WO2024019034A1 - 中空糸膜および血漿分離方法 - Google Patents
中空糸膜および血漿分離方法 Download PDFInfo
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- WO2024019034A1 WO2024019034A1 PCT/JP2023/026206 JP2023026206W WO2024019034A1 WO 2024019034 A1 WO2024019034 A1 WO 2024019034A1 JP 2023026206 W JP2023026206 W JP 2023026206W WO 2024019034 A1 WO2024019034 A1 WO 2024019034A1
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- hollow fiber
- fiber membrane
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M1/00—Suction or pumping devices for medical purposes; Devices for carrying-off, for treatment of, or for carrying-over, body-liquids; Drainage systems
- A61M1/34—Filtering material out of the blood by passing it through a membrane, i.e. hemofiltration or diafiltration
- A61M1/3496—Plasmapheresis; Leucopheresis; Lymphopheresis
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
- B01D69/02—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
- B01D69/08—Hollow fibre membranes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
- B01D71/06—Organic material
- B01D71/44—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds, not provided for in a single one of groups B01D71/26-B01D71/42
- B01D71/441—Polyvinylpyrrolidone
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
- B01D71/06—Organic material
- B01D71/66—Polymers having sulfur in the main chain, with or without nitrogen, oxygen or carbon only
- B01D71/68—Polysulfones; Polyethersulfones
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61M—DEVICES FOR INTRODUCING MEDIA INTO, OR ONTO, THE BODY; DEVICES FOR TRANSDUCING BODY MEDIA OR FOR TAKING MEDIA FROM THE BODY; DEVICES FOR PRODUCING OR ENDING SLEEP OR STUPOR
- A61M1/00—Suction or pumping devices for medical purposes; Devices for carrying-off, for treatment of, or for carrying-over, body-liquids; Drainage systems
- A61M1/14—Dialysis systems; Artificial kidneys; Blood oxygenators ; Reciprocating systems for treatment of body fluids, e.g. single needle systems for hemofiltration or pheresis
- A61M1/16—Dialysis systems; Artificial kidneys; Blood oxygenators ; Reciprocating systems for treatment of body fluids, e.g. single needle systems for hemofiltration or pheresis with membranes
- A61M1/1621—Constructional aspects thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2323/00—Details relating to membrane preparation
- B01D2323/15—Use of additives
- B01D2323/218—Additive materials
- B01D2323/2182—Organic additives
- B01D2323/21839—Polymeric additives
- B01D2323/2187—Polyvinylpyrolidone
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2325/00—Details relating to properties of membranes
- B01D2325/02—Details relating to pores or porosity of the membranes
Definitions
- the present invention relates to a hollow fiber membrane and a plasma separation method.
- apheresis treatment devices have been developed that use principles such as dialysis, filtration, and adsorption to remove pathogenic substances and excess water from a patient's blood and body cavity fluids and return them to the patient's body.
- blood is separated into blood cells, platelets, etc. and plasma using a hollow fiber membrane, and plasma containing pathogenic substances (IgG, cytokines, etc.) is extracted.
- plasma exchange therapy is known, in which plasma is discarded and replaced with fresh frozen plasma or the like.
- Patent Document 1 Patent No. 5290168
- Patent Document 2 International Publication No. 2020/203716
- hollow fiber membranes made of polyethersulfone have been disclosed.
- polyethylene and the like are known as other materials suitable for hollow fiber membranes used for plasma separation and the like.
- hollow fiber membranes made of polyether sulfone
- the hollow fiber membranes tend to become clogged. It has been desired to provide a hollow fiber membrane that can be used for various purposes.
- an object of the present invention is to suppress the occurrence of clogging of hollow fiber membranes when performing plasma separation using hollow fiber membranes.
- a hollow fiber membrane containing polyether sulfone, It has a non-uniform structure in the thickness direction,
- the hollow fiber membrane has a slope index of 2.00 or more, which is the ratio of the average pore diameter on the inner surface side to the average pore diameter on the outer surface side of the cross section of the hollow fiber membrane.
- the present invention when performing plasma separation using a hollow fiber membrane made of polyethersulfone, it is possible to suppress the occurrence of clogging of the hollow fiber membrane.
- FIG. 2 is a schematic diagram for explaining an example of a method for manufacturing a hollow fiber membrane.
- FIG. 2 is a schematic diagram for explaining depth filtration. It is a schematic diagram for explaining surface layer filtration (screen filtration).
- FIG. 2 is an SEM image of the cross section (a) of the hollow fiber membrane of Example 1, the inner surface side (b) of (a), and the outer surface side (c) of (a).
- FIG. This is an SEM image of a cross section of a hollow fiber membrane of Plasma Flow (reference product).
- 1 is an SEM image of a cross section of a hollow fiber membrane of Comparative Example 1. It is a graph for explaining a method of measuring a pore concentration diameter.
- FIG. 2 is a schematic diagram of a loop-type mini module.
- the hollow fiber membrane of this embodiment contains polyether sulfone.
- the proportion of polyether sulfone in the material constituting the hollow fiber membrane is preferably 90% by mass or more, more preferably 93% by mass or more, still more preferably 95% by mass or more.
- the hollow fiber membrane may be composed only of polyether sulfone.
- Polyether sulfone is a compound containing a structural unit represented by the following formula (1).
- polyether sulfone examples include Ultrason (registered trademark) E2020P, E6020P manufactured by BASF Corporation, or Sumika Excel (registered trademark) 3600P, 4100P, 4800P, 5200P, 7600P manufactured by Sumitomo Chemical Co., Ltd., preferably E6020P. , 4800P or 5200P. These may be used alone or in combination.
- the hollow fiber membrane of this embodiment may further contain a vinylpyrrolidone polymer.
- the vinylpyrrolidone polymer can suppress adsorption of blood components such as platelets and proteins to the hollow fiber membrane.
- the vinylpyrrolidone-based polymer is a polymer of monomers containing at least N-vinylpyrrolidone.
- the vinylpyrrolidone-based polymer contains a structural unit represented by the following formula (2).
- vinylpyrrolidone-based polymers include Kollidon (registered trademark) 30, 90, commercially available from BASF, or Luvitec (registered trademark) K30, K80, K85, K90, and VA64. These may be used alone or in combination.
- the content of the vinylpyrrolidone polymer in the entire hollow fiber membrane is preferably 1 to 10% by mass, more preferably 1.5 to 5% by mass.
- the hollow fiber membrane of this embodiment has a non-uniform structure (asymmetric structure) in the thickness direction.
- asymmetric structure examples include hollow fiber membranes in which density, porosity, cross-sectional porosity, etc. differ in the thickness direction.
- the average pore diameter on the inner surface side of the cross section (cross section: cross section in the thickness direction) is larger than the average pore diameter on the outer surface side.
- the hollow fiber membrane of this embodiment has, for example, a structure in which the inner surface side is sparse and the outer surface side is dense.
- the slope index of the hollow fiber membrane is 2.00 or more.
- the slope index is the ratio of the average pore diameter on the inner surface side to the average pore diameter on the outer surface side of the cross section of the hollow fiber membrane. Note that the average pore diameter and slope index can be measured by the method described in Examples below.
- the pore concentration diameter of the cross section of the hollow fiber membrane of this embodiment is preferably 0.090 ⁇ m or more. Further, the pore concentration diameter is preferably 0.5 ⁇ m or less, more preferably 0.3 ⁇ m or less. Note that the pore concentration diameter can be measured by the method described in Examples below.
- the inner diameter of the hollow fiber membrane is preferably 150 ⁇ m or more and 400 ⁇ m or less, more preferably 200 ⁇ m or more and 350 ⁇ m or less.
- the thickness of the hollow fiber membrane is preferably 50 to 200 ⁇ m, more preferably 60 to 150 ⁇ m. Note that the film thickness can be calculated from "(outer diameter - inner diameter)/2".
- the hollow fiber membrane (hollow fiber type membrane) is preferably composed of a semipermeable membrane.
- the hollow ratio of the hollow fiber membrane is preferably 15 to 60%, more preferably 20 to 50%. Note that the hollowness ratio is the ratio of the area of the hollow part in the cross section of the hollow fiber membrane, and is expressed as "cross-sectional area of the hollow part/(cross-sectional area of the membrane part + cross-sectional area of the hollow part) x 100 (%)".
- the hollow fiber membrane of this embodiment can be suitably used, for example, for separating biological materials and the like that are prone to clogging (plasma separation, etc.).
- Plasma is a liquid component obtained by removing cellular components such as blood cells (white blood cells and red blood cells) and platelets from blood.
- Plasma contains water, proteins, inorganic salts, sugars, fats, nitrogen compounds, and the like, as well as albumin, fibrinogen, IgG, cytokines, and the like.
- the method for manufacturing the hollow fiber membrane of this embodiment is, for example, the following method.
- the method for manufacturing the hollow fiber membrane described above The spinning stock solution and the internal solution are discharged from a double-tubular nozzle through an air traveling section into a coagulating solution, the spinning stock solution is coagulated in the coagulating solution, and the coagulated product of the spinning stock solution is pulled out of the coagulating solution.
- the internal fluid contains water,
- the total concentration of components other than water in the internal solution (internal solution concentration) is 70 to 90% by mass,
- a manufacturing method in which the nozzle draft ratio is 1.5 to 6.5.
- a spinning dope 10a and an internal liquid 10b are discharged from a double-tubular nozzle 11 through an air gap 20 into a coagulating liquid 21 to form a spinning dope 10a and an internal liquid 10b.
- the hollow fiber membrane 3 is obtained by coagulating the stock solution in the coagulation liquid 21 and drawing out the coagulated product of the spinning stock solution from the coagulation liquid 21.
- the hollow fiber membrane is pulled out, for example, by submerged guides 12, 13 and rollers 14, 15, 16. Note that the hollow fiber membrane 3 drawn out from the coagulation liquid 21 is, for example, immersed in a water washing bath 22 and then wound up by a winding machine 23 .
- the nozzle 11 is double-tubular and includes an outer tube and an inner tube provided inside the outer tube.
- the spinning dope is discharged from the gap (slit) between the outer tube and the inner tube, and the inner solution is discharged from the inside of the inner tube.
- the inner diameter of the outer tube is preferably 500 to 1500 ⁇ m, more preferably 600 to 1200 ⁇ m.
- the outer diameter of the inner tube is preferably 150 to 700 ⁇ m, more preferably 150 to 600 ⁇ m. Note that the outer diameter of the inner tube is preferably about the same as the inner diameter of the hollow fiber membrane.
- the discharge linear velocity and take-up speed of the spinning dope can be made to be approximately the same, which makes it possible to reduce the interfacial friction between the discharged spinning dope and the internal solution, and the hollow fiber membrane It is possible to prevent the inner surface from becoming rough.
- the discharge linear velocity of the spinning dope is calculated by calculating the discharge amount of the spinning dope by the slit cross-sectional area [ ⁇ (a/2) 2 - (b/2) 2 ] (see formula below).
- Discharge linear velocity of spinning dope [m/min] Discharge rate of spinning dope/slit cross-sectional area
- the discharge rate of spinning dope is preferably 1.0 to 5.0 cc/min, more preferably 1.5 to 4 cc/min. .0cc/min.
- the take-off speed is the rotational speed (surface speed) of the roller 14 provided at the exit of the coagulation bath (see FIG. 1).
- the nozzle draft ratio which is the ratio of the discharge linear velocity to the withdrawal speed (take-up velocity/discharge linear velocity), is preferably 1.5 to 6.5, more preferably 2.0 to 6.0. In this manner, by increasing the linear discharge speed relative to the take-up speed of the spinning dope, the characteristic membrane structure of the hollow fiber of the present invention can be obtained.
- the straight line distance of the aerial traveling portion 20 is preferably 10 to 200 mm, more preferably 10 to 100 mm.
- the hollow fiber membrane obtained by the spinning process may be further subjected to a washing process with pure water (water washing process).
- water washing process the flow of water is preferably in the opposite direction to the direction of movement of the hollow fiber membrane (countercurrent), but even if the flow is in the same direction as the direction of movement of the hollow fiber membrane (cocurrent). good.
- the spinning dope 10a contains, for example, a resin raw material containing the polyether sulfone, a solvent, and a non-solvent.
- the temperature (set temperature) of the spinning dope in the nozzle 11 is preferably 50 to 110°C, more preferably 60 to 100°C.
- the concentration of polyether sulfone in the spinning dope is preferably 10 to 30% by mass, more preferably 10 to 25% by mass. If the concentration of polyether sulfone is too low, the strength of the hollow fiber membrane may decrease. On the other hand, if the concentration of polyether sulfone is too high, the viscosity of the spinning dope may become too high, making it difficult to carry out spinning.
- the concentration of the vinylpyrrolidone polymer in the spinning dope is preferably 3 to 20% by mass, more preferably 5 to 15% by mass. If the concentration of the vinyl pyrrolidone-based polymer is too low, proteins in the blood may accumulate and cause clogging when used for plasma separation, resulting in rapid performance deterioration over time. On the other hand, if the concentration of the vinylpyrrolidone-based polymer is too high, the viscosity of the spinning dope may become too high, making it difficult to carry out spinning.
- the solvent is a liquid that can dissolve polyether sulfone.
- the solvent is preferably a polar solvent and preferably soluble in water.
- the polar solvent is an aprotic polar solvent.
- the aprotic polar solvent include N-methylpyrrolidone (NMP), dimethylformamide (DMF), dimethylacetamide (DMA), dimethylsulfoxide (DMSO), and acetonitrile.
- a non-solvent is a liquid (excluding water) that does not dissolve polyether sulfone.
- the non-solvent include glycol esters, glycerin, alcohols, etc., but glycol esters are preferred.
- glycol esters include ethylene glycol, triethylene glycol (TEG), polyethylene glycol (polyethylene glycol 200, polyethylene glycol 400, etc.), propylene glycol, and the like.
- the ratio of the amount of solvent (S) to non-solvent (NS) is preferably 35/65 to 55/45, more preferably 40/60 to 50/50. be. If the S/NS ratio in the spinning stock solution becomes too small, the dissolution of polyether sulfone becomes unstable, resulting in decreased spinning stability or inability to obtain an asymmetric structure suitable for the use of the present invention. . When the S/NS ratio becomes large, a hollow fiber membrane with an asymmetric structure may not be obtained or the spinning stability may decrease.
- the spinning dope may further contain water in addition to the solvent and non-solvent.
- the internal fluid contains water.
- the content of water in the internal liquid is preferably 10 to 30% by mass, more preferably 15 to 25% by mass.
- the internal solution may contain a solvent, a non-solvent, etc. in addition to water.
- the non-solvent include ethylene glycol, triethylene glycol (TEG), polyethylene glycol 200 or 400, glycerin, propylene glycol, and the like.
- the solvent include N-methylpyrrolidone (NMP), dimethylacetamide, dimethylformamide, dimethylsulfoxide, and the like.
- the concentration of the internal solution is preferably 70 to 90% by mass, more preferably 75 to 85% by mass.
- the nozzle draft ratio is preferably 1.5 to 6.5, more preferably 2.0 to 6.0.
- a temperature difference may be provided between the spinning dope and the internal liquid.
- the coagulating liquid preferably contains a solvent and a non-solvent (excluding water).
- the coagulating liquid may further contain water in addition to the solvent and the non-solvent.
- concentration of coagulation liquid concentration of coagulation liquid: CB concentration
- the ratio of the amount of solvent to non-solvent in the coagulation liquid is, for example, 40/60 to 50/50.
- the temperature of the coagulating liquid is preferably 30 to 80°C, more preferably 40 to 70°C.
- Example 1 The hollow fiber membrane of Example 1 was manufactured by basically the same method as the hollow fiber membrane manufacturing method described in the embodiment. The specific conditions are as follows.
- PES manufactured by BASF, 6020P
- PVP manufactured by BASF, Kollidon (registered trademark) K30
- N-methylpyrrolidone NMP, manufactured by Mitsubishi Chemical Corporation, solvent
- a spinning stock solution was obtained by mixing and dissolving 40.15% by mass of triethylene glycol (TEG, manufactured by Mitsubishi Chemical Corporation, non-solvent).
- composition of internal fluid A mixed solution of 37.8% by mass of NMP (solvent), 46.2% by mass of TEG (non-solvent), and 16.0% by mass of reverse osmosis (RO) water.
- the total concentration of the solvent and non-solvent in the internal fluid (IL) was 84% by mass.
- composition of coagulation liquid A mixed solution of 26.1% by mass of NMP (solvent), 31.9% by mass of TEG (non-solvent), and 42.0% by mass of RO water. Note that the total concentration of the solvent and non-solvent in the coagulation liquid (CB) (CB concentration) was 58% by mass.
- Discharge temperature of spinning dope (set temperature): 67°C Distance of aerial traveling part (air gap length: AG length): 30mm Drawing speed (spinning speed): 15 m/min (rolled up on the skein (winding machine 23)) Nozzle draft ratio: 4.05
- the bundle of hollow fiber membranes obtained by the above process was cut to a certain length, wrapped in gauze, washed with 80°C RO water, and dried at 60°C in a hot air dryer.
- the inner diameter (membrane inner diameter) of the obtained hollow fiber membrane was 300 ⁇ m, and the thickness (membrane thickness) was 75 ⁇ m.
- the film inner diameter and film thickness were measured by the following method. Pass an appropriate number of hollow fiber membranes through a hole with a diameter of 3 mm drilled in the center of a glass slide so that the hollow fiber membranes do not fall out, and cut the hollow fiber membranes with a razor along the top and bottom surfaces of the glass slide to obtain a cross section of the hollow fiber membranes. Get a sample. The inner diameter and outer diameter of the obtained hollow fiber membrane cross-section sample are measured using a projector (Nikon PROFILE PROJECTOR V-12).
- the dimensions of the outer surface of the hollow fiber membrane in the XX direction and the YY direction are measured for each hollow fiber membrane cross section, and the arithmetic mean value of these values is calculated.
- the outer diameter of one hollow fiber membrane cross section was taken as the outer diameter of one hollow fiber membrane cross section.
- the dimensions of the hollow part in the XX direction and the Y-Y direction were measured for each hollow fiber membrane cross section, and the arithmetic mean value was taken as the inner diameter of one hollow fiber membrane cross section. . Note that measurements were similarly performed on 10 cross sections, and the average values were taken as the inner diameter and outer diameter.
- the membrane thickness (average value) is calculated by the formula "(outer diameter - inner diameter)/2" based on the inner diameter of the hollow fiber membrane and the measurement results (average value) of the inner diameter.
- Examples 2 to 5, Comparative Example 1 As shown in Table 1, the manufacturing conditions of the hollow fiber membrane etc. were changed. Hollow fiber membranes of Examples 2 to 5 and Comparative Example 1 were produced in the same manner as in Example 1 except for the above. "%” in Table 1 indicates “mass%”. Note that FIG. 6 shows a cross-sectional SEM image of the hollow fiber membrane of Comparative Example 1.
- a bundle of a plurality of hollow fiber membranes cut into lengths of about 30 cm was wrapped with a polyethylene film to form a hollow fiber membrane bundle.
- This hollow fiber membrane bundle was inserted into a cylindrical polycarbonate container, and both ends were solidified with a urethane potting agent. The ends were cut to obtain a module with both ends open.
- the number of hollow fiber membranes was set appropriately.
- ports are provided at two locations on the cylindrical surface of the cylindrical container to allow fluid to perfuse the outer surface of the hollow fiber membrane, and headers are attached to both ends of the cylindrical container to allow fluid to perfuse the outer surface of the hollow fiber membrane. to allow fluid perfusion.
- a bundle of a plurality of hollow fiber membranes cut to a length of about 40 cm was bent, the ends overlapped, the ends were inserted into a pipe (sleeve), and the ends were solidified with a urethane potting agent.
- a loop-shaped mini module in which the hollow part of the hollow fiber membrane was opened was obtained by cutting a part of the adhesive fixing part (FIG. 8). The number of hollow fiber membranes was set appropriately.
- the hollow fiber membrane used in the plasma flow is a hollow fiber membrane made of hydrophobic polyethylene, and the surface (outer surface) is coated with an ethylene vinyl alcohol copolymer.
- the hollow fiber membrane has an inner diameter of 250 ⁇ m and a thickness of 50 ⁇ m.
- a scanning electron microscope (SEM) image of the hollow fiber membrane used for plasma flow is shown in FIG.
- the threshold value is increased by 5 points, and the number of determined pores for each threshold value is measured. Based on the results, a threshold value is adopted when the number of determined pores is maximum. The above binarization was performed based on the threshold value adopted in this way.
- the entire loop-shaped mini module was immersed in a sufficient amount of 2-propanol (hereinafter abbreviated as iPA) for 3 minutes to spread iPA throughout the lumen and membrane wall. While the entire hollow fiber membrane portion of the loop-type mini module was immersed in iPA, it was connected to a nitrogen line with a pressure gauge attached to the sleeve so that the pressurization pressure could be monitored, and pressurized. The point at which bubbles began to constantly appear from the membrane wall portion of the hollow fiber membrane was recorded as the bubble point P [Pa]. Measurements were performed three times for each sample, and the average value of the bubble point measurements was taken as the bubble point of that sample.
- iPA 2-propanol
- TMP transmembrane pressure difference
- the retention rate of fibrinogen sieving coefficient is an index showing how much it changes between 30 minutes after the start of circulation and 180 minutes after the start of circulation. It can be calculated using SCFib later. Note that, for example, when fibrinogen passes through the membrane 100%, the fibrinogen sieving coefficient is 1.
- the hollow fiber membrane of Comparative Example 1 which is considered to be prone to clogging, has a low retention rate of fibrinogen sieving coefficient (SCFib), whereas the hollow fiber membranes of Examples 1 to 5 have a low retention rate of SCFib. Is high.
- the fibrinogen sieving coefficient tends to decrease significantly when the pore concentration diameter becomes less than 0.090 ⁇ m. From the viewpoint of maintaining the fibrinogen sieving coefficient, it is considered desirable to maintain the pore concentration diameter at 0.090 ⁇ m or more.
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Abstract
Description
厚み方向に不均一な構造を有し、
前記中空糸膜の断面の外表面側の平均孔径に対する内表面側の平均孔径の比率である傾斜指数が2.00以上である、中空糸膜。
(ポリエーテルスルホン)
本実施形態の中空糸膜は、ポリエーテルスルホンを含む。中空糸膜を構成する材料中のポリエーテルスルホンの比率は好ましくは90質量%以上であり、より好ましくは93質量%以上、さらに好ましくは95質量%以上である。中空糸膜は、ポリエーテルスルホンのみから構成されていてもよい。
本実施形態の中空糸膜は、さらに、ビニルピロリドン系ポリマーを含んでいてもよい。ビニルピロリドン系ポリマーによって、血小板、タンパク等の血液中の成分の中空糸膜への吸着が抑制され得る。
本実施形態の中空糸膜は、厚み方向に不均一な構造(非対称構造)を有する。なお、非対称構造を有する中空糸膜としては、例えば、厚み方向で密度、空孔率、断面開孔率等が異なる中空糸膜が挙げられる。
なお、細孔集中径は、後述の実施例に記載の方法により測定することができる。
中空糸膜の厚みは、好ましくは50~200μmであり、より好ましくは60~150μmである。なお、膜厚は「(外径-内径)/2」より算出できる。
本実施形態の中空糸膜は、例えば、目詰まりが生じやすい生体材料等の分離(血漿分離等)に好適に用いることができる。
以下、上記の中空糸膜の製造方法の一形態について説明する。
上記の中空糸膜の製造方法であって、
紡糸原液および内液を二重管状のノズルから空中走行部を経て凝固液中に吐出して、前記紡糸原液を前記凝固液中で凝固させ、前記紡糸原液の凝固物を前記凝固液中から曳き出すことにより、中空糸膜を得る、紡糸工程を含み、
前記紡糸原液は、ポリエーテルスルホンを含む樹脂原料、溶剤および非溶剤を含み、
前記内液は水を含み、
前記内液中の水以外の成分の総濃度(内液濃度)が70~90質量%であり、
ノズルドラフト比が1.5~6.5である、製造方法。
図1を参照して、紡糸工程では、紡糸原液(spinning dope)10aおよび内液10bを二重管状のノズル11から空中走行部(エアギャップ)20を経て凝固液21中に吐出して、紡糸原液を凝固液21中で凝固させ、紡糸原液の凝固物を凝固液21中から曳き出すことにより、中空糸膜3が得られる。中空糸膜の曳き出し等は、例えば、液中ガイド12,13およびローラー14,15,16により行われる。なお、凝固液21中から曳き出された中空糸膜3は、例えば、水洗浴22に浸漬された後に、巻取機23によって巻き取られる。
紡糸原液の吐出線速度[m/分]=紡糸原液の吐出量/スリット断面積
紡糸原液の吐出量は、好ましくは1.0~5.0cc/分であり、より好ましくは1.5~4.0cc/分である。
引取り速度は、凝固浴の出口に設けられたローラー14の回転速度(表面速度)である(図1参照)。
引き取り速度に対する吐出線速度の比率(引取り速度/吐出線速度)であるノズルドラフト比は、好ましくは1.5~6.5であり、より好ましくは2.0~6.0である。このように、紡糸原液の引き取り速度に対して吐出線速度を早くすることにより、本発明の中空糸の特徴的な膜構造を得ることができる。
紡糸原液10aは、例えば、上記ポリエーテルスルホンを含む樹脂原料、溶剤および非溶剤を含む。
なお、紡糸原液は、溶剤と非溶剤とに加えて、さらに水を含んでいてもよい。
内液は、水を含む。内液中の水の含有率は、好ましくは10~30質量%であり、より好ましくは15~25質量%である。
凝固液は、好ましくは溶剤と非溶剤(水を除く)とを含む。なお、この場合、凝固液は、溶剤と非溶剤とに加えて、さらに水を含んでいてもよい。
凝固液中の溶剤および非溶剤の総量の比率(凝固液の濃度:CB濃度)は、好ましくは60~90質量%であり、より好ましくは65~90質量%である。
凝固液中の非溶剤に対する溶剤の量の比率は、例えば、40/60~50/50である。
実施形態で説明した中空糸膜の製造方法と基本的に同様の方法により、実施例1の中空糸膜が製造された。具体的な条件等は以下の通りである。
PES(BASF社製、6020P)17.0質量%、PVP(BASF社製、コリドン(登録商標)K30)10.0質量%、N-メチルピロリドン(NMP、三菱化学社製、溶剤)32.85質量%、および、トリエチレングリコール(TEG、三菱化学社製、非溶剤)40.15質量%を混合して溶解することより、紡糸原液を得た。
NMP(溶剤)37.8質量%、TEG(非溶剤)46.2質量%、および、逆浸透(RO)水16.0質量%の混合液。なお、内液(IL)中の溶剤および非溶剤の合計の濃度(内液濃度:IL濃度)は、84質量%である。
NMP(溶剤)26.1質量%、TEG(非溶剤)31.9質量%、および、RO水42.0質量%の混合液。なお、凝固液(CB)中の溶剤および非溶剤の合計の濃度(CB濃度)は、58質量%である。
紡糸原液の吐出温度(設定温度):67℃
空中走行部の距離(エアギャップ長:AG長):30mm
曳き出し速度(紡糸速度):15m/分(綛(巻取機23)に捲き上げた)
ノズルドラフト比:4.05
水洗槽(水洗浴)の流れ:向流
温度:30℃
なお、膜内径および膜厚は、以下の方法で測定された。
中空糸膜をスライドグラスの中央に開けられた直径3mmの孔に中空糸膜が抜け落ちない程度に適当本数通し、スライドグラスの上下面に沿ってカミソリにより中空糸膜をカットし、中空糸膜断面サンプルを得る。得られた中空糸膜断面サンプルについて、投影機(Nikon PROFILE PROJECTOR V-12)を用いて中空糸膜の内径および外径を測定する。
具体的には、中空糸膜断面1個につき中空糸膜外表面のX-X方向およびY-Y方向(断面上の直交する2方向)の寸法を測定し、それらの値の算術平均値を中空糸膜断面1個の外径とした。また、中空糸膜断面1個につき中空部のX-X方向およびY-Y方向(断面上の直交する2方向)の寸法を測定し、算術平均値を中空糸膜断面1個の内径とした。なお、10断面について同様に測定を行い、平均値を内径および外径とした。
膜厚(平均値)は、中空糸膜の内径および内径の測定結果(平均値)に基づいて、「(外径-内径)/2」の式により算出される。
表1に示されるように、中空糸膜の製造条件等が変更された。それ以外の点は実施例1と同様にして、実施例2~5および比較例1の中空糸膜が製造された。表1中の「%」は「質量%」を示す。
なお、図6に、比較例1の中空糸膜の断面SEM像を示す。
上記実施例および比較例の中空糸膜の各々について、以下の測定を行った。測定結果を表2に示す。また、実施例1の中空糸膜の走査型電子顕微鏡(SEM)像を図4に示す。
約30cmの長さに切断された複数の中空糸膜の束をポリエチレンフィルムで巻いて中空糸膜束とした。この中空糸膜束を円筒型のポリカーボネート製筒状容器に挿入し、両末端をウレタンポッティング剤で固めた。端部を切断して、両末端が開口したモジュールを得た。中空糸膜の本数は、適宜設定した。なお、円筒状の筒状容器の円筒面2箇所にポートを設け、中空糸膜の外面を流体が灌流できるようにし、筒状容器の両末端にはヘッダーを装着して、中空糸膜の内面を流体が灌流できるようにした。
約40cmの長さに切断された複数の中空糸膜の束を曲げて端部を重ね合わせ、該端部をパイプ(スリーブ)に挿入し、ウレタンポッティング剤で固めた。接着固定部の一部を切断して、中空糸膜の中空部が開口されたループ型ミニモジュールを得た(図8)。中空糸膜の本数は、適宜設定した。
まず、中空糸膜の断面(図4(a)参照)について、10000倍の走査型電子顕微鏡(SEM)を用いて撮像を得る。得られた断面画像において、中空糸膜の内表面側(図4(b)参照)および外表面側(図4(c)参照)の各々について、膜厚方向に(内表面から)5μm、および、膜厚方向と垂直な方向に10μmの範囲を測定範囲とした。この測定範囲に対して、画像解析ソフトを使用して、白/黒に画像を二値化し、該断面の中空糸膜の内表面側および外表面側の各々における細孔の孔径分布を測定し、円相当直径を計測した。得られた円相当直径の平均値を平均孔径とした。
傾斜指数=(中空糸膜の断面の内表面側の平均孔径)/(中空糸膜の断面の外表面側の平均孔径)
ループ型ミニモジュールを用い、PMI製のパームポロメーター(貫通細孔径分布測定装置)で平均孔径(平均細孔径)を測定した。なお、パームポロメーター用の溶媒としてパーフルオロポリエステル(商品名:Galwick)を使用した。このようにして得られた平均孔径の測定結果から、図7に示されるような平均孔径の分布を求め、最も分布数が多い(細孔分布密度が高い)平均孔径の値を細孔集中径とした(図7参照)。
ループ型ミニモジュールの全体を十分な量の2-プロパノール(以下iPAと略記する)に3分間浸漬して、内腔、膜壁部分にiPAを行き渡らせた。ループ型ミニモジュールの中空糸膜部分全体がiPAに浸った状態で、スリーブに圧力計を装着して加圧圧力がモニターできるようにした窒素ラインに接続し、加圧した。中空糸膜の膜壁部分からコンスタントに気泡が出始めたポイントをバブルポイントP[Pa]として記録した。1サンプルにつき3回の測定を実施し、バブルポイントの測定値の平均値をそのサンプルのバブルポイントとした。さらに、下記式により、iPAで測定したバブルポイント(P[bar])から算出される最大孔径を得た。
最大孔径[μm]=4γCOSθ/P
γは溶媒の表面張力(N/m)、θは膜素材と溶媒との接触角(°)、Pはバブルポイント圧力(Pa)を示す。iPAの表面張力γ=20.8、接触角0°よりCOSθ=1で計算される。
クエン酸を添加して凝固を抑制し、ヘマトクリット40±2%、タンパク濃度6~7g/dLに調製した牛血液を使用し、血液流量(Qb)100mL/分、ろ過流量(Qf)30mL/分の条件で180分間循環した。循環開始30分後および循環開始180分後における入口側圧力、出口側圧力、ろ液側圧力をそれぞれ測定した。得られた圧力の測定値から下記式により膜間圧力差(TMP)を求めた。
TMP=([入口側圧力]+[出口側圧力])/2-[ろ液側圧力]
上記TMPと同様の試験を行い、循環開始30分後および循環開始180分後における入口側、出口側、ろ液側の液をサンプリングし、それぞれELISA-KIT(コスモ・バイオ社製Fibrinogen ELISA Kit 96test (Cloud-Clone Corp.))を用いて濃度を求めた。得られた測定値から、下記式によって、フィブリノーゲンふるい係数(SCFib)を算出した。
SCFib=2×[ろ液濃度]/([入口濃度]+[出口濃度])
TMPの上昇抑制は、主に中空糸膜の目詰まりによって生じるため、実施例1~5の中空糸膜では目詰まりが抑制されていると考えられる。このため、目詰まりが生じやすいと考えられる比較例1の中空糸膜では、フィブリノーゲンふるい係数(SCFib)の保持率が低いのに対して、実施例1~5の中空糸膜ではSCFibの保持率が高くなっている。
Claims (5)
- ポリエーテルスルホンを含む中空糸膜であって、
厚み方向に不均一な構造を有し、
前記中空糸膜の断面の外表面側の平均孔径に対する内表面側の平均孔径の比率である傾斜指数が2.00以上である、中空糸膜。 - 前記中空糸膜の断面の細孔集中径が0.090μm以上である、請求項1に記載の中空糸膜。
- さらに、ビニルピロリドン系ポリマーを含む、請求項1または2に記載の中空糸膜。
- 血漿分離用である、請求項1~3のいずれか1項に記載の中空糸膜。
- 請求項1~4のいずれか1項に記載の中空糸膜を用いる、血漿分離方法。
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP5290168B2 (ja) | 2006-07-07 | 2013-09-18 | ガンブロ・ルンディア・エービー | 血漿分離膜 |
| WO2016031834A1 (ja) * | 2014-08-25 | 2016-03-03 | 旭化成メディカル株式会社 | 多孔質膜 |
| JP2020121299A (ja) * | 2019-09-06 | 2020-08-13 | 旭化成メディカル株式会社 | ウイルスの濃縮方法 |
| WO2020203716A1 (ja) | 2019-03-29 | 2020-10-08 | 旭化成メディカル株式会社 | 多孔質膜 |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP5290168B2 (ja) | 2006-07-07 | 2013-09-18 | ガンブロ・ルンディア・エービー | 血漿分離膜 |
| WO2016031834A1 (ja) * | 2014-08-25 | 2016-03-03 | 旭化成メディカル株式会社 | 多孔質膜 |
| WO2020203716A1 (ja) | 2019-03-29 | 2020-10-08 | 旭化成メディカル株式会社 | 多孔質膜 |
| JP2020121299A (ja) * | 2019-09-06 | 2020-08-13 | 旭化成メディカル株式会社 | ウイルスの濃縮方法 |
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