Array of hollow fibers and a system and method of manufacturing same
Inventors
Galea, Anna M. • LeRoy, Kristen • Vitale, Nicholas
Assignees
Publication Number
US-9579442-B2
Publication Date
2017-02-28
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
The invention features an array of hollow fibers with a predetermined diameter, 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 array is configured in a predetermined regular pattern with a predetermined packing density, defined as the fraction of the total cross-sectional area of the array occupied by the hollow fibers.
The background of the invention highlights problems with conventional hollow fiber oxygenators used for oxygenating blood. Wrapped hollow fiber oxygenators have hollow fibers wrapped irregularly around a hollow core, leading to random spacing and large void spaces that reduce efficiency. Bundled hollow fiber oxygenators use layers of fibers bundled and glued together but result in random fiber arrangement that prevents close packing and a regular pattern, again compromising efficiency.
In contrast, this invention addresses these issues by creating arrays of hollow fibers arranged in a predetermined regular pattern, such as hexagonally closely packed, with distances between fibers less than or equal to their diameter and a packing density fraction ranging approximately from 0.20 to 0.90. This results in increased fiber density, for example about 7.2 fibers per square millimeter for 0.2 mm diameter fibers. The invention also features methods and systems for manufacturing such arrays, including using headers with recesses to align fibers in the desired pattern and a manufacturing device with shims, adhesive applicator, and roller to assemble the array in layers with uniform adhesive application and consistent spacing.
Claims Coverage
The patent includes one independent claim describing an array of hollow fibers with features related to their arrangement and alignment. The inventive features extracted focus on the structure of the array, the pattern and packing density of the fibers, and the use of headers for alignment.
Array of hollow fibers with controlled alignment and spacing
An array comprising a plurality of hollow fibers of predetermined diameter configured to receive gas with oxygen and transfer oxygen to or carbon dioxide from a fluid, wherein the hollow fibers are aligned using a plurality of headers having recesses. The headers align the hollow fibers in a predetermined regular pattern with a predetermined packing density expressed as a fraction of the total cross-sectional area occupied by the fibers, ensuring relatively constant spacing along the array's length.
Fiber spacing less than or equal to fiber diameter
The array is configured so that the distance between the hollow fibers is less than or substantially equal to the predetermined fiber diameter, enabling increased packing density.
Packing density fraction range
The packing density fraction of the array is configured within the range of approximately 0.20 to about 0.90 of the total cross-sectional area of the array.
Hexagonal arrangement of hollow fibers
The hollow fibers are arranged in a hexagonal pattern, including embodiments where they are hexagonally closely packed for maximum density.
Headers with recesses for fiber alignment and layering
The plurality of headers includes a first end-header, a second end-header each having recesses on one side configured to receive a layer of hollow fibers, and multiple mid-headers with recesses on both sides configured to receive layers of hollow fibers. This design sandwiches layers of hollow fibers between headers to maintain alignment and spacing in the array.
The independent claim defines the inventive concept as an oxygenating hollow fiber array with fibers organized in a regular pattern and packing density through the use of headers with recesses for precise fiber alignment along the array length, with specific configurations such as fiber spacing less than or equal to fiber diameter and hexagonal close packing.
Stated Advantages
The invention provides an increased packing density of hollow fibers compared to conventional wrapped or bundled oxygenators, leading to enhanced efficiency in transferring oxygen to or carbon dioxide from a fluid.
The predetermined regular pattern and use of headers align hollow fibers with relatively constant spacing along the array, improving uniformity and performance.
The semi-automated manufacturing method with adhesive applicator and shims allows repeatable, uniform adhesive application and consistent fiber spacing during assembly, enhancing product quality.
Documented Applications
Oxygenation of blood or similar physiological fluids in medical applications such as oxygenators for patients with diseased or damaged lungs.
Transfer of oxygen into, and/or carbon dioxide from, organic or inorganic fluids using the hollow fiber array.
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