WO1998030308A1

WO1998030308A1 - Filtration cassette article and filter comprising same

Info

Publication number: WO1998030308A1
Application number: PCT/US1998/000362
Authority: WO
Original assignee: Kopf, Henry, B.
Priority date: 1997-01-13
Filing date: 1998-01-12
Publication date: 1998-07-16
Also published as: JP2001507986A; ATE286776T1; EP0980285B1; DE69828597T2; DE69828597D1; EP0980285A1; US5868930A; EP0980285A4

Abstract

A filtration cassette (12) of a type comprising filter sheets arranged in a multilaminate peripherally bonded array, wherein the filter sheets (104) alternate with permeate (106) and retentate (102) sheets. A stacked assembly (200) of such filtration cassettes may be employed to form stacked cassette filter. The filtration cassettes and filter of the invention may be advantageously employed for dewatering of aqueous biomass suspensions, desalting of proteins, removal of secreted metabolites from cellular suspensions, and the like.

Description

"FILTRATION CASSETTE ARTICLE AND FILTER

COMPRISING SAME"

BACKGROUND OF THE INVENTION

Field of the Invention

This invention relates generally to filtration cassettes, of a type comprising membrane

filter sheets arranged in a multilaminate, peripherally bonded array wherein the filter sheets

alternate with foraminous (e.g., screen or mesh) permeate sheet elements, and ribbed

retentate channel elements. The invention further relates generally to cross-flow filters

comprising a multiplicity of stacked filtration cassettes of such type, as well as to a method

of making such filtration cassettes.

Description of the Related Art

Stacked plate cross-flow filters are utilized in a variety of solids-liquid separation

operations, including the dewatering of solids-liquid suspensions such as aqueous biomass

suspensions, the desalting of proteins, and the removal of secreted metabolites from cellular

cultures.

In such systems, the stacked plates making up the cross-flow filter are typically

mounted in a unitary frame structure whereby the respective plates are retained in alignment

with one another, in a so-called "plate and frame" construction. The plate and frame filter typically utilizes a unitary liquid feed conduit provided

with openings at spaced intervals along its length and extending through the stacked plates as

a means to introduce influent solids-containing liquid into the flow channels defined between

adjacent plates in the stacked plate assembly. The flow channels in the plate and frame filter

contain filter elements, such as disposable filter paper sheets or polymeric membranes, with

which the solids-containing liquid is contacted and through which solids-depleted liquid

passes. A unitary liquid withdrawal conduit featuring openings at spaced intervals along its

length correspondingly extends through the stacked plates, in liquid flow communication

with the respective flow channels of the stacked plate assembly, and conveys solids-depleted

liquid out of the filter system.

As filtration proceeds, the filtered solids build up in the flow channels of the filter, on

the "feed liquid sides", i.e., active filtration surfaces, of the filter sheets. The filter then is

periodically backwashed, or alternatively, it may be fully shut down after a predetermined

time or after a predetermined level of solids has accumulated in the flow channels on the

filtration surfaces of the filter sheet elements, following which the system is drained of

liquid, and the filter sheets replaced as necessary.

In one type of presently marketed stacked filter system, commercially available from

Millipore Corporation (Bedford, Massachusetts) as the Prostak® cross-flow filter, the

adjacent filter plates define a flow channel. Solids-containing influent liquid is fed at one

side of the plate from a central location into a transversely extending feed distribution conduit, which is provided with openings at spaced-apart intervals along the length of the

conduit for egress of the solids-containing liquid. At the opposite side of the adjacent plates,

the flow channel is similarly constructed with a liquid collection conduit having openings

along its length to collect the solids-depleted liquid and discharge same from a central outlet

communicating with the collection conduit.

A major problem which has been encountered in cross-flow filters of the above-

described type is that the liquid flow distribution, as for example reflected by the volumetric

liquid flow rate or the liquid superficial velocity, is highly non-uniform in the transverse

direction of the flow channel. Such maldistribution of the solids-containing liquid is a result

of the fact that (1) the influent liquid is introduced into the feed distribution conduit at a

central location, and (2) the cross sectional area of the liquid inlet is smaller than the sum of

the inlet cross sectional areas of the cross flow subchannels.

Due to the pressure drop in the transverse direction, from the medial inlet port of filter

plate assembly to the extremities of the feed distribution conduit, the local longitudinal flow

(cross-flow) of liquid from the inlet side to the outlet side of the stacked plates, at

progressively farther transverse distances from the central liquid inlet port, is progressively

reduced in correspondence to the pressure drop experienced as the liquid is directed

transversely to the outer extremities of the distribution conduit.

As a result, there is preferential channeling of the liquid at the central part of the flow

channel from the inlet side to the outlet side thereof, and concomitant under-utilization of the peripheral areas of the filter. The available filter surface therefore is partially utilized in cross

flow and partially in dead end filtration. When the solids in the central portion have been

built up to a point requiring backwashing or cleaning of the filter, only that portion of the

filter utilized in cross flow can be cleaned. The peripheral areas of the filter sheet remain

fouled and cause carry-over of fouled material from one batch process to the next.

Such transverse maldistribution of the feed liquid in cross-flow filters of the

aforementioned type could conceivably be overcome by the provision of header manifolds to

introduce feed liquid into the filtration channels at multiple introduction points along the

sides of the stacked filter plates, with a corresponding outlet header manifold arrangement at

the opposite side of the stacked plates. Unfortunately, however, such provision would

significantly increase the overall system pressure drop as well as the complexity of the filter

system, since it would be necessary to positively seal the multiplicity of feed liquid branch

lines passing from the manifold into the filter.

Another type of stacked plate cross-flow filter which has been commercialized

employs a transversely extending liquid distribution conduit with spaced-apart openings

therein to introduce solids-containing liquid into the flow channel between adjacent stacked

plates, but instead of a central inlet port to flow the solids-containing liquid to such conduit,

the liquid is axially fed into the conduit from a feed line connected to a transverse extremity

of the conduit. Filters of such type are available from Millipore Corporation (Bedford,

Massachusetts) under the trademark Pellicon®. This feed arrangement results in a

progressive diminution of the liquid pressure at increasing transverse distances in the feed end of the distribution conduit, which in turn results in progressively transversely decreased

cross-flow rates of liquid in the flow channel.

In an effort to overcome the aforementioned liquid flow maldistribution

characteristics of stacked plate filters, filter plates have been constructed with baffle elements

defining discrete flow channels, with the intent of achieving a more uniform distribution of

the solids-containing influent liquid across the full areal extent of the filter elements in the

flow channels of the filter.

A filter plate commercially available from Toyo Soda Manufacturing Company, Ltd.

(Tokyo, Japan) has a structure in which solids-containing influent liquid is introduced to the

flow channel at a central inlet port along side of the plate. A wall is disposed in front of the

liquid inlet, extending upwardly from the floor of the flow channel and transversely toward

the extremities of the flow channel, to divide the influent system into two outwardly directed

streams. Downstream from such stream-splitting wall is a longitudinally extending divider

partition, the steam-splitting wall and the divider partition together forming a "T"

construction when viewed in plan view. Longitudinally spaced from a parallel to the stream-

splitting wall are a series of baffle partitions on either side of the divider partition. The

baffles extend transversely part-way across the flow channel on either side of the divider

partition, so that there is formed a serpentine flow path for each of the split streams, on the

respective sides of the partition. A unitary liquid outlet port is provided at the opposite side

of the stacked plates from the inlet port, whereby the respective serpentine flows are finally

joined and discharged from the flow channels of the filter. Although the dual serpentine flow path arrangement described above provides a

somewhat better distribution of liquid flow across the area extent of the filter paper element,

the sharp turns in the flow path at the extremities of the baffles create edge and entrance

effects in the flow streams which produce substantial dead space and bypassing therein. As a

result of such anomalous flow phenomena, the filtration efficiency of the baffled serpentine

flow arrangement is significantly reduced.

A microporous filter article is commercially available from Millipore Corporation

(Bedford, Massachusetts) under the trademark MF-Millipore, as a stacked array comprising a

top gasket sheet member, a filtrate separator plate, a filter sheet of microporous filtration

medium, a retentate separator plate, a second filter sheet of microporous filtration medium, a

filtrate separator plate, and a bottom gasket sheet member. The filtrate separator plates and

the retentate separator plate include a peripheral border including manifold openings therein,

circumscribingly enclosing a central screen or mesh flow channel area. In operation, a

recirculating fluid path across the filter sheets is directed by the retentate screen, in the flow

channel area of the retentate separator plate, which contacts the two filter sheets. The filter

sheets separate the solution or other feed material to be separated, according to the porosity

rating of the filter sheets. The filtrate screen, in the flow channel area of the filtrate separator

plate, carries away the filtrate to the manifold openings in the peripheral borders of the

filtrate separator plates. The filtrate then flows through the manifold openings of the filtrate

separator plates to a filtrate collection means such as a vessel which is provided exteriorly of

the filter comprising the stacked array of such filter articles. in Tangential ultrafiltration and microfiltration membrane cassette systems are available

from Filtron Technology Corporation (Northborough, Massachusetts) under the trademarks

Minisette, Centrasette, and Maxisette, which comprise multiple layers of membrane

assemblies composed of ultrafiltration or microfiltration membranes disposed between

polymeric screen or linear open channel retentate separators and screen filtrate separators.

Blocked borders on the filtrate and retentate screens direct the filtrate to collection ports on a

bottom cell manifold. Cassettes can be provided in a stacked array, or cell, mounted between

end plates, which may be provided with suitable ports, for introduction of feed material to be

separated in the cassettes, and for discharge or withdrawal of filtrate and retentate.

My prior U.S. Patent 4,882,050 issued September 19, 1989 describes a filter plate

characterized by substantially uniform transverse distribution of liquid from a unitary liquid

feed port, and highly uniform liquid cross-flow across the full transverse extent of the flow

channel formed when plates of such type are stacked to form a cross-flow filter.

The filter plate of this prior patent has a generally planar and rectangular shape with a

substantially flat bottom surface. A top surface of the plate is provided with an upwardly

extending wall circumscribingly bounding a flow channel of generally rectangular shape. A

liquid inlet port is disposed at a medial part of a first side of the flow channel, with the liquid

outlet port at a medial part of a second side of the flow channel opposite the first side thereof.

The liquid inlet port is joined in liquid flow communication with a liquid feed trough

extending transversely across the first side of the flow channel, and the liquid outlet port is

1 joined in liquid flow communication with a liquid collection trough extending transversely

across the second side of the flow channel.

In this construction, a plurality of spaced-apart partitions extend upwardly from the

floor of the flow channel between the liquid feed trough and the liquid collection trough.

These partitions are of lesser height than the walls circumscribing the flow channel and are

substantially parallel to one another, to define a series of sub-channels extending

longitudinally between the liquid feed trough and the liquid collection trough. Both the

liquid feed trough and the liquid collection trough are of progressively increasing depth from

their respective medial portions to their marginal extremities.

Plates according to this prior patent may be utilized in stacked pairs to form enclosed

flow channels within which filtration may take place in a highly efficient manner.

Specifically, a first plate of the type broadly described above is paired with a structurally

identical second plate positioned in inverted relationship to the first plate, such that the

respective circumscribingly bounding walls of the first and second plates are in abutting

sealing contact with one another. In this stacked arrangement, a filter element support of

generally rectangular shape approximating the dimensions of the flow channel is interposed

between the adjacent plates, with filter sheet elements between the support and each of the

respective pair filter plates.

My prior U.S. Patent 4,867,876 discloses a filter plate suitable for use with filter

elements to form a stacked plate filter. In the stacked plate filter, pairs of such filter plates

? are mated with filter elements therebetween, to form flow channels wherein solids-containing

liquid may be contacted with the filter sheet elements for filtration thereof to produce solids-

reduced liquid, and permeate.

The filter plate of U.S. Patent 4,867,876 has a generally planar shape with a

substantially flat bottom surface. A top surface of the plate is provided with a first upwardly

extending wall circumscribingly bounding a flow channel of generally rectangular shape.

The flow channel in this prior design is circumscribingly bounded by a second upwardly

extending wall interior to and of lesser height than the first circumscribingly bounding wall,

the second wall being in spaced-relation to the outer wall along diagonally opposed L-shaped

peripheral sections of the flow channel, each such L-shaped peripheral sections comprising a

leg extending transversely across the flow channel for a major portion of the length thereof,

and a leg dimension of the flow channel and communicating at its extremity with an opening

extending through the plate, with the portions of the periphery of the flow channel not

comprising such L-shaped sections comprising ridge elements extending between the first

and second circumscribingly bounding walls.

A liquid inlet port is disposed at a first side of the flow channel in this prior design,

with a liquid outlet port at a second side of the flow channel opposite the first side thereof.

The liquid inlet port in this prior filter plate is joined in liquid flow communication

with a liquid feed trough interior to the second bounding wall and extending transversely

across the first side of the flow channel. The liquid outlet port is joined in liquid flow

1 communication with a liquid collection trough interior to the second bounding wall and

extending transversely across the second side of the flow channel.

A plurality of spaced-apart partitions extend upwardly from the floor of the flow

channel between the liquid feed trough and the liquid collection trough. Such partitions are

substantially parallel to one another to define a series of sub-channels extending

longitudinally between the liquid feed trough and the liquid collection trough. These

partitions preferably are of lesser height than the first (outer) wall circumscribing the flow

channel and of substantially the same height as the second (inner) wall circumscribing the

flow channel.

Plates of the foregoing type may be utilized in stacked pairs to form enclosed flow

channels within which filtration may take place in a highly efficient manner. Specifically, a

first plate of this type broadly described above may be paired with a plate of the type broadly

described above may be paired with a corresponding second plate positioned in inverted

relationship to the first plate, such that the respective first circumscribingly bounding walls of

the first and second plates are abutting sealing contact with one another. In such stacked

arrangement, a filter element of generally rectangular shape approximating the dimensions of

the flow channel is interposed between the adjacent plates, suitably with its peripheral edges

reposed on the second bounding wall. Such filter element is provided with an interior flow

structure, whereby permeate entering the interior of the element is conveyed to the edge

portions of the element for discharge into the aforementioned L-shaped peripheral sections of

the flow channel between the respective first and second bounding walls. In an illustrative aspect, the filter element may comprise a foraminous support of generally rectangular shape

approximating the dimensions of the flow channel, interposed between the adjacent plates,

with filter sheet elements between the foraminous support and each of the respective filter

plates.

In the operation of a stacked filter plate assembly of the type disclosed in prior U.S.

Patent 4,867,876, liquid introduced via the liquid inlet port enters the liquid feed trough and

is laterally distributed from the associated portion of the feed trough to outer extremities

thereof. The liquid flow is directed into the sub-channels to yield a longitudinal liquid cross-

flow which is highly uniform over the full transverse extent of the flow channel, so that the

full areal extent of the filter element is highly effectively utilized. As a result, the solids

filtration capacity of the stacked plate assembly is substantially increased and the assembly is

capable of significantly extended operation prior to regeneration of the filter, as compared to

various prior art cross-flow plate and frame filters.

My prior U.S. Patent 5,049,268 discloses a filter plate which may be used in

invertedly facing pairs, with a sheet holder having filter sheets disposed on its respective

faces, mounted between the facing filter plates. The filter plate is characterized by (a) a

generally rectangular and generally planar shape with main top and bottom surfaces; (b) a

first wall extending upwardly from said main top surface and circumscribingly bounding a

flow channel area of generally rectangular shape thereon; (c) a second wall on said main top

surface extending upwardly therefrom, said second wall being interior to and of lesser height

than said first wall and in spaced relation to the first along diagonally opposed L-shaped peripheral sections of the flow channel area; (d) each L-shaped peripheral section comprising

a leg extending transversely across the flow channel area for a major portion of the width

thereof and a leg extending longitudinally for a portion of the length of the flow channel area

and communicating at its extremity with an opening extending through the plate, with

peripheral portions of the flow channel area not comprising such L-shaped sections

comprising ridges extending between the first and second walls; (e) an inlet port opening at a

corner portion of the filter plate at a first end thereof, extending through the plate, interiorly

positioned in a polygonal-shaped distribution basin on the main bottom surface of the plate,

said distribution basin being bounded by generally linear side edges defining corners of the

basin at respective intersections of the side edges; (f) an inlet trough opening extending

through said plate and transversely across a major portion of the width of said flow channel

area and along a first side edge of said distribution basin, such that said liquid inlet trough

opening communicates said distribution basin on the main bottom surface of the plate with

said flow channel area on the main top surface of the plate; (g) an outlet port opening at a

corner portion of said plate diagonally opposite said inlet port opening, said outlet port

opening extending through the plate, interiorly positioned in a polygonal-shaped collection

basin on the main bottom surface of the plate, said collection basin being bounded by

generally linear side edges defining corners of the collection basin at respective intersections

of the side edges thereof; (h) an outlet trough opening extending through the plate and

transversely across a major portion of the width of said flow channel area and long a first

side edge of said collection basin, such that said outlet trough opening communicates said

collection basin on the main bottom surface of the plate with said flow channel area on the

main top surface of the plate; and (i) a plurality of transversely spaced-apart partitions

⁽> extending upwardly from the floor of the flow channel area between the liquid feed trough

and the liquid collection trough, said partitions being of substantially the same height as the

second wall and substantially parallel to one another to define a series of channels between

the partitions, extending longitudinally between the liquid feed trough and the liquid

collection trough.

In one specific embodiment disclosed in prior U.S. Patent 5,049,268, the liquid

distribution basin and liquid collection basin each have quadrilateral shape, wherein each

basin comprises: the port opening being disposed at a first said corner and the side edges

intersecting at the first corner defining a first included angle w therebetween of from about

60° to about 110°; a second corner diagonally opposite the first corner, and the side edges

intersecting at the second corner defining a second included angle x therebetween of from

about 45° to about 90°; a third corner transversely adjacent the first corner and longitudinally

adjacent the second corner, with the side edges intersecting at the third corner defining a third

included angle y therebetween of from about 70° to about 135°; a fourth corner

longitudinally adjacent the first corner and transversely adjacent the third corner, with the

sides edges intersecting at the fourth corner defining a fourth angle z therebetween of from

about 60° to about 90°; and the side edge extending transversely between the second and

fourth corners also bounding the associated trough opening extending through the plate and

communicating the basin with the flow channel area.

The filter plate disclosed in prior U.S. Patent 5,049,268 is very highly efficient in

effecting mass transfer operations, e.g., dewatering of aqueous biomass suspensions, desalting of proteins, and removal of secreted metabolites from cellular suspensions. Such

filter plate may be readily formed as a unitary article by injection molding thereof from a

variety of plastics materials, such as polypropylene, polysulfone, polyvinylchloride. etc., but

due to the relatively complex geometric character of the filter plate, the injection molded

plates are relatively expensive to produce.

Accordingly, it would be a significant advance in the art, and is therefore an object of

the present invention, to provide a filtration article of a type which provides the superior

mass transfer efficiency and utility of the filter plate disclosed in prior U.S. Patent 5,049,268,

but which is much more economical to produce than the filter plate and sheet holder of such

prior U.S. Patent 5,049,268.

It is another object of the invention to provide a filter comprising a stack of improved

filtration articles of such type.

It is another object of the invention to provide a method of making such improved

filtration article, in a simple, efficient, and economical manner.

Other objects and advantages of the invention will be more fully apparent from the

ensuing disclosure and appended claims.

SUMMARY OF THE INVENTION The present invention relates generally to filtration cassettes, of a type comprismg

membrane filter sheets arranged in a multilaminate, peripherally bonded array, wherein the

filter sheets alternate with permeate sheet elements, and retentate channel elements.

In another aspect, the present invention relates to cross-flow filters comprising a

multiplicity of stacked filtration cassettes of the general type described in the preceding

paragraph, as well as to a method of making such filtration cassettes.

In one particular aspect, the present invention relates to a filtration cassette

comprising a multilaminate array of sheet members of generally rectangular and generally

planar shape with main top and bottom surfaces, wherein the sheet members include in

sequence in the array a first retentate sheet, a first filter sheet, a permeate sheet, and second

filter sheet, and a second retentate sheet, wherein each of the sheet members in the array has

at least one inlet basin opening at one end thereof, and at least one outlet base opening at an

opposite end thereof, with at least one permeate passage opening at longitudinal side margin

portions of the sheet members;

each of the first and second retentate sheets having at least one channel opening

therein, wherein each channel opening extends longitudinally between the inlet and outlet

basin openings of the sheets in the array and is open through the entire thickness of the

retentate sheet, and with each of the first and second retentate sheets being bonded to an

adjacent filter sheet about peripheral and side portions thereof, with their basin openings and

permeate passage openings and register with one another, and arranged to permit flow of

I S^' filtrate through the channel openings of the retentate sheet between the mlet and outlet basin

openings to permit permeate flow through the filter sheet to the permeate sheet to the

permeate passage openings;

the filtration cassette comprising a unitary article of inter-bonded sheet members.

In another particular aspect, the present invention relates to a filtration cassette

sequence in said array a first retentate sheet, a first filter sheet, a permeate sheet, a second

filter sheet, and a second retentate sheet, wherein each of the sheet members in said array has

at least one inlet basin opening at one end thereof, and at least one outlet basin opening at an

opposite end thereof, with at least one permeate passage opening at a longitudinal side

margin portion of the sheet members;

therein, extending longitudinally between the inlet and outlet basin openings of the sheets in

the array, and being bonded (e.g.., compression bonded) to an adjacent filter sheet about

peripheral end and side portions thereof, with their basin openings and permeate passage

openings in register with one another and the filtrate passage openings of each of the

retentate sheets being circumscribingly bonded to the adjacent filter sheet, and with a central

portion of each of the retentate sheets and adjacent filter sheets being unbonded to permit

l b permeate contacting the retentate sheet to flow through the filter sheet to the permeate sheet;

and

each of the filter sheets being secured at its peripheral portions on a face thereof

opposite the retentate sheet, to the permeate sheet.

planar shape with main top and bottom surfaces, wherein the sheet members include:

a first retentate sheet of suitable material, e.g. polysulfone, polyethersulfone,

polycarbonate, urethane, silicone, or other material of construction, having (i) at least one

longitudinally extending rib or partition element, such partition element(s) when provided in

multiple configuration being transversely spaced-apart from one another and being of

substantially the same height and substantially parallel to one another to define a single or a

series of channels between the partitions, extending longitudinally between the respective

inlet and outlet basin openings of associated filter elements and permeate sheet members, on

both faces thereof, (ii) filtrate passage openings at side portions of the sheets, and (iii) the

retentate sheet aligned to the first sheet of filter material at respective end and side portions

thereof, with the basin openings and filtrate passage openings of the associated sheet

members in register with one another and the filtrate passage opening of the retentate sheet

member being circumscribingly compressed against the first sheet of filter material, and with

a central portion of the first sheet of filter material and the retentate sheet member being unbonded to permit permeate contacting the retentate sheet member to flow through the first

sheet member of filter material to the permeate sheet member;

a first sheet member of filter material having (i) at least one basin opening, of a

suitable shape, e.g., polygonal, semicircular, oval or sector shape, at each of opposite end

portions of the sheet member defining respective inlet and outlet passages, and (ii) at least

one filtrate passage opening at the side portions of the sheet member, wherein the first sheet

member of filter material is bonded to the permeate sheet member at their respective end and

side portions, with their basin openings and filtrate passage openings in register with one

another and the basin openings being circumscribingly bonded at respective end portions of

the first sheet member of filter material and the permeate sheet member, and with a central

portion of the first sheet member of filter material and the permeate sheet member being

unbonded so as to define a central portion permeate channel of the permeate sheet

communicating with the filtrate passages in the first sheet member of filter material and in

the permeate sheet member;

a permeate sheet member, having (i) multiple basin openings of suitable shape at

each of opposite end portions of the sheet member defining respective inlet and outlet

passages, and (ii) filtrate passage openings at the side portions of the sheet member;

a second sheet member of filter material having (i) at least one basin opening at each

of opposite end portions of the sheet member defining respective inlet and outlet passages,

and (ii) at least one filtrate passage opening at the side portions of the sheet member, wherein the second sheet member of filter material is compression sealed to the retentate sheet

member at their respective end and side portions, with their basin openings and filtrate

passage openings in register with one another and the filtrate passage opening of the retentate

sheet member being compression sealed to the second sheet member of filter material, and

with a central portion of the second sheet member of filter material and the retentate sheet

member being unbonded to permit permeate contacting the retentate sheet member to flow

through the second sheet member of filter material; and

a second retentate sheet member of suitable material, e.g. polysulfone,

polyethersulfone, polycarbonate, urethane, silicone, having (i) at least one longitudinally

extending rib or partition element, provided that when multiple partition elements are

employed, the partition elements are transversely spaced-apart from one another, such

partition elements being of substantially the same height and substantially parallel to one

another, to define a single channel or a series of channels between the partitions, extending

longitudinally between the respective inlet and outlet basin openings of the filter elements

and permeate sheet members, on both faces thereof, (ii) filtrate passage openings at the side

portions of the sheet member, and (iii) the retentate sheet compression sealed to the second

sheet of filter material at respective end and side portions thereof, with their basin openings

and filtrate passage openings in register with one another and the filtrate passage opening of

the retentate sheet member being compression sealed to the second sheet member of filter

material, and with a central portion of the first sheet member of filter material and the

retentate sheet member being unbonded to permit permeate contacting the retentate sheet n member to flow through the second sheet member of filter material to the permeate sheet

member.

As used hereinafter, the term "sheet member" employed in reference to the various

laminae of the cassette - the cassette being the stack of generally planar sheet members

forming an operative mass transfer unit when coupled to fluid supply, retentate and filtrate

flow means - will be variously referred to as simply "sheet." It will therefore be noted that

the term "sheet" will denote the generally planar members of the cassette, the cassette thus

comprising an assembly of permeate sheets, filter sheets, and retentate sheets, coupled to one

another in such manner as to permit flow of the fluid to be separated through the flow

channel(s) of the device, for mass transfer involving passage of the filtrate through the filter

sheets, and retention of the retentate on the side of the filter sheet opposite the side from

which the filtrate emerges. The term "compressible" in reference to the retentate sheet or

other structural feature or sheet member of the present invention means that such component

or member is compressively deformable by application of load or pressure thereon.

The above-described filtration cassette of the invention comprises a "base sequence"

of elements, defined as a sequence of sheet elements constituting a retentate sheet (hereafter

designated by the symbol "R"), a filter sheet (hereafter designated by the symbol "F"), a

permeate sheet (hereafter designated by the symbol "P"), a second filter sheet ("F"), and a

second retentate sheet ("R"), thereby providing a sequence of sheet elements, R/F/P/F/R.

D The base sequence of sheet elements may be utilized in construction of filters

comprising a plurality of filtration cassettes, wherein the retentate sheet is utilized to seal the

top and bottom elements of a plurality of filtration cassettes of a sequence, comprising

retentate sheet "R", filter sheet "F", permeate sheet P, filter sheet "F", retentate sheet "R",

filter sheet "F", permeate sheet P, filter sheet "F", and retentate sheet "R". An illustrative

stacked cassette filter according to the invention may for example feature the sheet sequence

R/F/P/F/R/F/P/F/R/F/P/F/R, comprising a first retentate sheet, two base sequences of sheets

FPFR in a repetitive sequence, and a second retentate sheet. In all repetitive sequences, other

than a single cassette base sequence, the following relationship is observed: where X is the

number of filter sheets F, the quantity 0.5 X -1 is the number of interior retentate sheets R,

and the quantity 0.5 X is the number of permeate sheets P, with two outer retentate sheets

being utilized to seal the top and bottom extremities of the intervening sequence.

Thus, it is possible to utilize a large number of base sequence cassettes in a repetitive

sequence, to provide a stacked cassette filter of the desired mass transfer area. Many

configurations are possible. It is feasible in some instances, e.g., for mass transfer studies

and system quantitation, to utilize a single cassette comprising the base sequence R/F/P/F/R

wherein the outermost retentate sheets in the sequence are compression-sealed at their outer

faces to an end plate accommodating removal of permeate from the filtrate passage openings

of the constituent sheet members in the cassette.

The sheets of filter material used in the cassette article of the present invention may

be of any suitable porosity rating. As used herein, the porosity rating of a sheet of filter material is the smallest particle size which cannot pass through the pores of the filter

material. Typical porosity ratings are expressed in molecular weight (MW) and micrometer

units, e.g., a 2 micron filter media sheet being a material which will pass particles smaller

than 2 microns in diameter through the pores of the material, while particles larger than 2

microns will not be passed through the filter material, and as a further example, a 10,000

MW filter media sheet being a material which will pass particles smaller than 10,000 MW in

diameter through the pores of the material, while particles larger than 10,000 MW will not be

passed through the filter material.

In one preferred embodiment of the cassette article of the invention, a retentate sheet

is provided with a plurality of transversely spaced-apart, longitudinally extending ribs or

partitions, extending upwardly from (the central portion of) each of the main top and bottom

faces of the retentate sheet, such ribs or partitions being of substantially the same height and

substantially parallel to one another to define a series of channels between the partitions,

extending longitudinally between the respective basin openings of the retentate sheet, on both

faces thereof. The adjacent filter sheets may be further bonded to the outer extremities of the

ribs or partitions, and the ribs or partitions may be formed of any suitable material, e.g., a

flexible resilient adhesive bonding medium, such as a urethanes, epoxy or silicone adhesive

sealant medium, e.g., applied in a "bead" in the longitudinal direction of the retentate sheet

on both main top and bottom faces thereof.

As used herein, the term "bonded" in reference to adjacent sheets in the multilaminate

cassette means that the adjacent sheets are secured to one another in such manner as to prevent flow of the material being processed, e.g., the feed material to be separated, as well

as component materials therefrom (filtrate or permeate, as well as retentate), from flowing

through such secured areas or between the adjacent sheets at such secured areas. Preferably,

the bonding is carried out with a suitable adhesive or sealant medium, e.g., a urethane, epoxy,

cyanoacrylate, or silicone adhesive material, which fills the interstices in the bonded pair of

sheets, and adhesively joins one of the adjacent sheets to the other in the bonded areas.

As used herein, the term "compressive bonding" and "compress ively bonded" refer to

bonding and bonding operations in which the structure being bonded is subjected to a

compressive load or force, for sufficient time and under sufficient period to effect the

bonding securement of the structure. The invention may for example be carried out with

bonding of sheets in the multilaminate array to one another with cyanoacrylate or other "fast"

adhesives, or alternatively the adhesive or sealant medium may require extended cure at

ambient temperature or other appropriate cure conditions, and it may be advantageous to

conduct such cure with the laminate structure in a fixture or other assembly in which the

compressive bonding is effectively completed. Compressive bonding of laminae in the

practice of the invention is highly desirable, in order to assure the leak-tightness and

structural integrity of the resulting multilaminate assembly of the cassette.

In one specific embodiment of the cassette article of the invention, the inlet and outlet

basins each comprise two quadrilateral openings, wherein each basin opening comprises:

V side edges intersecting at a first corner of the basin opening defining a first included

angle w therebetween of 90°;

a second corner diagonally opposite said first corner, and the side edges intersecting

at such second corner defining a second included angle x therebetween of 90°;

a third corner transversely adjacent the first corner and longitudinally adjacent the

second corner, with the side edges intersecting at the third corner defining a third

included angle y therebetween of 90°;

a fourth corner longitudinally adjacent the first corner and transversely adjacent the

third corner, with the sides edges intersecting at the fourth corner defining a fourth

angle z therebetween of 90°.

In another embodiment of the cassette article of the invention, the inlet and outlet

basins each comprise four quadrilateral openings, wherein each basin opening comprises:

side edges intersecting at a first corner of the basin opening defining a first included

angle w therebetween of 90°;

at such second corner defining a second included angle x therebetween of 90°; a third corner transversely adjacent the first corner and longitudinally adjacent the

included angle y therebetween of 90°;

angle z therebetween of 90°.

Each sheet member in the cassette broadly described hereinabove may suitably

comprise filtrate passage openings at the side portions (margins) of the sheet member.

In a specific aspect of the invention, each of the permeate and retentate sheets may

constitute a foraminous material of from about 80 to about 300 mesh size. Each of the

foraminous permeate and retentate sheets may for example comprise a woven polymeric

mesh, e.g., of a material selected from the group consisting of polyester, polypropylene,

nylon, fluorocarbon polymers such as polytetrafluoroethylene, polyethylene, and

polysulfone, and composites comprising one or more of such materials.

The permeate and retentate sheets alternatively may comprise a non-woven material,

if of suitable foraminous character, or alternatively may comprise a sintered metal matrix, or

other structural element of the desired porosity and permeability characteristics.

Alternatively, the permeate and retentate sheets may be of an imperforate or solid rigid

character. - ^ The filter sheets used in the filtration cassette of the present invention may be of any

suitable materials, such as a material selected from the group consisting of cellulose,

polyphenylene oxide, polysulfone, cellulose nitrate, cellulose acetate, regenerated cellulose,

polyether amide, polyphenylene oxide/polysulfone blends, mixed esters of cellulose, and

polyether sulf one.

basins of the sheet members are structurally reinforced by radio frequency (RF) welding of

urethane or other suitable material such as ethylvinylacetate, silicone, and EPDM. In a

particularly preferred specific embodiment of the invention, a first assembly consisting of a

first filter sheet, permeate sheet, and second filter sheet are urethane bonded and then die cut

to form a first cutout of inlet and outlet basins. The longitudinal ends of the first assembly

then are covered on both sides (main faces) thereof with a thin sheet of urethane which

completely overlays the inlet and outlet basins. The first assembly with the respective

laminae, in the sequence of: urethane sheet, filter sheet, permeate sheet, filter sheet, and

urethane sheet, then is RF welded to form a second assembly. The RF welding fuses the two

sheets of urethane inside the inlet and outlet basins resulting in an encapsulation of the inlet

and outlet basins. The second assembly then is die cut a second time, to create an opening at

the inlet and outlet basins which is dimensionally smaller then the first cut.

The resulting newly formed inlet and outlet basins are now entirely encapsulated and

reinforced by the fused urethane sheets. This specific technique is a substantial improvement to existing stacked cassette elements because it prevents the delamination of ultrafiltration

membranes. Numerous membrane types, especially ultrafiltration membranes and reverse

osmosis membranes, are cast (manufactured) as a skin layered on a support structure. In use,

the turbulence associated with the fluid in the inlet and outlet basins results in delamination

and membrane cassette failure. The aforementioned encapsulation procedure reinforces and

seals the exposed skin of two part membrane structures wherein the membrane and cassette

life is greatly extended. Additionally, the reinforced inlet and outlet basins can be operated

at higher velocities for improved operation and cleaning without the occurrence of membrane

delamination.

Another aspect of the present invention relates to a stacked cassette cross-flow filter

comprising cassette articles of the type described above.

Still another aspect of the present invention relates to a filter assembly including a

pair of end plates or manifold plates between which the cassettes are secured for operation.

A still further aspect of the invention relates to a filtration cassette, e.g., of a type as

variously described above, comprising bonded portions which are bonded by a bonding

technique selected from the group consisting of heat bonding, ultrasonic bonding, radio

frequency bonding, and microwave bonding.

In yet another aspect of the invention, the filtration cassette comprises a permeate

sheet of a rigid character. Another aspect of the invention relates to a filtration cassette of the aforementioned

type, wherein the permeate channel is longitudinally continuous.

A further aspect of the invention relates to a filtration cassette of theabove described

type, in which the basins thereof are devoid of sharp corners.

Another aspect of the invention relates to a filtration cassette of the previously

described type, in which the inlet and outlet portions of the cassette include a transversely

extending weld line interior to a basin thereof, and with adhesive bonding of such end portion

interior to the weld line.

A still further aspect of the invention relates to a stacked cassette filter comprising a

filtration cassette of the type previously described, wherein an outermost retentate sheet is

bonded to a rigid endplate, and a compressible gasket is disposed between the rigid endplate

and a manifold plate of the filter.

Other aspects and features of the present invention will be more fully apparent from

the ensuing disclosure and appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

M Figure 1 is a perspective view of a filter assembly comprising a filtration cassette

according to one embodiment of the present invention with compressible end gaskets and end

plates.

Figure 2 is an exploded perspective view of a filtration cassette according to one

embodiment of the present invention.

Figure 3 is a top plan view of a portion of a filtration cassette, featuring two

quadrilateral-shaped basins.

Figure 4 is a top plan view of a portion of a filtration cassette according to another

embodiment of the invention, featuring four quadrilateral-shaped basins.

Figure 5 is a perspective elevation view of a filter comprising a multiplicity of

cassette articles according to the present invention.

Figure 6 is a plan view of a filter sheet of a type which may be usefully employed in

the cassette of Figure 2.

Figure 7 is a plan view of a retentate sheet of a type which may be usefully employed

in the cassette of Figure 2.

«, Figure 7A is a top plan view of a portion of a retentate sheet according to another

embodiment of the invention, featuring four quadrilateral-shaped basins.

Figure 8 is a plan view of a compressible end gasket of a type which may be usefully

employed in the cassette of Figure 2.

Figure 8A is a plan view of a compressible end gasket according to another

embodiment of the invention, featuring four quadrilateral- shaped basins.

Figure 9 is a plan view of a formaminous permeate sheet of a type which may be

usefully employed in the cassette of Figure 2.

Figure 10 is a perspective view of a filter comprising a multiplicity of cassettes and

compressible end gaskets of the type shown in Figures 1 and 2.

Figure 11 is a top plan view of a filtration cassette according to one embodiment of

the invention.

Figure 12 is a top plan view of a portion of a cassette, composed of sheet members

P/F/P featuring two quadrilateral-shaped basins after the first die cut.

3 c Figure 12A is a top plan view of a portion of a filtration cassette, composed of sheet

members P/F/P according to another embodiment of the invention, featuring four

quadrilateral-shaped basins after the first die cut.

Figure 13 is a top plan view of a portion of a cassette, composed of sheet members

P/F/P after RF welding the encapsulating material, and featuring two quadrilateral-shaped

basins.

Figure 13A is a top plan view of a portion of a filtration cassette, composed of sheet

members P/F/P after RF welding the encapsulating material according to another

embodiment of the invention, and featuring four quadrilateral-shaped basins.

Figure 14 is a top plan view of a portion of a cassette, composed of sheet members

basins after the second die cut.

Figure 14A is a top plan view of a portion of a filtration cassette, composed of sheet

members P/F/P after RF welding the encapsulating material according to another

embodiment of the invention, featuring four quadrilateral-shaped basins after the second die

cut.

Figure 15 is a top plan view of a rigid retentate plate according to one embodiment of

the present invention, such as may be employed in the filtration cassette of the invention. Figure 16 is a top plan view of a further embodiment of a rigid permeate plate such as

may be employed in the filtration cassette of the invention.

Figure 17 is a top plan view of a compressible resilient gasket, such as may be

employed between a rigid endplate and a manifold plate of a filter assembly comprising a

filtration cassette in accordance with the present invention.

Figure 18 is an exploded elevation view of a filter assembly comprising a filtration

cassette according to the invention, and utilizing a "hard shell" arrangement with a

compressible gasket between the hard shell endplate and the manifold plate of the filter

assembly.

DETAILED DESCRIPTION OF THE INVENTION, AND

PREFERRED EMBODIMENTS THEREOF

The disclosures of my prior U.S. Patent Application No. 08/405,493, now issued as

U.S. Patent 5,593,580, and my prior U. S. Design Patent No. 357,059 issued April 4, 1995

hereby are incorporated herein by reference, in their entirety.

The filter cassette article of the present invention is adapted to be employed in

stacked arrays to form a stacked cassette filter assembly in which the base sequence of

retentate sheet (R), filter sheet (F), permeate sheet (P), filter sheet (F), and retentate sheet (R) may be repeated in the sequence of sheets in the filter assembly as desired, e.g., in a

repetitive sequence of retentate sheet (R), filter sheet (F) , retentate sheet (R), filter sheet (F),

permeate sheet (P), filter sheet (F) , retentate sheet (R), filter sheet (F), permeate sheet (P),

filter sheet (F), retentate sheet (R), filter sheet (F), retentate sheet (R). Thus, the filter

cassette of a desired total mass transfer area is readily formed from a stack of the repetitive

sequences. In all repetitive sequences, except for a single unit sequence, the following

relationship is observed: where X is the number of filter sheets, 0.5X-1 is the number of

interior retentate sheets, and 0.5X is the number of permeate sheets, with two outer retentate

sheets being provided at the outer extremities of the stacked sheet array.

The filter sheets, and the retentate and permeate sheets employed therewith, may be

formed of any suitable materials of construction, including, for example, polymers, such as

polypropylene, polyethylene, polysulfone, polyethersulfone, polyetherimide, polyimide,

polyvinylchloride, polyester, etc.; nylon, silicone, urethane, regenerated cellulose,

polycarbonate, cellulose acetate, cellulose triacetate, cellulose nitrate, mixed esters of

cellulose, etc.; ceramics, e.g., oxides of silicon, zirconium, and/or aluminum; metals such as

stainless steel; polymeric fluorocarbons such as polytetrafluoroethylene; and compatible

alloys, mixtures and composites of such materials.

Preferably, the filter sheets and the retentate and permeate sheets are made of

materials which are adapted to accommodate high temperatures and chemical sterilants, so

that the interior surfaces of the filter may be steam sterilized and/or chemically sanitized for

regeneration and reuse, as "steam-in-place" and/or "sterilizable in situ" structures, respectively. Steam sterilization typically may be carried out at temperatures on the order of

from about 121°C to about 130°C, at steam pressures of 15-30 psi, and at a sterilization

exposure time typically on the order of from about 15 minutes to about 2 hours, or even

longer. Alternatively, the entire cassette structure may be formed of materials which render

the cassette article disposable in character.

The end plates used with the cassette articles of the invention to form a unitary filter

assembly may be formed of any suitable materials of construction, including, for example,

stainless steel or other suitable metal, or polymers such as polypropylene, polysulfone, and

polyetherimide.

Figure 1 is a perspective view of a cross-flow filter 10 comprising a cassette article 12

according to one embodiment of the present invention. The cassette is of a multilaminate

construction, comprising a plurality of sheets as described hereinafter in greater detail,

peripherally bonded to one another at their end and side margins.

For ease of description in the ensuing discussion, the respective corners of the

cassette as shown in Figure 1 are lettered consecutively, beginning at the lower right-hand

corner A as shown and, proceeding counterclockwise, including upper right-hand corner B,

upper left-hand corner C, and lower left-hand corner D.

In the vicinity of these consecutive corners A, B, C, and D of the cassette are

provided openings 16, 18, 20, and 22, respectively, which extend through the cassette and are employed for mounting of the cassette on rods of diameter closely approximate but slightly

smaller than the respective openings. In this respect, it is to be noted that opening 22 is of

larger size (diameter) than the remaining openings 16, 18, and 20. The purpose of such

disparity in opening size is to provide a "keying" feature whereby the proper alignment of the

plate is secured, since only opening 22 will fit over a large-sized rod of corresponding

diameter, whereas openings 16, 18, and 20 will not accommodate passage over such a large-

sized rod.

Other features or structures may be employed for the same purpose, viz., of keying

the cassette to a predetermined proper orientation, in place of the different sized opening 22

relative to the remaining same-sized corner openings 16, 18, and 20. For example, one of the

respective corner openings may be of a different shape than the others, e.g., square or

triangular in cross-section, rather than circular. Alternatively, the corner profile of one

corner of the cassette may be notched or differently shaped in relation to the other corners, to

provide a readily visibly discernible keying or orientational structure of the cassette article.

The filtration cassette 12 is provided at its respective side margins with openings 64,

66, 68, and 70 which are smaller than openings 16, 18, and 20 and which are employed for

keeping the compressible retentate sheet in place.

The filtration cassette 12 also is provided at its respective side margins, at the mid-

section of the longitudinally extending cassette, with openings 24 A, B, C, D, E and 26 A, B,

C, D, E extending through the cassette. These openings may be employed for egress of permeate produced in the filtration operation when the cassette is deployed in the stacked

cassette filter assembly illustrated, and/or otherwise for accommodating ingress/egress of a

selected fluid, such as steam or other sterilant fluid for effecting cleaning and regeneration of

the filter, or a secondary fluid for mass transfer contacting with a primary fluid passage

through the filter.

This filter 10 comprises a base including a mounting plate 30 having vertically

upwardly extending rods 34, 36, and 38 at its respective corner portions as shown. Each of

the rods 34, and 36 are of the same diameter, while the fourth rod 38 is of larger diameter, to

provide the plate orientation keying structure, which will ensure that the constituent plates of

the filter assembly are assembled in the proper orientation, since the corresponding rod

mounting openings 18 and 20 in the cassettes, e.g., cassette 12, are of the same diameter,

accommodating the smaller diameter rods, while the third rod mounting opening 22 is of

larger diameter, to accommodate rod 38. Thus, by providing a rod of larger diameter, and

forming the cassettes 12 with correspondingly shaped openings, the proper registration of the

cassette openings with the proper rods is assured, resulting in correct orientation of the

respective stacked filtration cassettes in the array.

This filter 10 comprises a base including a mounting plate 30 having vertically

upwardly extending rods 72, 74, 76, and 78 correspond to openings 64, 66, 68, and 70 for

mounting and alignment of the compressible retentate sheets 14A and 14B.

3L It will be appreciated from the foregoing that any other cassette orientation

registration device may be employed to ensure to correct positioning of the successive

stacked filtration cassettes on the mounting plate 30. For example, the cassettes are oriented

with their successive notches superposed with respect to one another. Alternatively, the

cassette itself may be embossed, etched, or otherwise manufactured with an orientational

device, e.g., a raised protrusion in the shape of an arrow, to indicate the correct orientation of

the filtration cassettes when stacked on the mounting plate 30. Although only one filtration

cassette is illustratively shown in the Figure 1 embodiment, it will be recognized that one or a

plurality of cassettes may be employed to form a filter in accordance with the present

invention.

Between the cassette 12 and mounting plate 30, there is provided a compressible

retentate sheet 14B which is equipped with openings to accommodate its positioning over the

respective rods 34, 36, 38, 72, 74, 76, and 78 so that the compressible retentate sheet seals

the bottom surface of the cassette 12. The retentate sheets in the multilaminate array may for

example have a thickness between 0.125 mm and 6.0 mm, and the other sheets in the array

may have correspondingly dimensioned thicknesses appropriate to the mass transfer

operation being conducted with the cassette.

Overlying the cassette 12 in the exploded array of Figure 1 there is provided a

compressible retentate sheet 14A which is equipped with openings to accommodate its

positioning over the respective rods 34, 36, 38, 72, 74, 76, and 78 so that the compressible

retentate sheet seals the top surface of the cassette 12.

31 Overlying the cassette 12 in the exploded array of Figure 1 is an upper end plate 60,

which is provided with suitable openings 18, 20, 22, 64, 66, 68, and 70 accommodating the

insertion therethrough of the rods 34, 36, 38, 72, 74, 76, and 78.

Overlying the cassette 12 in the exploded array of Figure 1 is an upper end plate 60,

which as shown is suitably engaged by mechanical fastener assemblies 85, comprising

washer 86 and lock-nut 88, which threadably engages the complementarily threaded upper

ends of the respective rods 84A...84K, and 84L.

At the upper left-hand corner portion C of the mounting plate 30 shown in Figure 1,

adjacent to rod 36, there is provided a liquid outlet conduit 8 in flow communication with

openings 50 A and 50B extending through the end plate 30 and communicating with the

quadrilateral-shaped collection basins 54 A and 54B of the cassette.

The mounting plate 30 also is provided at its right-hand side margins, at the distal

section of the longitudinally extending plate, with permeate collection trough 58 which is in

flow communication with permeate outlet conduits 62 A and 62B. This is employed for

egress of permeate produced in the filtration operation (and issuing from filtrate or permeate

opening 26 A, B, C, D, E in cassette 12) and/or otherwise for accommodating ingress/egress

of a selected fluid, such as steam or other sterilant fluid for effecting cleaning and

regeneration of the filter. At the lower right-hand corner portion A of the end plate 60 shown in Figure 1 there

is provided a liquid inlet conduit 44 in flow communication with openings 46A and 46B (not

shown) extending through the end plate 60 and communicating with the quadrilateral- shaped

collection basins 48 A and 48B of the cassette.

The end plate 60 also is provided at its left-hand side margin, at the near-section of

the longitudinally extending plate, with permeate collection trough 56 (not shown) in flow

communication with permeate outlet conduits 52A and 52B. This conduit is employed for

opening 24 A, B, C, D, E in cassette 12), and/or otherwise for accommodating ingress/egress

regeneration of the filter.

The cassette 12 shown in Figure 1 has a quadrilateral-shaped feed distribution trough,

in which liquid entering in feed liquid conduit 44 issues from feed liquid openings 46A and

46B (not shown) therein and is distributed in the feed distribution basin 48A and 48B, from

which it passes longitudinally through the cassette 12, in a flow channel provided between

the retentate sheet and adjacent filter sheets, as hereinafter more fully described. In the flow

channel, the permeate components of the feed material passes through the filter sheets

adjacent to the retentate sheet, and flows into next-adjacent permeate channels, from which

the permeate flows to openings 24 A, B, C, D, E and 26 A, B, C, D, E. The retentate then

issues from an opposite end portion of the central flow channel of the cassette into the collection basins 54A and 54B, from which the retentate is discharged from the filter through

openings 50 A and 5 OB into liquid conduit 8.

It will be appreciated that the permeate openings 24 A, B, C, D, E and 26 A, B, C, D,

E may, as previously described, be coupled to a flow circuit including a second mass transfer

medium which is to be passed in mass transfer relationship to the primary feed material

stream entering the filter in conduit 44. By such arrangement, mass transfer is able to be

carried out in both directions across the filter sheets in the cassette. Alternatively, the filter

may be used as shown, with the openings 24 A, B, C, D, E and 26 A, B, C, D, E being used

for discharge of permeate. It will be recognized that instead of two permeate conduits 62A

and 62B on the mounting plate 30, and two permeate conduits 52A and 52B on the end plate

60, both permeate outlet conduits may be provided on mounting plate 30, or on end plate 60,

or alternatively, both plates may feature any number of permeate discharge conduits secured

thereto and in communication with the permeate openings of the cassette(s).

Figure 2 is an exploded perspective view of a cassette 12 employed in the Figure 1

filter, and comprising, a compressible retentate sheet 102, a filter sheet 104, a foraminous

permeate sheet 106, a filter sheet 108, and a compressible retentate sheet 110, as constituent

sheets in the multilayer array.

As shown, each of the constituent filter sheets 104, 106, and 108 has a generally

quadrilateral-shaped cut-out opening 114A and 114B at one end thereof, and a similar cut out

Ho opening 112A and 112B at the opposite end thereof, and each of the sheets is provided with

corner openings 16, 18, 20, 22, 64, 66, 68, and 70.

As shown, each of the compressible retentate sheets 102 and 110 have quadrilateral

retentate channels 116A and 116B.

Each of sheets is generally co-extensive in areal extent with the others, and when

consolidated into a unitary cassette article, the cutout openings 112A and 112B and 114A

and 114B and retentate channels 116 A and 116B in each of the respective sheet elements are

in registration, as are the rod openings 16, 18, 20, 22, 64, 66, 68, and 70. The sheets are each

bonded at their side and end extremities to the next adjacent sheet in the cassette, and the

retentate sheet 102 is bonded at its peripheral region 120 to the corresponding peripheral

region of filter sheet 104, and in like manner the retentate sheet 110 is bonded at its

peripheral portion 122 to filter sheet 108. Permeate sheet 106 is bonded at its outer periphery

124 on its top face to filter sheet 104, and the permeate sheet at its bottom face is bonded

along its peripheral region 126 to filter sheet 108.

On the retentate sheets, a longitudinally extending, transversely spaced-apart rib 128

is provided, extending from the inlet basin opening 112 and 112B to the collection basin

opening 114A and 114B.

The permeate sheet 106 is suitably bonded to the adjacent filter sheets (108 and 104,

respectively) in such manner as to leave an unbonded central area 130 on permeate sheet 106 which communicates with the filtrate or permeate openings 24 A, B, C, D, E and 26 A, B, C,

D, E whereby filtrate is readily removed from the cassette in use.

Figure 3 is a top plan view of a portion of a cassette article 12, wherein the collection

basin is composed of two quadrilateral shaped basins 54A and 54B.

Figure 4 is a top plan view of a cassette 12 according to another embodiment of the

invention featuring four quadrilateral shaped basins 54A, 54B, 54C, and 54D. Shown in

dashed line representation in the basin is the liquid collection conduit 50A, 50B, 50C, and

50D, denoting the position of the liquid withdrawal conduit relative to the basin structure. It

will be recognized that the inlet distribution basins corresponding to the outlet collection

basin shown in Figures 3 and 4, respectively, are similarly configured, with respect to their

shape and component angles, relative to the same cassette article, although the distribution

and collection basins could in some applications advantageously be hemispherical or of

different shape and size characteristics.

Although the quadrilateral shape of the respective liquid distribution basins 48A and

48B and collection basins 54A and 54B may be widely varied in the broad practice of the

present invention, as regards the specific values of the corner angles of such basins, the

specific shape and angles shown in Figures 3 and 4 are most preferred to facilitate uniformity

of flow path length for liquid across the entire areal extent of the respective basins and flow

channel area, i.e., a generally uniform velocity profile of the fluid flowing longitudinally

across the flow channel area of the cassette. In the filtration cassette shown in Figure 4, wherein the distribution basins each

comprise four quadrilateral sub-basins 54A, 54B, 54C, and 54D, each sub-basin suitably

comprises: side edges intersecting at a first corner defining a first included angle a

therebetween of 90°; side edges intersecting at a second comer defining an included angle b

therebetween of from about 90°; a third comer transversely opposite the first comer, with the

side edges intersecting at the third comer defining an included angle c therebetween of 90°;

and a fourth comer transversely opposite the third corner, with the side edges intersecting at

the fourth comer defining an included angle d therebetween of 90°.

In like manner the distribution and collection basins could in some applications

advantageously be hemispherical or of different shape and size characteristics.

The filter cassette of the present invention may be fabricated in any suitable manner,

including casting, injection molding, dielectric bonding, solvent bonding, adhesive bonding,

etc., the specific method of fabrication depending on the material of construction and the

desired end use. For example, polysulfone is a preferred material of construction for the

filter sheets, alternating with polysulfone retentate sheets, and foraminous polypropylene

permeate sheets, and bonded by urethane or cyanoacrylate adhesive.

In one particularly preferred embodiment of the invention, the cyanoacrylate adhesive

Super Bonder #4981 from Loctite Corporation, Newington, CT is utilized the adhesive

bonding medium for construction of the cassette.

M In another particularly preferred embodiment of the invention, a two part urethane

CONATHAMES #DPST-20256 (part A and part B) Conap, Inc., Olean, NY is employed as

the cassette bonding material.

When polysulfone, polypropylene, and urethane are utilized as materials of

construction, dielectric bonding may suitably be employed as the method of fabrication.

Alternatively, when polypropylene, polypropylene, and cyanoacrylates are utilized as

the materials of construction, wet bonding may suitably be employed as the method of

fabrication.

Figure 5 shows a perspective elevation view of a filter according to one embodiment

of the invention, utilizing a plurality of cassettes according to the invention, to form a stacked

cassette array.

This stacked cassette filter 200 comprises a base 202 including a mounting plate 30

having vertically upwardly extending rods 34, 36, 38, 72, 74, 76, and 78 at the respective

comer and side portions as shown. Each of the rods 34 and 36 is of the same diameter, while

the third rod 38 is of larger diameter, to provide a cassette orientation keying structure, which

will ensure that the constituent cassettes and compressible retentate sheets of the filter

assembly are assembled in the proper orientation, with the corresponding rod mounting openings in the cassette being appropriately sized for such rods. Rods 72, 74, 76, and 78 are

of the same diameter to provide support and alignment of the compressible retentate sheet.

The stacked cassettes 220 form a stack cassette array 222 which is retained between

the plate 30 and end plate 60, as shown, with mechanical fastener means 85 being provided

on the respective threaded rods to provide the necessary compressive action on the cassette

array 222. The upper end plate features a permeate outlet conduit 52A and 52B, and a

corresponding permeate egress conduit is provided on the opposite side at the bottom of plate

30, 62 A and 62B. At the upper left-hand corner portion of mounting plate 30 is provided a

retentate discharge conduit 8, and at the lower right-hand of the filter is provided a feed

material inlet conduit 44, as shown.

Inlet conduit 44 may be joined to a suitable source of material to be separated, which

then can be provided under suitable temperature, pressure, and flow rate conditions to the

filter 200 for separation therein into retentate, discharged in conduit 8, and permeate,

discharged in conduit 52A and 52B (as well as the corresponding filtrate or permeate

conduits 62 A and 62B at the opposite lower portion of the filter).

the cassette of Figure 2, and wherein all parts and elements are correspondingly numbered to

Figure 2.

Ir Figure 7 is a plan view of a retentate sheet of a type which may be usefully employed

in the cassette of Figure 2 , and wherein all parts and elements are correspondingly numbered

to Figure 2.

Figure 7A is a top plan view of a portion of a retentate sheet according to another

embodiment of the invention, featuring four quadrilateral-shaped basins 116 A, B, C, and D,

and featuring additional permeate channels 24 F-L and 26 F-L, beyond the corresponding

two basin structure of Figure 7, but wherein all other elements of Figure 7A are numbered

correspondingly to Figure 7.

employed in the cassette of Figure 2, featuring longitudinal retentate channels 80 A and B

separated by rib 90, and wherein the permeate openings and rod mounting openings are

numbered correspondingly to Figure 2.

Figure 8A is a plan view of a compressible end gasket according to another

embodiment of the invention, featuring four quadrilateral-shaped basins 80 A-D, separated

by longitudinally extending, transversely spaced-apart ribs 90 A-C, and wherein the permeate

openings and rod mounting openings are numbered correspondingly to Figure 8 and Figure 2.

Figure 9 is a plan view of a formaminous permeate sheet of a type which may be

usefully employed in the cassette of Figure 2, and which is numbered correspondingly to

Figure 2. Figure 10 is a perspective exploded view of a filter 222 comprising a multiplicity of

cassettes and compressible end gaskets of the type shown in Figures 1 and 2, and wherein

corresponding parts and elements are numbered correspondingly to Figures 1 and 2.

Figure 11 is a perspective view of a filtration cassette according to one embodiment

of the invention, wherein the parts and elements are numbered correspondingly to Figure 2.

Figure 12 is a top plan view of a portion of a cassette 302, composed of sheet

members P/F/P featuring two quadrilateral-shaped basins 314 A, B at one end portion of the

multilaminate stack, and two quadrilateral-shaped basins 312 A, B at the other end portion of

the multilaminate stack, after the first die cut.

Figure 12A is a top plan view of a portion of a filtration cassette, composed of sheet

members P/F/P according to another embodiment of the invention, featuring four

quadrilateral-shaped basins 314 A-D, after the first die cut.

Figure 13 is a top plan view of a portion of the cassette of Figure 12, numbered

correspondingly thereto, and composed of sheet members P/F/P after RF welding the

encapsulating material 324.

l Figure 13A is a top plan view of a portion of the filtration cassette of Figure 12A,

numbered correspondingly thereto, and composed of sheet members P/F/P after RF welding

the encapsulating material 324.

Figure 14 is a top plan view of the cassette of Figures 12 and 13, numbered

encapsulating material, and featuring two quadrilateral-shaped basins after the second die

cut.

Figure 14A is a top plan view of the filtration cassette of Figures 12A and 13 A,

the encapsulating material, and featuring four quadrilateral-shaped basins after the second die

cut.

Figure 15 is a top plan view of a rigid permeate sheet 400 which may be employed in

the practice of the present invention, as a component sheet of the filtration cassette. As

shown, the permeate sheet comprises a plate member 402 of generally rectangular form,

being elongate in the vertical direction as illustrated. The permeate sheet has a main top

surface 430 and an opposite main bottom surface (not shown in the view of Figure 15).

At the corners of the permeate sheet 400 are provided mounting openings 406, 408,

410 and 412. Opening 406 is of larger size than the remaining openings 408, 410, and 412,

as a keying feature of the sheet. The permeate sheet, which may be of significant thickness in relation to the filter sheets and permeate sheets, is provided at its respective ends with

basin openings 422 and 424. The basin openings may be single openings at each end of the

sheet, or as in the illustrated embodiment, may comprise multiple openings at each end.

Preferably such basin openings are characterized by the absence of sharp corners and thus

may be provided with the rounded edge corner conformation shown.

The permeate sheet also is provided with registration openings 414, 416, 418 and 420,

which likewise may provide a keying function, relative to correct orientation of the permeate

sheet and associated sheets of the filtration cassette as assembled therewith.

The permeate sheet shown in Figure 15 is provided with a central permeate collection

region 450 which is characterized by a series of longitudinally spaced-apart ridge elements

having valleys therebetween so as to provide transversely extending channels in the sheet.

By means of this permeate collection region, permeate passing through the filtration sheet at

such face of the permeate sheet contacts the ridged surface of the collection region and is

channeled to the marginal, longitudinally extending permeate troughs 436 and 438. The

channeled permeate flows through the left-hand passages 432 to the permeate discharge

openings 426, with permeate concurrently and likewise flowing through right-hand passages

434 to the right-hand permeate discharge openings 428.

In this manner, the permeate passing through the filter sheet at each of the main top

and bottom faces of the permeate sheet is contacted with the collection region 450 of the sheet and is channeled into the longitudinal troughs and respective permeate discharge

openings 426, 428.

It will be understood that the central collection region 450 of the permeate sheet may

be configured in any of a wide variety of structural and geometric arrangements to channel

permeate to the respective discharge openings of the sheet.

Figure 16 is a top plan view of a permeate sheet 500 according to another

embodiment of the invention. The corresponding parts and elements of Figure 16 are

numbered correspondingly to the parts and elements of Figure 15, by addition of 100 to the

reference numbers of the corresponding parts and elements of Figure 15.

In the Figure 16 embodiment, the permeate discharge openings 526 and 528 on the

respective left-hand and right-hand margins of the permeate sheet are each longitudinally

continuous. Otherwise the permeate sheet of Figure 16 corresponds to the structure and

characteristics of the permeate sheet of Figure 15.

The longitudinally continuous permeate openings 526 and 528 are employed in the

plate of Figure 16 to facilitate lay-up and assembly of the corresponding filtration cassette. It

has been found that when the filtration cassette is of substantial length (elongate or

longitudinal extent), and the permeate plate includes a series of longitudinally spaced-apart

permeate openings, registration of the respective filter sheets, permeate sheets, and retentate

sheets is frequently difficult, and that the provision of a continuous permeate opening at each

$0 of the respective sides of the elongate permeate sheet permits a more easily facilitated

registration of the filter sheet and retentate sheets in the fabrication of the filtration cassette.

Figure 17 is a top plan view of a flexible resilient gasket 600, such as may be

employed between an exterior rigid endplate when employed in a filtration cassette

assembly, and a manifold plate of the filter comprising such filtration cassette. The gasket

600 comprises an elongate body 602 having a top main surface 630 and a corresponding

bottom main surface (not shown in the view of Figure 17), with mounting openings 606, 608,

610 and 612. Basin opening 622, 624 provided at opposite end portions of the gasket. The

gasket also features alignment opening 614, 616, 618 and 620, and longitudinally spaced-

apart left-hand permeate openings 626 and longitudinally spaced-apart permeate openings

628.

The gasket 600 permits a "hard shell" filtration cassette, i.e., a filtration cassette

comprising an outermost rigid endplate, to be efficiently sealingly mated to a manifold plate

of a filter comprising the filtration cassette.

The gasket may be compressively retained between the endplate of the filtration

cassette and the manifold plate of the filter, as hereafter described.

Figure 18 is an exploded elevation view of a filter assembly FA comprising a

filtration cassette FC according to the invention, utilizing a "hard shell" arrangement, with

5- compressible gaskets G,, G₂ between the respective hard shell endplates EP,, EP₂ and the

respective manifold plates MP,, MP₂ of the filter assembly.

The filtration cassette FC includes a central permeate sheet P. to the respective faces

of which are bonded the filter sheets F, and F₂. Exterior to the the filter sheets in the cassette

array are retentate sheets R, and R . The retentate sheets R, and R₂may be of rigid and solid

form, and are respectively bonded to the end plates EP,, EP₂ to complete the structure of the

filtration cassette. It will be appreciated that the filter assembly FA may comprise a number

of sequentially arranged filtration cassettes FC, only one being shown in Figure 18 for ease

of simplicity and to facilitate description. In this manner, a "hard shell" cassette is formed.

A gasket Gi is provided between the endplate EP, and the manifold plate MP, of the

filter assembly, such manifold plate having an outlet O from which the filtered retentate may

be discharged from the filter assembly, as well as a permeate port PT from which the

collected permeate is discharged from the filter assembly. The permeate port PT may be

provided in duplicate, with one port located behind the visible port PT in the schematic

drawing of Figure 18, so that a separate port is provided at each of the margins of the

assembly communicating with the permeate collection troughs of the side margins of the

filtration cassette(s) in the filter assembly.

In like manner, a gasket G₂ is provided between the endplate EP₂ and the manifold

plate MP₂ of the filter assembly, such manifold plate having an inlet I to which the material

to be filtered is introduced to the filter assembly. In such filter assembly, the gaskets effect sealing of the hard shell filtration cassette

against the manifold plates of the filter assembly, with each of the sheets EP,, Rj, F,, P, F₂,

R₂, and EP₂ being interbonded to form a unitary cassette article.

It will be appreciated that the filtration cassette of the present invention may be

variously fabricated, utilizing foraminous, e.g., screen or mesh, or rigid sheets in its

construction, the choice of a specific type component sheet being readily determinable for a

given end use application of the invention.

As mentioned, the filtration cassette of the present invention comprises a unitary

particle including inter-bonded sheet members, wherein bonding may be variously effected,

e.g., by techniques including heat bonding, ultrasonic bonding, radio frequency bonding,

microwave bonding, adhesive bonding, etc. In some instances it may be desirable to form

one or more of the sheets with portions thereof including carbon filler, whereby mated sheets

in the array of sheet members may be microwave bonded to one another. For example, the

retentate sheet could be formed with a carbon impregnated peripheral portion which when

sandwiched with the filter sheet and the permeate sheet in sequence may be subjected to

microwave heating in a microwave oven to bond the constituent retentate sheets to the

adjacent sheets.

Alternatively, the constituent sheet members may be laid up with microwave heating

tapes being applied to the areas to be bonded, whereby such tapes under microwave

-T 3 conditions are heated to effect bonding of the sheets between which the tape is interposed.

Microwave susceptor strips, ribbons, or particles may for example be employed on or within

the corresponding sheets, so that fabrication can be carried out in a conventional microwave

oven environment.

Accordingly, the invention contemplates the provisions of sheet members including

regions or portions thereof which are bondable to corresponding areas of adjacent sheets

under exposure to microwave radiation. Alternatively, radiation frequency or ultrasonic

bonding could be utilized with a radiation-susceptible material being employed to effect

bonding of the appertaining sheet areas.

As mentioned herein, it is preferred that the inlet and outlet basins of the filtration

cassette be devoid of sharp corners, so that any intersecting linear surfaces converge at a

rounded or curvate corner. Such configuration assists the hydrodynamic characteristics of

the cassette and facilitates its cleaning, since the presence of sharp corners can produce

stagnant areas in which solids, e.g., biomass, proteins, or other solid or depositable species

can accumulate and adversely effect the clean (e.g., sterile) character of the filtration cassette.

It will be apparent from the foregoing that the respective sections of stacked cassettes

may be variously joined in fluid flow communication with one another, in parallel or in

series, to form stacked filter "trains" whose constituent sections may be employed to carry

out a number of unit operations on an influent or feed material, such as concentrating

(dewatering), washing, dialyzing, desalting, etc.

$\ For example, a stacked filter train of series-connected sections may be employed in a

culturing system of the type disclosed and claimed in my prior U.S. Patent 4,885,087, and

U.S. Serial No. 07/207,655 filed June 21, 1988 (and corresponding international patent

application no. PCT/US89/02011 filed 10 May 1989 for "CULTURE DEVICE AND

METHOD"), the disclosures of which hereby are incorporated by reference, in applications

such as the production in vitro of human immunodeficiency virus (HIV) on cellular or

synthetic substrates. In such HIV production application, a first stacked cassette section

could be employed to concentrate HIV, a second section could be utilized to add media to or

withdraw media from the system, all without withdrawing any virus, such as may otherwise

present a risk of immunosuppressive infection. Thus, a closed system virus culturing

arrangement is provided, which is highly advantageous not only for the production of HIV

but also the culturing or other processing of pathogenic as well as non-pathogenic bacterial,

viral, and yeast species.

Industrial Applicability

The filtration cassettes of the invention may be usefully employed to perform various

mass transfer operations, such as liquid-liquid extraction, dewatering and concentration of

solids suspensions, desalting of proteins, introduction of nutrient media for biomass

culturing, harvesting of secreted metabolites and other products for cellular suspensions, etc.

The cassette articles of the invention are particularly useful for forming stacked

cassette filter assemblies. In such assemblies, respective sections of stacked cassettes may be variously joined in fluid flow communication with one another, in parrallel or in series, to

form stacked filter "trains" whose constituent sections may be employed to carry out a

number of unit operations on an influent or feed material, such as concentrating (dewatering),

washing, dialyzing, desalting, etc.

For example, a stacked filter train of series-connected sections may be employed in a

application no. PCT/US89/02011 filed 10 May 1989 for "CULTURE DEVICE AND

viral, and yeast species.

Claims

THE CLAIMS

1 ΓÇ₧ A filtration cassette comprising a multilaminate array of sheet members of generally

rectangular and generally planar shape with main top and bottom surfaces, wherein the sheet

members include in sequence in the array a first retentate sheet, a first filter sheet, a permeate

sheet, and second filter sheet, and a second retentate sheet, wherein each of the sheet

members in the array has at least one inlet basin opening at one end thereof, and at least one

outlet base opening at an opposite end thereof, with at least one permeate passage opening at

longitudinal side margin portions of the sheet members;

filtrate through the channel openings of the retentate sheet between the inlet and outlet basin

permeate passage openings;

╧Ç

2. A filtration cassette according to claim 1, wherein the permeate sheet is of rigid

character.

3. A filtration cassette according to claim 1, wherein the permeate sheet is of screen or

mesh construction.

4. A filtration cassette according to claim 1, wherein the sheet members are inter-

bonded by a bonding technique selecting from the group consisting of heat bonding,

ultrasonic bonding, radio frequency bonding, and microwave bonding.

5. A filtration cassette according to claim 1, wherein at least two sheet members of the

cassette are at least in part microwave bonded to one another.

6. A filtration cassette according to claim 1, wherein inlet and outlet basin openings are

devoid of sharp comers.

7. A filtration cassette according to claim 1 , wherein filter sheets are bonded to

respective faces of the permeate sheet, with a weld line interior to the basin openings, and

with adhesive bonding interior to the weld lines.

8. A filtration cassette according to claim 7, wherein said weld line is formed by radio

frequency welding or ultrasonic welding.

9. A filtration cassette according to claim 1 , wherein permeate passage openings at

longitudinal side margin portions of the sheet members are longitudinally continuous.

10. A stacked cassette filter including a stacked assembly of filtration cassettes, wherein

each filtration cassette comprises a multilaminate array of sheet members of generally

longitudinal side margin portions of the sheet members;

permeate passage openings;

11. A stacked cassette filter according to claim 10, wherein an outermost filtration

cassette comprises an outermost retentate sheet of rigid character.

12. A stacked cassette filter according to claim 10, wherein an outermost filtration

cassette comprises a retentate sheet bonded to an endplate to provide a hard shell cassette

structure, and the endplate is positioned adjacent a manifold plate of the filter with a

compressible gasket between the endplate and the manifold plate.