Array of hollow fibers and a system and method of manufacturing same
Inventors
Galea, Anna M • LeRoy, Kristen • Vitale, Nicholas
Assignees
Publication Number
US-9034083-B2
Publication Date
2015-05-19
Expiration Date
2032-04-10
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Abstract
An array of hollow fibers including a plurality of hollow fibers of a predetermined diameter configured to receive a gas having oxygen therein and transfer the oxygen to a fluid and/or transfer carbon dioxide in the fluid to a gas. The array is configured in a predetermined pattern having a predetermined packing density that is a fraction of a total cross-sectional area of the array occupied by the hollow fibers.
Core Innovation
This invention features an array of hollow fibers arranged in a predetermined pattern with a predetermined packing density, designed to receive a gas containing oxygen and transfer the oxygen to a fluid, or transfer carbon dioxide from the fluid to the gas. The hollow fibers have a predetermined diameter and are configured such that their spacing is less than or substantially equal to their diameter, achieving a packing density that is a fraction of a total cross-sectional area of the array occupied by the hollow fibers.
The problem solved by this invention arises from conventional hollow fiber oxygenators, which suffer from random or irregular spacing of hollow fibers and large void spaces that compromise oxygenator efficiency. Wrapped hollow fiber oxygenators wrap fibers around a hollow core, leading to inefficient spacing and voids, while bundled oxygenators bundle fibers potted in glue resulting in random arrangements and insufficient packing density. This invention addresses these inefficiencies by providing a method and system to manufacture hollow fiber arrays with improved fiber density and regular patterns such as hexagonal close packing.
The invention also discloses a method and system for manufacturing the array, involving the use of a device with a base and adhesive applicator, shims sized to fit the base, multiple layers of hollow fibers, and a roller. The method includes applying adhesive to the top shim or layers, placing fiber layers with controlled spacing, rolling adhesive away from the array’s center to ensure uniform distribution, and repeating to build an array with a predetermined number of layers. This organized fabrication process allows the formation of a hollow fiber array that overcomes the randomness and low packing density of prior designs.
Claims Coverage
The patent includes six independent claims covering methods and systems for manufacturing an array of hollow fibers with improved packing density and uniform adhesive application.
Method for manufacturing hollow fiber array with iterative adhesive application and layering
A method involving providing a manufacturing device with a base and adhesive applicator, placing shims and layers of hollow fibers in the base, applying adhesive via an applicator to shims or fiber layers, rolling adhesive away from the center of fiber layers, removing shims progressively, and repeating these steps to form an array with a predetermined number of layers.
Method using adhesive applicator with blades for uniform adhesive distribution
Applying adhesive to an adhesive applicator that includes multiple blades each with a contact surface, and optionally pivotably attaching the applicator to the base to contact and distribute adhesive uniformly on the layers or shims.
Method including opposing shims for controlled fiber layer placement
A method where an array manufacturing device has a base with opposing sides, opposing shims sized to fit these sides are placed, a fiber layer is positioned between the shims, adhesive is applied to the shims and fiber layer, adhesive is rolled away from the center, and steps are repeated to build the array.
Method for assembling hollow fibers with end-headers and mid-headers
Providing layers of hollow fibers and headers including end-headers and mid-headers with recesses configured to fit fiber layers, applying adhesive to headers, sandwiching fiber layers between headers in a repeating fashion until a desired layer count is achieved.
System for manufacturing a hollow fiber array with base, adhesive applicator, shims, fibers, and roller
A system comprising a base defining a bed, an adhesive applicator receivable in the base (including opposing arms and blades with adhesive contact surfaces), a plurality of shims sized to fit into the base, layers of hollow fibers sized to fit, and a roller for spreading adhesive, with optional pivotable attachment of the adhesive applicator to the base.
System variant with opposing sides and shims to maintain fiber layer alignment
A system including a base with opposing sides, an adhesive applicator receivable in the base, layers of hollow fibers, shims sized to fit the opposing sides, and a roller, with the adhesive applicator optionally pivotably attached to the base.
The independent claims collectively protect methods for manufacturing hollow fiber arrays with controlled layering and adhesive application to achieve high packing density and uniformity, as well as systems equipped with specialized bases, adhesive applicators with blades, shims, rollers, and headers to align and assemble the hollow fibers in predetermined patterns.
Stated Advantages
Provides an increased packing density of hollow fibers in the array compared to conventional oxygenators, allowing more efficient oxygenation of fluids.
Enables a regular predetermined pattern such as hexagonal close packing, which is not achievable with wrapped or bundled designs.
Allows for uniform and repeatable adhesive application using an adhesive applicator with blades and rollers, improving manufacturing consistency.
Facilitates alignment of hollow fibers through the use of headers and shims, maintaining spacing that is equal to or less than the fiber diameter.
Documented Applications
Oxygenation of blood or similar physiological fluids for patients with diseased or damaged lungs using the hollow fiber arrays.
General transfer of oxygen from a gas to a fluid or carbon dioxide from a fluid to a gas, including organic or inorganic fluids.
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