Mecs Diayzer

• US 20080093298A1
• Filed: 10/06/2005
• Published: 04/24/2008
• Est. Priority Date: 10/06/2004
• Status: Active Grant

• Current Assignee: Outset Medical, Inc.
• Original Assignee: Brian Paul, David Browning, Goran Jovanovic, James Curtis, Sundar Atre
• Inventors: Curtis, James, Atre, Sundar, Paul, Brian, Jovanovic, Goran, Browning, David
• Granted Patent: US 8,128,822 B2
• Time in Patent Office: Days
• US Class Current: 210/646
• CPC Class Codes: A61M 1/16 with membranes
• CPC Class Codes: A61M 2205/0244 Micromachined materials, e.g. made from silicon wafers, microelectromechanical systems [MEMS] or comprising nanotechnology
• CPC Class Codes: B01D 2313/08 Flow guidance means within the module or the apparatus
• CPC Class Codes: B01D 2313/14 Specific spacers
• CPC Class Codes: B01D 61/28 Apparatus therefor
• CPC Class Codes: B01D 63/081 Manufacturing thereof
• CPC Class Codes: B01D 63/082 comprising a stack of flat membranes

Abstract

The present invention is related to hemodialysis, and more particularly, to a dialyser with improved efficiency of mass transfer across a dialysis membrane utilizing microchannel separation provided in accordance with embodiments of the present invention. In accordance with an embodiment, a dialyzer is provided comprising a plurality of semipermeable membrane sheets and a plurality of flow separators. The membrane sheets and flow are arranged in alternating configuration and coupled into a laminae stack defining a plurality of parallel microchannel layers. Each microchannel layer comprises a plurality of first microchannels and a plurality of second microchannels. The first and second microchannels of each microchannel layer are in fluid communication with each other via one of the plurality of membrane sheets therebetween. The MECS dialyzer is characterized as having a high surface to volume ratio and a high mass transfer coefficient.

Claims

1. A dialyzer comprising:

a plurality of semipermeable membrane sheets; and

a plurality of flow separators, the membrane sheets and flow separators arranged in alternating configuration and coupled into a laminae stack defining a plurality of parallel microchannel layers, each microchannel layer comprising a plurality of first microchannels and a plurality of second microchannels, the first and second microchannels of each microchannel layer in fluid communication with each other via one of the plurality of membrane sheets therebetween, the first microchannels for receiving a first fluid stream comprising blood and the second microchannels for receiving a second fluid stream comprising dialysate.

2. The dialyzer of claim 1, wherein the first microchannels of each microchannel layer are parallel and the second microchannels of each microchannel layer are parallel.

3. The dialyzer of claim 2, wherein the first and second microchannels of the microchannel layers are parallel.

4. The dialyzer of claim 2, wherein the first and second microchannels of the microchannel layers are orthogonal.

5. The dialyzer of claim 1, wherein the flow separators comprise:

a plurality of first microchannel sheets having a first side and a second side opposite the first side, the second side having parallel grooves therein;

a plurality of second microchannel sheets having a first side and a second side opposite the first side, the first and second sides having parallel grooves therein, the laminae stack having a laminae stack top side and a laminae stack bottom side, wherein each microchannel layer comprises a laminae sub-stack comprising either a first and second microchannel sheet with a membrane sheet therebetween and coupled therewith, the grooves in facing relationship separated by the membrane sheet at the laminae stack top and bottom sides, or two second microchannel sheets with a membrane sheet therebetween and coupled therewith, the grooves in facing relationship separated by the membrane sheet.

6. The dialyzer of claim 1, wherein the flow separators comprise:

a plurality of first microchannel sheets having a first side and a second side opposite the first side, and a first end and a second end opposite the first end, at least one side having parallel grooves extending from the first end to the second end;

a plurality of second microchannel sheets having a first side and a second side opposite the first side, and a first end and a second end opposite the first end, at least one side having parallel grooves extending from the first end to the second end, wherein each microchannel layer comprises a laminae sub-stack comprising a first and second microchannel sheet with a membrane sheet therebetween and coupled therewith, the grooves in facing relationship separated by the membrane sheet.

7. The dialyzer of claim 6, wherein the plurality of first microchannel sheets further comprise a first plena groove at each of the first and second ends, the first plena groove in fluid communication with the grooves on the first microchannel sheets, and wherein the plurality of second microchannel sheets further comprise a second plena groove at each of the first and second ends, the second plena groove in fluid communication with the grooves on the second microchannel sheets.

8. The dialyzer of claim 1, each membrane sheet having a first side and a second side opposite the first side, and a first end and a second end opposite the first end, the flow separators depending from the first and second sides defining parallel grooves extending from the first end to the second end, wherein each microchannel layer comprises a unit laminae stack comprising at least two membrane sheets, the grooves in facing relationship and the flow separators adjacent each other and coupled therewith defining alternating layers of first and second microchannels.

9. The dialyzer of claim 8, further comprising a first header and a second header, the first header comprising an inlet in fluid communication with the first microchannels at the first end and an outlet in fluid communication with the second microchannels at the first end, the second header comprising an inlet in fluid communication with the second microchannels at the second end and an outlet in fluid communication with the first microchannels at the second end.

10. The dialyzer of claim 8, further comprising a first header and a second header, the first header comprising a first inlet in fluid communication with the first microchannels at the first end and a second inlet in fluid communication with the second microchannels at the first end, the second header comprising a first outlet in fluid communication with the first microchannels at the second end and a second outlet in fluid communication with the second microchannels at the second end.

11. A dialysis system, comprising:

blood-handling apparatus;

dialysate-handling apparatus;

a dialyzer comprising a plurality of semipermeable membrane sheets; and

a plurality of flow separators, the membrane sheets and flow separators arranged in alternating configuration and coupled into a laminae stack defining a plurality of parallel microchannel layers, each microchannel layer comprising a plurality of first microchannels and a plurality of second microchannels, the first and second microchannels of each microchannel layer in fluid communication with each other via one of the plurality of membrane sheets therebetween, the blood-handling apparatus in fluid communication with the first microchannels, the dialysate-handling apparatus in fluid communication with the second microchannels, the first microchannels for receiving a first fluid stream comprising blood and the second microchannels for receiving a second fluid stream comprising dialysate.

12. The dialysis system of claim 11, the blood-handling apparatus adapted to supply blood to the first microchannels at a first end and withdraw blood from the first microchannels at a second end, and the dialysate-handling apparatus adapted to supply dialysate to the second microchannels at the second end and withdraw dialysate from the second microchannels at the first end.

13. The dialysis system of claim 11, the blood-handling apparatus adapted to supply blood to the first microchannels at a first end and withdraw blood from the first microchannels at a second end, and the dialysate-handling apparatus adapted to supply dialysate to the second microchannels at the first end and withdraw dialysate from the second microchannels at the second end.

14. The dialysis system of claim 11, each membrane sheet having a first side and a second side opposite the first side, and a first end and a second end opposite the first end, the flow separators depending from the first and second sides defining parallel grooves extending from the first end to the second end, wherein each microchannel layer comprises a unit laminae stack comprising at least two membrane sheets, the grooves in facing relationship and the flow separators adjacent each other and coupled therewith defining alternating layers of first and second microchannels.

15. A method for dialysis of blood, comprising:

providing a dialyzer comprising;

a plurality of semipermeable membrane sheets; and

a plurality of flow separators, the membrane sheets and flow separators arranged in alternating configuration and coupled into a laminae stack defining a plurality of parallel microchannel layers, each microchannel layer comprising a plurality of first microchannels and a plurality of second microchannels, the first and second microchannels of each microchannel layer in fluid communication with each other via one of the plurality of membrane sheets therebetween, the blood-handling apparatus in fluid communication with the first microchannels, the dialysate-handling apparatus in fluid communication with the second microchannels;

supplying the first microchannels with blood;

supplying the second microchannels with dialysate;

withdrawing blood from the first microchannels; and

withdrawing dialysate from the second microchannels.

16. The method of claim 15 wherein the flow of blood through the first microchannels is non-turbulent.

17. The method of claim 15 wherein the flow of blood through the first microchannels is laminar.

18. The method of claim 15 wherein supplying the first microchannels with blood, supplying the second microchannels with dialysate, withdrawing blood from the first microchannels, and withdrawing dialysate from the second microchannels, comprises:

supplying the first microchannels with blood at a first end;

supplying the second microchannels with dialysate at a second end;

withdrawing blood from the first microchannels at a second end; and

withdrawing dialysate from the second microchannels at a first end; and

wherein the flow of blood through the first microchannels is countercurrent to the flow of dialysate through the second microchannels.

19. The method of claim 15 wherein supplying the first microchannels with blood, supplying the second microchannels with dialysate, withdrawing blood from the first microchannels, and withdrawing dialysate from the second microchannels, comprises:

supplying the first microchannels with blood at a first end;

supplying the second microchannels with dialysate at a first end;

withdrawing blood from the first microchannels at a second end; and

withdrawing dialysate from the second microchannels at a second end; and

wherein the flow of blood through the first microchannels is concurrent to the flow of dialysate through the second microchannels.

20. The method of claim 15 wherein the flow of blood through the first microchannels is crosscurrent to the flow of dialysate through the second microchannels.

21. The method of claim 15 wherein the first and second microchannels have an internal dimension of up to 1000 microns.

22. A dialyzer comprising:

a plurality of semipermeable membrane sheets; and

a plurality of flow separators, the membrane sheets and flow separators arranged in alternating configuration and coupled into a laminae stack defining a plurality of parallel microchannel layers, each microchannel layer comprising a plurality of first microchannels and a plurality of second microchannels, the first and second microchannels of each microchannel layer in fluid communication with each other via one of the plurality of membrane sheets therebetween, the first microchannels define a first inlet and a first outlet, and the second microchannels define a second inlet and a second outlet.

23. A dialyzer comprising;

a semipermeable membrane sheet; and

a plurality of flow separators, the membrane sheet disposed between the flow separators, the membrane sheet and flow separators coupled into a laminae stack defining a microchannel layer, the microchannel layer comprising a plurality of first microchannels and a plurality of second microchannels, the first and second microchannels in fluid communication with each other via the membrane sheet therebetween, the first microchannels for receiving a first fluid stream comprising blood and the second microchannels for receiving a second fluid stream comprising dialysate.