FORMING DIFFUSION MEMBRANE UNITS WITH JOINED CAPILLARY MEMBRANE TUBES

Abstract: A method of forming a diffusion membrane unit (10) comprising a joined plurality of separate capillary membrane tubes, and then applying junction lines of adhesive material (26, 28, 32) across the parallel membrane tubes at points spaced from the ends, and allowing the adhesive material to harden to join said membrane tubes.

Description: FORMING DIFFUSION MEMBRANE UNITS WITH JOINED CAPILLARY MEMBRANE TUBES Background of the Invention Capillary fiber dialyzers are currently being used in the dialysis of blood, and also show promise for use as oxygenators for blood and for other types of semi- permeable diffusion apparatus. An example of such a capil¬ lary fiber dialyzer is the CF® dialyzer sold by the Artificial Organs Division of Travenol Laboratories, Inc. Other forms of capillary dialyzers involving a multiple tube flow path includes a Kohl U.S. Patent No. 3,557,962, Riede U.S. Patent No. 4,016,082, West German Patent Publication No. 2,824,898 of Cordis Dow Corporation, published * on December 21, 1978, and West German Patent No. 2,622,684. It has long been known to be desirable, particu¬ larly in blood dialysis as well as other diffusion tech¬ niques involving blood, for the blood flow paths to be of capillary nature, having a transverse dimension of, for example, 500 microns or less. These capillary flow paths for the blood or other material improve the dialysis efficien-cy of the device. Such capillary tubes are used, for example, in the commercial capillary fiber dialyzer mentioned above, as well as other commercial capillary fiber dialyzers. It would be desirable to form joined arrays of capillary semi-permeable tubes, for example, to obtain an independent sheet of such joined capillary tubes. However, no efficient and effective way of manufacturing joined arrays of such tubes having a maximum transverse inner diameter of less than one millimeter has been available prior to this present invention. In accordance with this invention, a diffusion membrane unit defining an internal flow path is provided in which joined tubes define individual flow channels through the diffusion membrane unit which may have a max mum transverse dimension of less than one millimeter or one thousand microns, with a minimum transverse dimensio being as low as 0 or 100 microns, for greatly improved dialysis efficiency, or corresponding improvements in any other desired diffusion process. 10 Description of the Invention In accordance with this invention, a method is provided for forming a diffusion membrane unit comprising 15 a joined plurality of capillary membrane tubes, which co prises: forming a plurality of parallel, separate membra tubes into a flat, substantially two dimensional array, followed by applying junction lines of adhesive material across the parallel membrane tubes. Thereafter, the ad- 20. hesive material is allowed to harden, with the result th the parallel capillary membrane tubes are joined together into an integral diffusion membrane unit for installation into a housing. Preferably, the parallel, separate capillary 25 membrane tubes are joined by the junction lines in space relation to each other for an improved exposure of tubula membrane area to the exterior. This, in turn, will impro the efficiency of the diffusion membrane unit. It may be desirable for the hardened adhesive 30 material to be essentially similar to the material com¬ prising the membrane tubes. For example, cupraammonium cellulose material which maybe used to form the tubes may also be used as the adhesive material to join the membra tubes. Accordingly, some diffusion action can take place 35 through the tube walls that are in contact with the adhes material. Alternatively, the capillary membrane tubes may be made of any semipermeable membrane material, for example, other forms of cellulose, polycarbonate resins, or the like for dialysis, or, for exygenation of blood, polytetrafluoro- ethylene, silicone rubber, or preferably porous hydrophobic materials such as porous polypropylene or polytetrafluoro- ethylene, having pores on the order of 0.1 to 1 micron, by way of example. Conventional materials for membrane plasma- pheresis or ultrafiltration,may also be used if desired. Any non-toxic, preferably semipermeable, binder may also be used in accordance with this invention. For example, water-compatible or water soluble materials such as carboxymethyl cellulose, polyvinyl alcohol, hydroxypropyl cellulose or starch may be used in conjunction with hydro- philic hemodialysis membrane tubing. Also binders soluble in organic solutions may be used with appropriate tubing materials. Alternatively, a heat seal technique may be used so that the junction lines of adhesive material across the parallel membrane tubes are produced by the very tubes themselves.- Also hot-melt sealant binders such as poly(ethylene-vinyl acetate) may be applied, preferably after the fiber is dried. Semiperm ' eable dialysis type fibers made of a cellulose-based material, polycarbonate, or crosslinked polyvinyl alcohol, for example, may be made by any known process, for example, by a hot melt technique or a solution spinning technique, depending on the circumstances. Preferable, the capillary membrane tubes may have a wall thickness of 3 to 50 microns and a bore diameter of 70 to 700 microns. Preferably, the bore diameter for capil¬ lary fibers used in hemodialysis may be 200 - 50 microns If the capillary membrane tube is intended for use for the oxygenation of blood, it may preferably have a bore diameter of 500 - 200 microns. For example, the junction lines of ahesive mate¬ rial may cross the plurality of capillary membrane tubes in an X-shaped or crossing wave pattern to extend essentiall the entire length of the membrane unit. Parallel junctio lines crossing the capillary membrane tubes may also be used as desired with a plurality of such junction lines being positioned between the ends. Other patters using one or more junction lines may be used as well. As an advantage of this invention, the supporte integral diffusion membrane unit may comprise capillary membrane tubes having thinne ir walls *, because the tubes ar supported as a membrane unit, and not just as separate fibers, which provides them a measure of protection. Alternatively, a plurality of single layers of parallel,, separate, capillary membrane tubes may be bough together in facing relationship, with the layers of paral membrane tubes defining sinuous paths. The specific sinu paths of each layer of parallel fibers may be different, with the result that portions of the adjacent layers of fibers are out of contact with each other, -and other por¬ tions of each layer of parallel fibers are in contact wit the adjacent layers. A.cco-rdingl , the individual fibers each layer may be in crossing, contacting relationship wi the fibers of adjacent layers. Adhesive means are provid for adhering the crossing fibers together, which adhesive means may be applied by a solution spray, an applicator roller, or the like. As a manufacturing technique, the single fibers may be conventionally extruded and then brought into thei flat, substantially two-dimensional array by a roller system containing one or more concave, rollers, or by a system of combs to guide the fibers into the desired clos parallel, substantially two-dimensional array. Preferably, the flat, substantially two-dimen¬ sional arrays of fibers contemplated in this invention co prise no more than ten layers of parallel, separate, capillary membrane tubes. Since the capillary membrane tubes may have a bore diameter on the order of 200 micron for example, and a " wall thickness on the order of 20 microns, the individual fibers may have an outer diameter on the order of 240 microns. Thus, the flat, substantially two-dimensional array containing ten -layers of such fibers still will only have a thickness of about 2400 microns, while the same array may have a width of three or four centi¬ meters, ' by way of example. Such a structure thus retains its substantially two-dimensional characteristic. Pre¬ ferably, no more than five separate layers of capillary membrane tubes are utilized in this invention. After the array of fibers is secured in a housing and supported thereby, if the adhesive material is made from a soluble substance, the housing interior may be washed with the appropriate solvent to dissolve the adhesive material and remove it from the housing. This tends to pro- vide improved diffusion characteristics to the diffusion membrane unit of this invention. ' Preferably a water soluble adhesive material is used, the solvent being water. Figure 1 is a perspective view of a diffusion membrane member, comprising a joined, flat, substantially two-dimensional array of capillary membrane tubes, posi¬ tioned in a housing for use as a diffusion device, for example, a dialyzer. , Figure 2- is a plan view showing a flat array of fibers carrying junction lines of adhesive material in a wave-shaped, crossing multiple X-pattern. Figure 3 is a plan view of a flat, substantially two-dimensional array of fibers in which the lines of adhesive material cross the array in transverse, straight lines. Figure 4 is a plan view of a multi-layered, flat, substantially two-dimensional array in which the individual layers of parallel, separate capillary membrane tubes occupy sinuous paths. Figure 5 is a schematic plan view of a system for advancing the fibers to bring them into closely-spaced, substantially two-dimensional array. Figure 5_ is an elevational view of the arrange ment of Figure 5- Figure 6 is a schematic plan view of alternati apparatus for bringing an array of fibers into closely- spaced, substantially two-dimensional relationship. Figure 7 is a schematic elevational view of apparatus for applying junction lines to a continuous ban of membrane tubes in substantially two-dimensional array, produce the pattern of junction lines illustrated in Figure 2. Figure 8 is a schematic, plan view of the array parallel fibers of Figure 7 showing the motion of the app cator apparatus. Figure 9 is a schematic, elevational view of apparatus adapted to form the multi-layered array of para lel tubes in which the individual layers of parallel tube define sinuous paths. Figure 10 is a schematic ' plan view shewing the action of the apparatus of Figure 9. Referring to Figure 1, a composite diffusion me brane device comprising a flat, substantially two-dimensi al array of capillary fibers 10, enclosed in a rectangula housing, is disclosed. If desired, a plurality of flat arrays 10 may be stacked together and placed in a housing to provide a composite diffusion core of greater thicknes than the substantially two-dimensional structure made in accordance with this invention. Diffusion members 10 may be potted at their end 14 in a manner analogous to current technology for hollow fiber dialyzers, to define sealed manifold chambers 16, 1 respectively defining an inlet 19 and an outlet 21 which communicate only with the bores cf the fibers i diffusio member 10, for the purpose of defining a first flow path through the device within the bores of the capillary tube A second flow p h through the diffusion device along the exteriors of the capillary tubes of the diffusi device 10 may then be defined by a second fluid inlet 20 and outlet 22, positioned in the side of housing 12 in a manner which is also analogous to conventional fiber dia¬ lyzer technology. The rectangular shape of housing 12 and diffusion member or members 10 provides a substantially simplified and efficient diffusion device which is easy to manufacture. Examples of members 10 are disclosed in Figures 2- . Referring to Figure 2, a substantially two- dimensional array of a single layer of parallel capillary fibers 24 is shown. In accordance with this invention, junction lines of adhesive material 26, 28 have been applied across the width of the array of capillary fibers or tubes, to hold the array of tubes into an integral array for ease of handling and for retention of the individual tubes in the desired configuration. The pattern of application of the junction lines of adhesive material is, as show , wave- shaped for each of lines 2β, 28, with the respective shapes being of opposite phase so that they form, a crossing, multiple X-pattern, which preferably extends frcm end to end along the entire .length of the array of fibers 24. Alterna¬ tively, a single wavy line may be used as the junction lines of adhesive material. Preferably, the array of fibers 24 is positioned closely together but in spaced relation, for example, from 0.01 to 0.05 inch apart, for improved diffusion efficiency In operation. This spacing Is maintained by junction lines 2β, 28 of adhesive material, with the resulting structure being a composite, strong member which retains individual fibers in their proper positions. Preferably, the capillary tubes in the array of tubes 24 may be made of a cellulose type material, for example, cuprammonium cellulose. The junction lines of adhesive 26, 28 may then also be made of the sane cupram- monium cellulose material, or another cellulose-cased material, which is applied in liquid form to the array of tubes, and caused to solidify by a coagulation step appro priate to cupraammonium cellulose, or by evaporation of a solvent, or the like. However, other adhesive or potting materials may be used for junction lines 26, 28 as desire Referring to Figure 3, another flat, substantia two-dimensional, single-layered array of capillary membra tubes 30 is shown, with the junction lines 32 in this instance crossing the array of membrane tubes 30 in trans verse, straight lines. It should be noted that a plurali of junction lines 32 are positioned intermediate of the e of array 30, to provide intermediate stabilization-and su port of the diffusion member array 30. As before, both t tubes of array 30 and the junction lines 32 may comprise cupraammonium cellulose. However, in addition, as ' in the case of junction lines 26, 28, junctions ' lines 32 may com¬ prise other materials such as various forms of glue, pott compound or the like. In both the instances of Figures 2 and 3, the capillary membrane tube arrays are typically made in a co tinuous length, and are then cut to the desired length. is preferable in the instance of Figure 3 to cut through middle of some of junction lines 32 to separate the lengt of membrane tubing into separate members for installing i a housing. However, it is preferable still for one or mo lines 32 to be located intermediate the ends of the cut- sections, for added stabilization of the composite tubula array. Referring to Figure 4, a multi-layered flat, su stantially two-dimensional array of capillary membrane tubes is disclosed. A plurality of single layers 34, 36, of parallel, membrane tubes are held together in facing r lationship with layers 34, 36, 38 each defining sinuous paths. As shown, the specific sinuous paths of each laye of parallel fibers are different (or out of phase), so th portions 40 of the adjacent layers (for example, layers 3 and 38) are out of " contact with each other. At the same time, other portions 42 of, for example, layers 36, 38 are in contact with each other as adjacent layers, so that the. individual fibers of each layer are in crossing, contacting relationship with fibers of adjacent layers, at points 3. The fibers are adhesively adhered together at the fiber crossing po.ints 43 of adjacent layers by use, for example, of an assembly technique described below, with points 43 arranged together to define adhesive junction lines. This resulting composite array of.'capillary mem- brane tubes provide large diffusion wall surface area in an essentially two-dimensional array, with low masking of the respective fibers by each other because they are in crossing relationship to adjacent fibers, and with lengthened flow paths due to the sinuous nature of the " fibers. Referring to Figures 5 and 5a, apparatus is shown for automatically bringing the capillary ' membrane tubes together into closely-spaced, flat, substantially two- dimensional array. The capillary tubes 44 may be fed to the apparatus shown in Figures 5 and 5a from feed spools or the like, to pass across guide roller 46 and to change the angle of travel of capillary tubes 44 in the process. From there, tubes 44 pass across concave roller 48, which, as shown, has the effect of impelling them more closely together into tangent or slightly spaced relation. Following this, the array of tubes 44 is drawn up¬ wardly across control bar 50, and from there they are flattened out into their desired planar structure by guide roller . From there, the array of capillary tubes 44 passes onwardly to apparatus for applying the desired junc¬ tion lines of adhesive material across the parallel membrane tubes 44, followed by a cutting step for* cutting the con¬ tinuous lengths of joined membrane tubes into diffusion membrane sections of desired length. . Referring to Figure 6, a similar array of capil¬ lary membrane tubes 44a can be brought into closely spaced two-dimensional array be being passed through a series of comb members 54, to gradually step down the lateral spacin ■ of the capillary membrane tubes 44a as desired, while retaining the substantially two-dimensional characteristic thereof, by progressively narrowing the spacing of the slo between the comb teeth. Following this støp, as in the processing step illustrated in Figure 5 S the array of membrane tubes 44a m be conveyed through apparatus for applying the junction li of adhesive material, followed by a cutting step to form t diffusion membrane sections. Referring to Figures 7 and 8, there is shown apparatus for applying junction lines of adhesive material across the parallel membrane tubes, and specifically, in a pattern similar to that shown in Figure 2. The plurality membrane tubes 4 ' 4b may be unwound off of spools and fed across rollers 58 through 64, with rollers 8 and 6l being driven. A continuous belt 66 is threaded around rollers 5 and 60, to support the membrane tubes 44b as the junction lines of adhesive material are applied. Roller 63 may be a heated roller to help in curi of the adhesive material,- or alternatively hot air may be blown over the joined membrane tubes 44b for curing pur¬ poses, if desired, or any other curing technique may be utilized as a substitute for roller 63- Roller bar 64 then may guide the joined membrane tubes 44b toward a cutting station, to cut the material in desired lengths. Adhesive stripe applicator members 68, 0 are operated by a simple mechanical guiding mechanism 72 of co ventional design which reciprocates applicator members 68, 70 back and forth across the width of the moving belt of membrane tubes 44b. Moving in the direction of arrows 74 in the spcific instance shown, stripe applicator members 6 70 can move back and forth across the width of the belt of membrane tubes 44b in alternating manner. Accordingly, since belt of capillary tubes 44b is moving, the junction lines of adhesive material 26, 28 which are laid down by 5 applicators 68, 70 forms the out-of-phase, sinuously patterned crossing junction lines as shown in Figure 8 and also Figure 2. The adhesive material is applied to stripe appli¬ cator units 68, 70 through α nduits 76, being metered 10 through the applicator unit 68, 70 by metering pumps 78, which may be gear pumps. Conduits 76 lead to a tank 80, containing the liquid adhesive material which may be pres¬ surized with a supply of pressurized nitrogen gas 82 or by any other convenient means for pressurizing the adhesive 15. material, for flow through the conduits 76 and metering pumps 78, for application as stripes26, 28 to the array of membrane tubes 44b. Referring to Figures 9 and 10, apparatus is shown for the manufacture of capillary tube membrane units of a 20 design similar to that -of Figure 4. in Figures 9 and 10, a two-layered membrane unit is under manufacture, but obvious modifications of the apparatus permit the manufac¬ ture of three-layer and higher multiple layer units. A pair of flat, substantially two-dimensional, 25 single layered arrays of capillary tubes 84, 86 may be formed from spools, and the individual capillary tubes brought into close proximity with each other in a manner previously described. After the arrays 84, 86 pass across guide rollers 88, they pass through comb-like members 90, 30 92 which, in turn, as shown by Figure 10, reciprocate laterally back and forth in a direction parallel to the planes of the flat arrays 84, 86 to the form a sinuous pattern in the arrays. The differin ' arrays 84, 86 define differing sinuous paths as shown in Figure 10, so that 35 portions of each array are out of contact with the adjoin¬ ing arrays, for example, portions 90 of array 84 and of array 86. Other portions of the arrays, for example portions 94 of both of them, are in facing, overlying relation with the adjacent array. As can be seen, the respective membrane tubes of each array, 84, 86 cross at .an acute angle to the membrane tubes of the adjacent arra with the tube crossing points 96 being shown in Figure 10 Adhesive material is applied to the fiber array for example,- by a spray apparatus 98 for applying a solu¬ tion of the particular adhesive used, in a volatile solve to the crossing arrays 84, 86, preferably just before the are brought into contact with each other as shown in Figure 10. Accordingly, the individual capillary tubes o arrays 84, 86 are joined together by the adhesive at thei crossing points 96. Following this, the joined units of arrays 94, are passed across roller members 100, 102 and 104, one or more of which may be heated rollers to cure the adhesive. Alternatively, or additionally, a hot air unit may be use to assist in the drying or curing process. Following thi guide roller 106 is provided to direct the newly-formed composite of capillary tubings 108 to a cutting station. • The resulting unitary structures may be inserte into a housing similar to that shown in Figure 1, to de¬ fine a first flow path within the bores of the tubes of arrays 84, 86, and a second flow path along the exterior of the tubes. It can be seen that the assembly method of this invention permits the assembly of capillary membrane tube having very small maximum transverse dimensions, prefer- _ ably less than 1000 microns, with minimum transverse di¬ mensions being as low as about 70 or 100 microns. This type of capillary membrane tube provides greatly improved diffusion efficiency, for example, as a dialysis membrane Accordingly, the known advantages of these capillary mem- brane fibers, coupled with the advantages of a diffusion membrane which is unitary and readily handlable during the manufacturing process without falling apart into its component capillary tubes, are provided. Furthermore, crossing fiber configurations of the -diffusion membrane units in accordance with this invention provide improved efficiency of operation in terms, for example, of dialy- sance, due to the crossing relationship of the membrane tubings. In the instance where a water soluble adhesive material is used to make the junction lines of the diffu- • *« •' sion membrane devices, such as polyvinyl alcohol or starch, and after the diffusion membrane devices have been in¬ stalled in housings 12, water may be inserted through one of ports 20 or 22 to bathe the exterior surface of the diffusion membrane device, thus washing away the adhesive material. This, of course, exposes more surface area of the tubular membranes to dialysis solution, for example, during operation of the device so that the diffusion efficiency of the device will be increased. At the same time since the tubes are secured at potted ends 14, -they will remain in the generally desired configuration in which- they were sealed by the adhesive material. *•» Highly hydrophilic materials, very compatible with water but technically insoluble because of their high molecular weight, such as carboxymethyl cellulose, may also be used as the adhesive material which may be washed away by water after installation in housings 12 in a manner similar to more soluble adhesive materials. The above has been offered for illustrative pur¬ poses only, and is not intended to limit the invention of this application, which is as defined in the claims below. OMPI . '• , WIPO «

Claims: THAT WHICH IS CLAIMED IS: 1. The method of forming a diffusion membrane device comprising a joined plurality of capillary mem¬ brane tubes, which comprises: forming a plurality of parallel, separate capil lary membrane tubes into a flat, substantially two-dimen¬ sional array; applying junction line means of adhesive material across said parallel membrane tubes; allowing said adhesive material to harden to join said membrane tubes; and inserting said flat array into a housing to define a first flow path within the bores of said tubes and a second flow path along the exteriors of said, tubes. 2. The method of Claim 1 in which said paralle separate, capillary membrane tubes are joined In spaced ^ relation to each other.by said junction lines applied at positions intermediate the ends of said flat array. 3. The method of Claim 2 in which said hardens adhesive material is essentially similar to the material comprising said membrane tubes. 4. The method of Claim 2 in which said membran and adhesive material are made of a semipermeable materia based en cellulose, and said membrane tubes are less than 1000 microns in diameter. 5. The method of Claim 2 in which said membran and adhesive are made from cuprammonium cellulose. OMPI 6. The method of Claim 1 in which said junction line means of adhesive material cross said plurality of capillary membrane tubes in a wave-shaped, crossing multiple X-pattern. 7. The method of Claim 1 in which said junction line means of adhesive material cross said plurality of i i capillary membrane tubes in transverse, straight lines. 8. The method of Claim 1 in which the capillary membrane tubes are separately extruded and hardened, and thereafter brought together into said flat, substantially two-dimensional array by means for bringing said fibers into closer parallel relation with each other. 9. The method of Claim 8 in which said means for bringing the fibers into closer, essentially two- dimensional, parallel relation with each other is accom¬ plished by passing, said fibers first across concave roller means, and then across second cylindrical roller means under sufficient tension whereby the array of parallel capillary membrane tubes is shaped by the respective roller means. 10. The method of Claim 8 in which said extruded capillary membrane tubes are brought together through a series of comb means for guiding said tubes into closely spaced, parallel, substantially two-dimensional array. 11. The method of Claim 1 in which said flat, substantially two-dimensional array comprises a single layer of parallel, separate capillary membrane tubes. 12. The method of Claim 1 in which said flat, substantially two-dimensional array comprises no more than 10 layers of said parallel, separate capillary membrane tubes. 13. The method of Claim 1 In which a junction line stripe of adhesive is applied to said substantially two-dimensional array by drawing said array underneath stripe applicator means, and reciprocating said stripe applicator means back and forth across the width of said moving flat array of capillary membrane tubes, and there¬ after cutting said tubes into lengths for insertion Into a housing. 14. The method of Claim 13 in which said strip applicator means comprises a plurality of stripe applicat units reciprocating back and forth across the width of said moving array of flat parallel capillary membrane tub to form sinuous junction lines out of phase one with the other. 15. The method of Claim 1 including the subse¬ quent steps of sealing said flat, substantially two- dimensional array into a housing, and thereafter washing the exterior surfaces of said array with a solvent for th adhesive material to remove said adhesive material. 16. The method of Claim l6_in which said adhesive material is made of a substance which is easily dispersable in water, and said solvent comprises water. 17. The method of forming a diffusion membrane device comprising a joined plurality of capillary mem¬ brane tubes, which comprises: forming a plurality of parallel, separate capil¬ lary membrane tubes into a flat, substantially two- dimensional array; applying junction lines of adhesive material across said parallel membrane tubes in a continu¬ ous pattern extending essentially the entire length of said substantially two-dimensional array; allowing said adhe¬ sive material to harden to join said membrane tubes together; and inserting said flat array into a housing to define a first fluid flow path within the bores of said tubes and a second flow fluid path along the exteriors of said tubes. 18. The method in which a plurality of single layers of parallel, separate, capillary membrane tubes are brought together in facing relationship, said layers of parallel membrane tubes defining sinuous paths, the specific sinuous paths of each layer of parallel fibers being different, whereby portions of said adjacent layers are out of contact with each other, and other portions are in contact with the adjacent layers, whereby the individual fibers of each layer are in crossing, contacting relation¬ ship with the fibers of adjacent layers, and providing adhesive means adhering said crossing fibers together. 19. The method of Claim 18 In which the separat capillary membrane tubes forming said arrays are passed across a roller carrying said adhesive solution prior to being formed into said joined arrays. 20. The method of Claim 19 in which said capil lary membrane tubes are sprayed with adhesive for main¬ taining said sinuous overlyafξig arrays in adirering relatio to each other. 21. The method of Claim 20 including the subse¬ quent steps of sealing said flat, substantially two- dimensional array into a housing, and thereafter washing the exterior surfaces of said array with a solvent for the adhesive material to remove said adhesive material. 22. The method of Claim 21 in which said adhe¬ sive material is made of a substance which is easily dis- persible in water and said solvent comprises water. OM /,, WI 23. The method of forming a diffusion membrane device comprising a plurality of capillary membrane tubes, which comprises: forming a plurality of parallel, separate, capil¬ lary membrane tubes into a plurality of single-layer, two-dimensional arrays of closely spaced parallel fibers, ^fche parallel tubes of each single-layered array defining a sinuous pattern, while applying adhesive between said arrays and bringing the arrays into facing contact with each other, the differing arrays defining, in turn, differing sinuous paths whereby portions of each array " are out of contact with the adjoining arrays, and other portions of each array are in facing, overlying relation with adjacent arrays, with the respective membrane tubes of each array crossing at an acute angle the fibers of the adjacent arrays; allowing said adhesive material to harden to cause said arrays of membrane tubes to be joined together into a single unitary structure; and inserting said unitary structure into a housing to define a first flow path within the bores of said tubes and a -second flow path along the exteriors of said tubes. 24. The method of Claim 23 including the subse¬ quent step of washing the exterior surfaces of . said array with a solvent for the adhesive material to remove said adhesive material. 25. The method of Claim 23 in which said adhe¬ sive material is made of a substance which is easily dis- persable in water and said solvent comprises water. 26. A diffusion membrane which comprises.a joined plurality of capillary membrane tubes occupying a flat, substantially two-dimensional array, a plurality o junction lines of cured adhesive material extending trans versely, across said flat array, and a housing enclosing said flat array with manifold port means defining a first separate flow path within the bores of said tubes and a second separate flow path along the exteriors of said tub 27. The diffusion membrane device of Claim 26 in which said hardened adhesive material is essentially similar to the material comprising said membrane tubes. 28. The diffusion membrane device of Claim 27 which said membrane adhesive materials are made of a semi permeable cellulose-based material. 29. The diffusion membrane device of Claim 26 which said junction lines of cured adhesive material cros the flat array in an X-shaped pattern. 30. The diffusion membrane device of Claim 26 in which said junction lines of adhesive material cross said flat array in a wave-shaped pattern. 31. The diffusion membrane device of Claim 26 in which said junction lines of adhesive material cross the plurality of capillary membrane tubes.in transverse, straight lines, a plurality of said straight lines being positioned intermediate the ends of said flat array. 32. The diffusion membrane of Claim 26, sealed into a housing, and essentially freed by washing of said junction lines of cured adhesive material. 33- A diffusion membrane device comprising a joined plurality of capillary membrane tubes in flat, substantially two-dimensional array comprising multiple layers of substantially parallel capillary membrane tubes, the parallel tubes of each of the plurality of single- layered arrays lying in facing contact with at least one adjacent single-layered, two -dimensional array, both two-dimensional arrays defining, in turn, differing sinuous paths, whereby portions of each single-layered array are out of contact with adjoining single-layered arrays, and other portions of each single-layered array are in facing, overlying relation with adjacent single- layered arrays, with the respective fibers of each single- layered array crossing at an acute angle the fibers of the adjacent, single-layered arrays, the crossing fibers of the respective single-layered arrays being adhered to each other, whereby said diffusion membrane member defines a single, unitary " structure. 3*4. The diffusion membrane device of Claim 33 which is inserted into a housing, and connected to manifold members of said housing to define a first flow path within the bores of said tubes and a second flow path along the exteriors of said tubes. 35. The diffusion membrane device of Claim 33 which comprises two flat, sinuous arrays. 36. A diffusion membrane which comprises a joined plurality of capillary membrane tubes occupying a flat, substantially two-dimensional array, junction line means of cured adhesive material extending across said flat array to adhere the membrane tubes together into a unitary structure, said junction line means extending continuously along the entire length of said flat, two- dimensional array, and a housing enclosing said flat arra with manifold port means defining a first, separate flow path within bores of said tubes, and a second, separate flow path along the exteriors of said tubes. 37. The diffusion membrane device of Claim 36 which said cured adhesive material is essentially similar to the material comprising said membrane tubes. 38. The diffusion membrane device of Claim 36 in which said membrane tubes and adhesive material are made of a semipermeable, cellulose-based material. 39. The diffusion membrane of Claim 36, sealed in a housing, and freed by washing of said cured adhe¬ sive material. 40. The method of forming a diffusion membrane device comprising a joined plurality of capillary membrane tubes, which comprises: forming a plurality of parallel, separate capil¬ lary membrane tubes into a flat, substantially two- dimensional array; applying junction line means of adhesive material across said parallel membrane tubes; allowing said adhesive material to harden to join said membrane tubes; and inserting said flat arr£,y into a housing to define a first flow path within the bores of said tubes and a second flow path along the exteriors of said tubes; and there¬ after washing the exterior surfaces of said array with a solvent for the adhesive material to remove said adhesive material. 41. The method of Claim 40 in which said adhesive material is made of a substance which is -easily dispersable in water, and said solvent comprises water.

Inventors: KOPP C, SHAH D
Applicants: BAXTER TRAVENOL LAB, BAXTER TRAVENOL LAB INC
Application year: 1981
Main classification: B32B3
IPC codes: B01D63, B29C65