Methods for making a housingless hollow fiber filtration apparatus

1. A method of manufacturing a hollow fiber filtration apparatus comprising the steps of:

forming a continuous bundle of hollow fibers aligned longitudinally along a winding apparatus;

attaching end cap housings to the continuous bundle of hollow fibers at a set position along the winding apparatus wherein the end cap housing comprises an exterior fill port;

injecting a potting material into the exterior fill port such that potting material contacts the bundle of hollow fibers;

curing the potting material to form a potting sleeve;

cutting the end cap housings to expose open hollow fibers while retaining a portion of the end cap housings;

providing two thermoplastic parts wherein said thermoplastic parts have matching apertures along the edges of the thermoplastic parts to form inlet and outlet ports when sealed;

positioning the hollow fiber unit between the two thermoplastic parts such that the end cap housings are inserted into the apertures; and

melt sealing the peripheral edges of the two thermoplastic parts together to form a closed filtration apparatus.

2. The method of claim 1 wherein the end cap housings are attached using a two part locking connection, overmolding, or a combination thereof.

3. The method of claim 1 wherein the potting material comprises a UV cured adhesive, visible light cured adhesive, heat cured adhesive, thermoplastic resin, thermoset resin, or combination thereof.

4. The method of claim 1 further comprising the step of applying a sealant coating to the bundle of hollow fibers to provide adhesion between fibers.

5. The method of claim 1 wherein the thermoplastic parts comprise planar flexible films.

6. The method of claim 5 further comprising the steps of:

forming additional melt seals longitudinally along opposing sides of the planar flexible films to form a flexible bag having two additional compartments along the peripheral edges of said flexible bag; and

filling said compartments with at least one of air, liquid, or foam.

7. The method of claim 6 wherein the inlet and outlet ports are in juxtaposition along one edge of the flexible bag and the planar flexible films are melt sealed along the opposing side of the inlet and outlet ports to form a compartment along the lower edge of the flexible bag and wherein said compartment if filled with at least one of air, liquid, or foam.

8. The method of claim 1 wherein the thermoplastic parts comprise rigid three-dimensional parts.

9. The method of claim 1 wherein the end cap housing is attached to the inlet port and outlet port by an adhesive, solvent bond, threaded seal, retaining clip, melt seal, compression seal, pressure fit, or a combination thereof.

10. The method of claim 1 further comprising the step of applying a sealant coating to the bundle of hollow fibers to provide adhesion between fibers.