Laminated cassette device and methods for making same

A cassette, comprising:

• one or more filtrate channel spacers, each of the one or more filtrate channel spacers defining an open interior volume bounded by an inner perimeter and including at least one feed port, at least one retentate port, and at least one filtrate port;
• one or more non-flexible feed channel spacers, each of the one or more feed channel spacers defining an open interior volume bounded by an inner perimeter and including at least one feed port, at least one retentate port, and at least one filtrate port;
• one or more membranes, where one membrane is disposed between each of the one or more filtrate channel spacers and each of the one or more feed channel spacers;
• a thin film of a pressure-sensitive adhesive, where the adhesive binds together the one or more filtrate channel spacers, the one or more feed channel spacers, and the one or more membranes;
• one or more filtrate screens, where one filtrate screen is inserted into the open interior volume of each of the one or more filtrate channel spacers;
• a first and second retaining member at either end of the cassette;
• where the one or more filtrate channel spacers and the one or more feed channel spacers are arranged such that the feed ports, the retentate ports and the filtrate ports are positioned in respective alignment;
• where the inner perimeter of the one or more filtrate channel spacers is shaped to reduce non-uniformities in a filtrate flow through the one or more filtrate channel spacers;
• and where the inner perimeter of the one or more feed channel spacers is shaped to reduce non-uniformities in a feed flow through the one or more feed channel spacers, and wherein the cassette is disposable.

A cassette, comprising:

• at least one filtrate channel spacer defining an open interior volume bounded by an inner perimeter and including at least one feed port and at least one filtrate port, where the inner perimeter is shaped to reduce non-uniformities in a filtrate flow through the filtrate channel spacer;
• at least one non-flexible feed channel spacer defining an open interior volume bounded by an inner perimeter and including at least one feed port and at least one filtrate port, where the spacer is die-cut to have a uniform inner perimeter thus reducing non-uniformities in a feed flow through the feed channel spacer;
• at least one membrane disposed between the at least one filtrate channel spacer and the at least one feed channel spacer;
• where the at least one filtrate channel spacer and the at least one feed channel spacer are assembled such that the feed ports and the filtrate ports are positioned in respective alignment;
• a thin film of pressure sensitive adhesive, where the thin film of adhesive binds together the at least one filtrate channel spacer, the at least one feed channel spacer, and the at least one membrane;
• and
• a first and second endplate attached at either end of the cassette.

A self-contained filtration assembly, comprising:

• a shell having a top portion, a bottom portion, an inlet connection and an outlet connection;
• at least one disposable filtration cassette disposed between the top portion of the shell and the bottom portion of the shell;
• where the at least one disposable filtration cassette includes one or more non-flexible filtrate channel spacers, each of the one or more filtrate channel spacers defining an open interior volume bounded by an inner perimeter and including at least one feed port and at least one filtrate port, where the inner perimeter is shaped to reduce non-uniformities in a filtrate flow through the filtrate channel spacer,
• one or more non-flexible feed channel spacers, each of the one or more feed channel spacers defining an open interior volume bounded by an inner perimeter and including at least one feed port and at least one filtrate port, where the inner perimeter is shaped to reduce non-uniformities in a feed flow through the feed channel spacer,
• one or more membranes, the one or more membranes disposed between the one or more filtrate channel spacers and the one or more feed channel spacers,
• where the one or more filtrate channel spacers and the one or more feed channel spacers are arranged such that the feed ports and the filtrate ports are positioned in respective alignment, and
• a thin film of pressure sensitive adhesive, where the thin film of adhesive binds together the one or more filtrate channel spacers, the one or more feed channel spacers, and the one or more membranes;
• where the inlet connection directs a feed flow into the at least one filtration cassette;
• the outlet connection directs a filtrate flow out of the at least one filtration cassette;
• and
• the shell and the at least one filtration cassette are bonded together about the periphery.

A filtration capsule, comprising:

• a housing having at least one inlet connection and at least one outlet connection;
• at least one filtrate channel spacer having at least one filtrate port;
• at least one non-flexible feed channel spacer having at least one filtrate port;
• at least one membrane disposed between the at least one feed channel spacer and the at least one filtrate channel spacer;
• a thin film of pressure sensitive adhesive, where the thin film of adhesive binds together the at least one filtrate channel spacer, the at least one feed channel spacer, and the at least one membrane;
• where the at least one filtrate channel spacer and the at least one feed channel spacer are disposed in the housing and assembled such that the filtrate ports are positioned in respective alignment;
• the at least one inlet connection provides a feed flow to the at least one feed channel spacer;
• and
• the at least one outlet connection provides a filtrate flow from the at least one filtrate channel spacer, said capsule being disposable.

A method of fabricating a filtration cassette, comprising:

• applying a thin film of pressure sensitive adhesive to a non-flexible feed channel spacer having at least one feed port and at least one filtrate port;
• applying the thin film of pressure sensitive adhesive to a filtrate channel spacer having at least one feed port and at least one filtrate port;
• disposing a membrane between the feed channel spacer and the filtrate channel spacer;
• arranging the feed channel spacer, the membrane, and the filtrate channel spacer such that the feed ports and the filtrate ports are in respective alignment;
• and
• binding the feed channel spacer, the membrane, and the filtrate channel spacer together with the thin film of pressure sensitive adhesive.

A method of fabricating a filtration capsule, comprising:

• applying a thin film of pressure sensitive adhesive to a non-flexible feed channel spacer having at least one filtrate port;
• applying the thin film of pressure sensitive adhesive to a filtrate channel spacer having at least one filtrate port;
• disposing a membrane between the feed channel spacer and the filtrate channel spacer;
• arranging the feed channel spacer, the membrane, and the filtrate channel spacer such that the filtrate ports are in respective alignment;
• disposing the feed channel spacer, the membrane, and the filtrate channel spacer in a housing;
• and
• binding the feed channel spacer, the membrane, and the filtrate channel spacer together with the thin film of pressure sensitive adhesive.