter device are configured for serial flow. In yet
further embodiments, the fluid communication ports are configured
such that change parts can be inserted to change the communication
port of a filter device from a parallel configuration to a serial
configuration and vice versa. This can be accomplished, for
example, by inserting or removing a plug in the fluid communication
port. In some embodiments, a combination of serial and parallel
flow is used for the various filter devices (i.e., a quantity of
the filter devices are used for parallel flow, and the remaining
quantity of the filter devices are subject to serial flow). In such
configurations, the filter devices typically have different types
of filter media and filtration requirements. For example, a series
of filter devices with depth media may be subjected to parallel
flow followed by a filter device with a membrane filter media
connected in series.
[0054] In some embodiments, the filter devices are configured to
support tangential flow filtration. In such configurations, two
fluid communication ports are in fluid communication with at least
one of the chambers and are separated from each other such that the
source fluid needs to travel along a length of the filter media
(i.e., tangential flow).
[0055] In addition to the use as filtering device, one of ordinary
skill in the art of cell growth technology will recognize the
capability of using the apparatuses and methods of the present
disclosure for cell growth. For such purposes, the filter media of
the filter device described can be replaced with a suitable cell
growth media. The filter device can thus become a cell growth
device.
[0056] The cell growth device provides an apparatus for maintaining
a controlled environment for the growth of cells. In certain
preferred embodiments, multiple cell growth devices are
interconnected by multiple fluid inlet and outlet ports to provide
the necessary liquid and gas exchange required for optimum cell
growth. The individual cell growth devices can be further sealed by
a chamber formed by multiple rigid stackable members that may
direct a positive or negative fluid pressure, for example, via
pressure port similar to pressure port 88, to the outer film walls
of the film enclosures of the cell growth device. The compressive
and expansion effect on the films walls can create either a
directional fluid flow through the cell growth substrate or a rise
and fall of the liquid/gas interface across the surface of the cell
growth substrate within the cell growth device. The action of
compressing or expanding the outer cell growth device walls allows
for the controlled rise or fall of the fluid within the cell growth
device. The use of valves, including, for example check valves, at
up and/or down stream fluid locations allows directional fluid flow
to be achieved.
[0057] In some embodiments, a combination of cell growth devices
and filter devices are configured in stackable members such that
both cell growth and filtration can be accomplished within a single
apparatus. In some embodiments, cell growth fluid is periodically
moved from at least one of the filter devices to at least one of
the cell growth devices. Valves are used to control the direction
and flow of fluids in accordance with the desired protocol. In some
embodiments, waste product may be removed and/or nutrients may be
added during the process. In some embodiments, a third expandable
device for fluid storage is used that is neither a cell growth
device nor a filter device. This third type of device can be used
as a temporary storage unit for fluid when rotating fluids between
devices in the apparatus (i.e., exchanging fluid in a cell growth
device with fluid in a filter device) or adjusting cell growth
fluid levels within the cell growth devices.
[0058] Various modifications and alterations of the embodiments
will be apparent to those skilled in the art without departing from
the spirit and scope of the disclosure. It should be understood
that the disclosure is not limited to illustrative embodiments set
forth herein.
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