CA1085318A

CA1085318A - Separatory apparatus and method of manufacture

Info

Publication number: CA1085318A
Application number: CA261,336A
Authority: CA
Inventors: Paul W. Gics
Original assignee: Gics Pharmaceuticals Inc
Current assignee: Gics Pharmaceuticals Inc
Priority date: 1975-09-17
Filing date: 1976-09-16
Publication date: 1980-09-09
Also published as: US4031012A; ATA689076A; BR7606189A; SE7610299L; FR2324336A1; DK417876A; DE2641709A1; AR214181A1; IT1069855B; BE846296A; NL7610332A; ZA765590B; JPS5248575A; AU1789176A

Abstract

Abstract of the Disclosure A separatory apparatus comprises a card shaped core, flexible core extenders, hollow capillary fibers wound around the core and bonded to the core extenders, and a sealing flange having about the same rigidity and about the same density as the material from which the core extenders are fabricated.
The apparatus has a casing with fluid distribution channels for the fluid flowing external to the capillaries. A hermetic seal is established by a sealing flange at each end of the casing and an O-ring at each end which is compressed while simultaneously ultrasonically welding headers to the open end of the casing. Only one header is used where the fibers wrap around one end of the core and the top fibers are separated from the bottom fibers at the other end of the core.

Description

" 1085318 This invention relates to separatory apparatus.
A number of designs for mass transfer devices and separatory apparatuses using small capillary tubing made of semi-permeable membrane and methods for making the same are known. Among these designs and methods are those described in Patent Nos. 2,972,349, 3,228,876, 3,228,877, 3,339,341, 3,422,008, 3,455,460, 3,475,331, 3,536,611, 3,579,810, 3,691,068, 3,~g~ ~ 3,8 3,704,223, 3,794,468, ~iS~ff2S, and ~t8I~
These mass transfer devices typically comprise a plurality of hollow capillary fibers made of semi-permeable membrane in a housing with appropriate inlet and outlet passages. The fibers generally extend from end to end within the housing. The exteriors of the fibers are encapsulated at opposite ends of the core by spaced bands of a rigid potting compound. The fibers have open ends so that fluid can be passed through them. The core is placed in a housing made of a casing and two end caps. Sealing means are pro-vided so that a first fluid can flow through an opening in one end cap, through the fibers, and out the opposite end cap, while at the same time a second fluid can flow around the exterior of the fibers through openings in the cas-ing.
One method of manufacturing these devices comprises attaching bundles of fibers to the potting compound. Another method involves wrapping a single fiber around a core and then encapsulating the fiber with the potting compound at the opposite ends of the coreO The ends of the fibers are then exposed by cutting through the fibers and the potting material in a plane per-pendicular to the axis of the core.
Although the above-described methods produce a useful separatory apparatus of the kind described above9 they are not without disadvantages.
~hief among these disadvantages is lack of uniformity from unit to unit. Most of these units are essentially hand made. One unit, for example, is made up by taking a plurality of parallel fibers in a bundle with an out-side diameter approximating the inside diameter of the housing and inserting los~3~8 the bundle in the housing. However, the fibers may be squeezed and twisted, thereby causing distortion in the inside diameter of the fibers.
Another problem with many of these devices is that they are bulky due to the use of a large, cylindrical core. Large bulk tends to increase the cost of the device. Also, those devices using cylindrical cores have a long spiral flow path which gives rise to high pressure drop and increased chance of plugging of the fibers.
Another disadvantage of existing devices is that spacing and den-sity of the capillary fibers during assembly often is not closely controlled.
This tends to increase the bulk of the device and give non-uniform flow through the fibers, with resultant poor mass transfer.
Another problem with many of the devices is that there is no means for directing the flow of the fluid flowing external to the fibers. Therefore, channelling and dead spaces where no mass transfer occurs can resultO
Another disadvantage of these devices is the means used for preven-ting the fluid inside the fibers from mixing with the fluid outside of the fibers. Typically a rigid potting compound is used to encapsulate the fibers -in conjunction with an unsupported 0-ring to provide a seal. However, the rigid sealing material tends to permanently deform when under pressure, there-by causing leaks.
Typically the end caps are either solvent or adhesive bonded to the casing. Although these methods provide a seal, it is a time consuming and expensive process because when solvent is used it must be allowed to complete-ly dry, and when adhesive is used it must be allowed to cure. Furthermore, since pressure from the end cap typically is used to compress an 0-ring, the caps must be held against the casing while the solvent is drying or the adhe-sive is curing. Another method of attaching end caps is by screw threads.
However, there is a tendency for the threaded headers or end caps to back off with time and leaks develop.
Therefore, it is desirable to produce a compact mass transfer , . , :
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--- 10853~8 device which has a multiplicity of uniform fibers, has no dead spaces, has no fluid flow channelling, does not leak, and is inexpensive to manufacture.
Therefore there is provided in accordance with this invention, in a separatory device having a hollow fiber membrane and a housing where, in use, a first fluid flows inside the membrane and a second fluid flows in a portion of the housing ;n contact with the outside of the membrane, the improvement comprising: a thin card-shaped supporting core; at least one layer of selectively permeable continuously hollow fibers positioned on the supporting core as the membrane; and a potting compound sealing collar at least at one end of the core binding the fibers together and attaching the bound fibers to the core.
Preferably, there is a sealing collar at each end of the core to form with the housing a reservoir at each end of the housing beyond the collars and a reservoir between the collars.
In one embodiment, the membrane is formed by winding at least one strand of fiber around the core at a selected spacing between windings and at a selected angle relative to the sides of the core and thereafter cutting the fiber and potting compound at least at one end of the core to create strands of fibers and to expose fiber ends having openings communicating with the interior of each strand.
Each layer of fibers may comprise a plurality of parallel strands having a selected spacing relative to adjacent strands and a selected angle relative to the sides of the core. Preferably the fibers have an angle between 0 and 30 relative to the long sides of the core. In a preferred embodiment, the angle of the fibers is 5. The fibers of each layer may have an angle relative to the side of the core that is reverse in direction to the angle of the fibers in each contiguous layer to form a criss-cross configuration.
The core may include a rigid middle section and a core extender at least at one end of the middle section, the fibers extending over the core extender.

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~ 3S3~8 Preferably the core extender is fabricated from a material with about the same rigidity and about the same density as the potting compound.
The core extender may he permanently attached to the middle section, which may be perforated and made from polycarbonate. The core extender and the potting compound may be flexible polyurethane.
In one embodiment, the housing comprises a casing with open opposite ends enclosing and supporting the core and fibers, a first header attached to and supported by the casing at one open end of the casing, and a second header attached to and supported by the casing at the open end of the casing opposite the first header; a f;rst fluid passage is in communica-tion with the first header and the fibers; a second fluid passage is in communication with the second header and the fibers; each sealing collar extends beyond the end of the casing and has an enlarged flange beyond the end of the casing; and a flexible 0-ring is compressed between an interior wall of the header and the flange above a support projection of the casing to form a hermetic seal. Preferably the headers are welded to the casing and the 0-ring is compressed when the headers are ultrasonically welded to the casing.
Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings~ wherein:
Figure 1 is a top plan view of a separatory apparatus in accord-ance with this invention.
Figure 2 is a cross-sectional side view taken along the center line 2-2 of Figure 1.
Figure 3 is a cross-sectional view perpendicular to the longitudinal axis of the apparatus taken along lines 3-3 of Figure 1.
Figure 4 is a cross-sectional view perpendicular to the longitudinal axis of the apparatus taken along lines 4-4 of Figure 1.
Figure 5 is a cross-sectional view perpendicular to the longitudinal axis of the apparatus taken along lines 5-5 of Figure 1.
Figure 6 is a top plan view of the core of the apparatus of the invention with a few fibers wound thereon in accordance with this invention.

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Figure 7, appearing on the same sheet as Figure 2, is a cross-sectional view similar to Figure 2 depicting the apparatus during assembly.
Figure 8 is a side elevation view of an ultrasonic welding jig used during the assembly of the apparatus.

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~0853~8 Figure 9 is a side elevation view partially in cross-section along the center line of an alternative embodiment of the invention, and Figure 10 is an end elevation view of a header or end cap for the alternative embodiment of Figure 9.
Referring to Figure 1, there is shown a top plan view of an assembled separatory apparatus 10 in accordance with this invention. The apparatus comprises a casing or housing 20 and casing headers or end caps 22.
The internal construction of the apparatus is shown in detail in Figures 2 through 5. In these figures, there is shown a core 12 having a core extender 14 attached at one end and a core extender 15 attached at the opposite end with capillary fibers 16 positioned on the core. The core 12 is thin and has a smooth rectangular surfaceO The advantage of this card-shaped core 12 is that it has maximum surface area with minimum bulk. A separatory apparatus utiliz-ing a card-shaped core is compact and also inexpensive to manufacture. The core extenders 14 and 15 are attached to a tongue 24 at each end of the core, which tongue has holes therein for facilitating the mechanical coupling between the core 12 and the extenders 14 and 15.
The core is preferably perforated although it may be solid. The core 12 as shown in Figures 2 and 6 has a plurality of rectangular openings 26 extending between the sides of the core perpendicular to the axis of the fibers. Most of the surface area of the core is removed with cross ribs 28 and sides 30 providing structural integrity for the core. This use of large perforations increases exposure of the fibers to fluid flowing exterior to the fibers and allows cross flow through the core. In addition, the use of large perforated areas decreases the weight of and amount of material used for the apparatus, thereby reducing manufacturing costs. Other shapes of perforations can be used. The size and positioning of the perforations of the core are determined according to the particular flow conditions desired.
While reference has been made to perforated cores, it is also pos-sible to use in the practice of this invention non-perforated cores or porous .

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cores made from a material such as porous ceramic. What is required is that the core be inert to the fluids used in the separatory apparatus, and in the case of biological fluids~ be non-toxic. The material of choice for the core is polycarbonate since polycarbonate is readily available, inexpensive, easy to mold and machine, and has high strength.
The core 12 of Figures 2-6 has the core extenders 14 and 15 attach-ed to the tongue extensions 24 at the opposite ends of the core. The core extenders 14 and 15 serve to lengthen the core and provide a surface to which the fibers may be permanently bonded. The core extenders 14 and 15 preferably are about as thick as the core. The core extenders can be preformed and then bonded with solvent or adhesive to the core. However, the preferred method of attaching the core extenders to the core is by overmolding the core with the core extenders, thereby forming and attaching the core extenders in one step.
The material used for the core extenders must be inert, non-toxic when the device is used for biological applications, and be able to be bonded to the core. In the case of a polycarbonate core, epoxies and polyurethanes are satisfactory for the core extender.
On the surface of the core and core extenders there is a plurality of selectively permeable, continuously hollow capillary fibers or tubules 16.
A multiplicity of individual fibers of length approximately equal to the length of the core and core extenders may be attached to the core.
However, it is preferred that one or more single strands of con-tinuously hollow capillary fiber be uniformly wound around the core and core extenders. Using such a method results in a uniform configuration of contigu-ous, aligned fibers, on both sides of the core as shown in Figures 2-6. A
single continuous fiber may be wound on the core 12 by using an electrical coil winding machine such as that made by the Coil Winding Equipment Corpora-tion of Oyster Bay, New York. An electrical coil winding machine turns the core ~hile shuttling the fiber strand back and forth across the core surface.

A coil winding apparatus applies the fibers in layers. As shown in Figures 2-6, a bottom layer 32 comprises a series of contiguous, uniformly aligned individual strands formed from one continuous fiber. The strands may be parallel to the sides of the core, or may be pitched in relation to the sides of the core. As shown in Figure 6, it is preferred that the fibers be pitched at an angle of about 5, although the angle can be from 0 to about 30. Additionally, a combination of angles may be employed, for example, one angle may be used to the mid-point along the length of the device and the angle then reversed to give a pi winding or zigzag winding.
Above this first layer 32 there is a second layer 34 which also is pitched in relation to the side of the core, thereby giving a criss-cross configuration of the layers. The advantage of the criss-cross and zigzag con-figuration is that there is no channelling and areas of stagnation of fluid in the region external to the fibers are avoided. This results in improved mass transfer. Also the uniform configuration in the criss-cross and zigzag mini-mizes the amount of surface area of the fibers which are covered by the fibers above and below each fiber, thereby increasing the surface area available for mass transfer. Additionally, the winding of the fiber on the core results in minimum distortion of the diameter of the fiber to provide a substantially uniform diameter from end to end of each strand to enhance the flow of the fluid therethrough. This is particularly important where the fluid flowing through the fibers is blood, as would be the case where the apparatus is employ-ed as an artificial kidney, to minimize the chan~es of clotting of the blood.
Furthermore, the fact that the fibers are uniformly aligned without adjacent fibers constricting each other results in low pressure drop for the fluid flowing inside the fibers.
Although Figure 6 shows only two layers of fibers, theoretically there is no limit to the number of layers which may be used. As the number of layers is increased, the surface area available for mass transfer increases.
However, as the number of layers increases the amount of fluid flowing outside ~.

~0853:18 of the fibers which penetrates to the innermost layers decreases and the bulk of the apparatus increases. Typically there are from 1 to about 1,000 layers on each side of the core and preferably about 20 layers. It is possible to have as many as 1,000,000 fibers on top of a six inch wide core.
In one particular separatory apparatus designed to function as an artificial kidney, the core has a width of four inches on which the fibers are wound and a length of approximately eight inches. The space for the fibers on one side o the core 12 as shown in Figures 2 through 5 is approximately one-half inch high. ~ith these dimensions an effective and efficient hemo-dialyzer for an artificial kidney has approximately 4,000 strands on each side of the core.
Preferably the fibers do not cover the outer rib 30 of the core.
This allows the core to be slipped into a slot 36 (Figures 3 and 4) in the casing 20 where the slot supports the core.
Various materials can be used for making the permeable continuous hollow fiber suitable for practice of this inventionO A list of such materials is provided in United States Patent No. 3,422,008.
Fibers that are useful for an apparatus embodying the features of this invention have an external diameter which is generally less than one millimeter and preferably less than 0.6 millimeters, and which can even be between about 5 and about 100 microns. It is generally preferred that the out-side diameter of the hollow fibers be between 200 to 300 microns. The outside diameter may be as large as 1,000 microns for certain fiber material such as silicone used in an oxygenator.
Advantageously a wall thickness to outside diameter ratio of from about 1/8 to about 1/3 is employed in the hollow fibers. The wall thickness of the fibers is generally in the range of from about 1 micron to about 80 microns and preerably from about 2 to about 15 microns. ~all thicknesses below this range may result in an inability to withstand the desired pressures whereas thicknesses out of this range increase the resistance to mass transfer -10853~8 through the fiber wall. These characteristics vary with the particular mater-ial being used and the particular type of separation involved.
Preferred fibers for use in this invention, when the apparatus is used as an artificial kidney or a blood oxygenator, are made from regenerated cellulosic fibers softened with glycerin. Such materials are distributed under the trade mark Cuprophan by Enka Glanzstoff A.G. located in Work Wuppertal-Barmen, ~est Germany. Fibers of diameters of about 200 to about 300 microns with wall thicknesses of about 11 micron are satisfactory when the apparatus is used for blood ox~genation or purification of blood as in an artificial kidney function.
As shown in Figures 1 and 2 the casing has a first and second fluid passage 44, 45 on the top side of the casing in communication with the interior 46 of the casingO The exterior wall of the passages 44 and 45 has the configuration of a Hansen fitting so that the separatory apparatus can be used with connections conventionally used with artificial kidneys. Fluid passage 44 is an inlet passage for the fluid exterior to the fibers, and the fluid passage 45 is an outlet or discharge passage for the same fluid. Although the fluid passages 44, 45 are shown on the same side of the casing, they may be on opposite sides of the casingO
Both the inlet passage 44 and the discharge passage 45 have a plenum 47 which acts as a circumferential distribution channel (Figures 2 and 4) along the inner wall 37 of the expanded casing end portions 38. The wall 48 of the thinner mid-section 49 of the casing 20 extends into the expanded section 38 at each end of the casing and into the region below the inlet and discharge passages 44, 45, thereby forming the plenums 47. The purpose of the plenums is to insure even distribution of the fluid on the exterior of the capillary tubing, thereby providing optimum mass transfer in the deviceO
The extreme end sections 51 of the casing are larger than even the expanded sections 38. The casing wall 52 in the expanded portion 38 of the casing extends into this area, thereby forming a slot 53 between an extension 10853~

54 of wall 52 and the OuteT wall 56 at the extreme ends of the casing. The purpose of this slot is to engage a conforming projection 57 of the casing header 22O
As shown in Figures 2 and 5 the fibers 16 are surrounded at each end by a sealing collar 18 made of a potting compound which secures the fibers to the core extenders 14 and 15 and forms sealing flanges 19 at each end. Only the terminal portions of the fibers are impregnated with the potting compound and only in the region of the core extenders. Sufficient sealing compound is applied to completely cover the terminal portions of all the fibersO
The sealing compound necessarily must be made of an inert material, and in the case of biological applications, a non-toxic materialO Also it must be of a material which will bond to both the fibers and the core exten-ders O ' ' The material used for sealing collars 18 should have about the same density and the same rigidity as the material used for the core extenders 14 and 15 so that when the compound and the fibers 16 are cut to expose open ends of the $~ers, the cutting tool does not wobble and therefore leave rough edges on the ~i~bers.
This invention conte~plates that the core extenders 14 and 15 and the sealing collars 18 be made from the same material. This gives identical density and rigidity to the sealîng collar and the core extenders. Further-more, the sealing collars should be made from a flexible material to give a good hermetic seal when used in conjunction with an O-ring 41. Therefore, when a polycarbonate core 12 is used it is preferred that a flexible poly-urethane be used to fabricate the sealing collars 18. A particularly satis-actory polyurethane is clear, thixotropic, extrudable material produced by B.J.B. Enterprises of Huntington Beach, California under the tradename T.C.
512-3. This material has a shore A hardness of from about 65 to about 70 at room temperature, an elongation of about 160%, and a tensile strength of about 750 psi after it has cured. The material is inert, bonds well to polycarbonate, .
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iO !3S3~8 and has sufficient flexibility to gi~e a good hermetic seal in conjunction with the 0-ring 41.
rn assembling the apparatus the core 12 with the fiber 16 wound thereon is inserted in the casing 20 by engaging the edges 30 of the core in the slots 36 in the side of the casing 20. As shown in Figure 7 a potting shell 77 is attached to one end of the casing 20 and the potting compound which forms the sealing collar 18 and sealing flange 19 is injected into the sealing 1ange 77. The device is advantageously rotated to deaerate and pack the potting compound. After the potting compound of the sealing collar has cured, the process is repeated on the opposite end of the housing as shown in Figure 7. Thereafter, the potting compound, fibers, and core extenders are cut along a cutting line representatively shown by the dotted lines 78 and 79 in Figure 7. Thus, the single or few fi~ers that are wound on the core become a plural-ity of fibers with each fiber extending from one end of the core to the other with the ability of fluid flow therethrough.
As shown în Figures 2 and 5 an 0-ring 41 is positioned between each header 22 and the casing 20. The combination of the 0-ring 41 and flexible sealing flange 19 gives a hermetic seal at each end to prevent mixing of the fluids flowing on the outside of the fibers and the fluids flowing through the fibers.
Each header has a fluid passage 61, 62 through it, the fluid pass-age communicating with the fibers inside the casing. Each header has a projec-tion 57 which is inserted into the slot 53 at the end of the casing. Radially inward from the outer projection 57 which fits into the slot there is a smaller projection 63. T~e-0-ring 41 is seated between these inner and outer projec-tions as shown in Figures 2 and 5~ The header 22 presses the 0-ring 41 against the sealing flange 19, thereby squishing the 0-ring 41 and slightly deforming t~e sealing flange. However, since the sealing flange is made from a flexible material, the deformation is not permanent, and thus a good hermetic seal results. Furthermore, the amount of deformation of the sealing flange is limited by the wall extension 54 directly beneath the 0-ring, ~hich provides support to the sealing flange 19. Thus, a permanent seal is obtained, unlike that obtained with other mass transfer devices which utilize a sealing flange made from a rigid material which permanently deforms.
The headers 22 are made from the same material as the casing, which preferabl~ is polycarbonate.
The headers may be attached to the casing with solvent or adhesiveO
In the case of pol~carbonate a suitable solvent is tetrahydrofuranO Suitable adhesives for polycarbonate include the epoxy resins.
The preferred method of attaching the headers 22 to the casing 20 is by ultrasonic welding. Ultrasonic welding yields a quick secure bond. In addition, by using ultrasonic welding it is possible to compress the 0-ring 41 at the same time as the headers 22 are attached to the casing 20.
This invention contemplates ultrasonically welding both headers 22 onto the casing 20 at the same time. As shown in Figure 8 the casing 20, with core 12, fibers 16, and sealing collar 18 therein, headers 22 and 0-rings 41 -are placed Yertically in a welding jig 74. A second welding jig 75 is placed on the top header 22 with the O-ring 21 associated therewith in placeO Guides 71J 72, and 73 contact and stabilize the housing prior to activation of the welder. Ultrasonic horns 76 are placed at both ends of the casing and activated. Upon activation of the horns, the guides 71, 72 and 73 move away from the housing. As the casing material and header material exposed to the ultrasonic vibrations melt and flow, compression on the 0-rings at both ends increases. As the vibration of the casing and headers ceases, a sensor (not shown) deactivates the horns 76 and the welding action StOpSo Thus, by using this method it is possible to quickly and inexpen-sively simultaneously weld both headers to the casing without the use of messy solvents and adhesives, while at the same time compressing the O-rings.
Furthermore, a good hermetic seal with a predeternlined amount of compression is obtained.

lV8S3~8 The assembled apparatus, as shown in Figures 1, 2 and 8 has four fluid passages, two on one side of the casing and one on each end of the cas-ing. In operation, the fluid which flows external to the fibers enters through passage ~4 on one side of the casing, flows through a plenum 47 distribution channel and then around the outside of the fibers 16, and out through the other flow passage 45 via its plenum distribution channel 47. The fluid flow-ing inside of the fibers enters through the flow passage 61 in the header at one end of the casing, flows through the open ends 42 of the fibers projecting through the sealing collar 18, ~a few of which are shown oversized in Figure 5), out through the fibers at their opposite end and then through the discharge flow passage 62 at the opposite end of the casing. Although counter-current flow results, either cocurrent or counter-current flow may be used.
Although this apparatus has been shown with opposite terminal por-tions of the fibers, it is possible to produce a unit with U-shaped fibers 80 as shown in Figure 9.
For this device a single strand is or plural strands 80 are wound around a core 81. A core extender 82 is attached to one end, since only one end needs to be cut to expose open ends of the fibers. Upon completion of the winding of the core it is placed inside the housing 83 with the edges of the core mating with slots (not shown~ in the same way the core 12 mates with the slots 36 in the apparatus of Figures 1-8. Thereafter, potting compound is applied to the end to be cut to bond the fibers to the core and to form a seal-ing collar 84.
The end with the extender 82 is cut to expose the open ends of the fibers 80 and the end cap 85 is attached to the housing 83 by an adhesive or by ultrasonic welding to complete the unit.
End cap 85 has a partition 86 that mates with and cooperates with the extender 82 to form two reservoirs 87 and 88, one above the extenders 82 and one below the extender 820 An inlet passage 89 communicates with the upper reservoir 87 and 10853~8 an outlet passage 90 communicates ~ith the lower reservoir 88.
The walls of the housing 83 form a plenum 91 similar to the plenum 47 in the apparatus of Figures 1-8 except the plenum 91 has an upper and a lower section separated by a partition ~not shown) in the plane of the core 81 that cooperates with the core 81 beyond the plenum area to separate the upper and lower parts of the housing. An upper reservoir 92 and a lower reservoir 93 are thus formed. An inlet passage 94 communicates with the lower reservoir 93 and an outlet passage 95 communicates with the upper reservoir 92.
In operation, fluid that flows external to the fibers enters pas-sage 94 and flows along the bottom of the housing counter current to the fluid flowingin the fibers, which enters via passage 89 and exits via passage 90.
The external fluid flows around the end of the core 81 and thru U-shaped fibers 80 and then along the cap to exit passage 90. A hole 96 is provided in the core 81 to enhance the flow of the fluid externally around the fibers.
In the operation of a separatory apparatus embodying features of this invention, one or more components flowing inside of the tubing permeate, ultrafilteratej or by osmotic pressure flow to the outside of the tubing where they are absorbed by the fluid flowing external to the tubing. Similarly, ~-components in the fluid on the outside of the tubing can flow into the tubing, for both operations can be conducted simultaneously. When the device is used as an artificial kidney, it is preferred that the blood flow within the tubings and the dialysate fluid flow external to the tubing. Similarly, when the device is used as an oxygenator it is preferred that the blood flows inside the tubing and the oxygen containing gas flows outside the tubing. In such an operation, oxygen selectively permeates through the fibers and is absorbed by the blood while carbon dioxide in the blood is released by the blood to flow through the tubing, where it is picked up by the oxygen containing gas.
An effective oxygenator also results when the core has several holes therethrough similar to the core 12 and the housing has inlet and outlet passages on opposite sides similar to housing &3. The oxygen flows through the tubules and the oxygen flows external to the tubules.
Besides use as an artificial kidney or blood oxygenator, a separator~ apparatus having features of this invention has many other uses.
Among these alternate uses are those listed in United States Patent No.
3,228,876 beginning at column 15 and United States Patent No. 3,422,008 beginn-ing at column 16, line 17.
While certain features of this invention have been described in detail with respect to various embodiments thereof, it will of course be apparent that other modifications can be made within the spirit and scope of this invention, and thus the appended claims should not be necessarily limited to the description of the preferred embodiment.

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Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. In a separatory device having a hollow fiber membrane and a housing where, in use, a first fluid flows inside the membrane and a second fluid flows in a portion of the housing in contact with the outside of the membrane, the improvement comprising: a thin card-shaped supporting core;
at least one layer of selectively permeable continuously hollow fibers positioned on the supporting core as the membrane; and a potting compound sealing collar at least at one end of the core binding the fibers together and attaching the bound fibers to the core.

2. The separatory device as claimed in claim 1 wherein there is a sealing collar at each end of the core to form with the housing a reservoir at each end of the housing beyond the collars and a reservoir between the collars.

3. The separatory device as claimed in claim 1 wherein the membrane is formed by winding at least one strand of fiber around the core at a selected spacing between windings and at a selected angle relative to the sides of the core and thereafter cutting the fiber and potting compound at least at one end of the core to create strands of fibers and to expose fiber ends having openings communicating with the interior of each strand.

4. The separatory device as claimed in claim 1 wherein each layer of fibers comprises a plurality of parallel strands having a selected spacing relative to adjacent strands and a selected angle relative to the sides of the core.

5. The separatory device as claimed in claim 3 or 4 wherein the fibers have an angle between 0° and 30° relative to the long sides of the core.

6. The separatory device as claimed in claim 3 or 4 wherein the angle of the fibers is 5°.

7. The separatory device as claimed in claim 3 or 4 wherein the fibers of each layer have an angle relative to the side of the core that is reverse in direction to the angle of the fibers in each contiguous layer to form a criss-cross configuration.

8. The separatory device as claimed in claim 1 wherein the core includes a rigid middle section and a core extender at least at one end of the middle section, the fibers extending over the core extender.

9. The separatory device as claimed in claim 8 wherein the core extender is fabricated from a material with about the same rigidity and about the same density as the potting compound.

10. The separatory device as claimed in claim 8 or 9 wherein the core extender is permanently attached to the middle section.

11. The separatory device as claimed in claim 8 or 9 wherein the middle section of the core is perforated.

12. The separatory device as claimed in claim 8 or 9 wherein the middle section of the core is made from polycarbonate.

13. The separatory device as claimed in claim 8 or 9 wherein each core extender is made from flexible polyurethane.

14. The separatory device as claimed in any of the preceding claims 1 to 3 wherein the potting compound is flexible polyurethane.

15. The separatory device as claimed in any of the preceding claims 1-3 wherein the housing has at least one fluid inlet passage positioned on a side thereof, and further comprising a circumferential flow distri-bution channel along the interior wall of the housing beneath at least one of the fluid inlet passages on the side of the housing.

16. The separatory device as claimed in claim 1 wherein the housing comprises a casing with open opposite ends enclosing and supporting the core and fibers, a first header attached to and supported by the casing at one open end of the casing, and a second header attached to and supported by the casing at the open end of the casing opposite the first header; a first fluid passage is in communication with the first header and the fibers; a second fluid passage is in communication with the second header and the fibers; each sealing collar extends beyond the end of the casing and has an enlarged flange beyond the end of the casing; and a flexible O-ring is compressed between an interior wall of the header and the flange above a support projection of the casing to form a hermetic seal.

17. The separatory device as claimed in claim 16 wherein the headers are welded to the casing and the O-ring is compressed when the headers are ultrasonically welded to the casing.

18. The separatory device as claimed in any of the preceding claims 1 to 3 further comprising slots in opposing walls of the housing to accommodate the long edges of the core.