Development of a new arterial-line filter design using computational fluid dynamics analysis

Arterial-line filters used during extracorporeal circulation continue to rely on the physical properties of a wetted micropore and reductions in blood flow velocity to affect air separation from the circulating blood volume. Although problems associated with air embolism during cardiac surgery persist, a number of investigators have concluded that further improvements in filtration are needed to enhance air removal during cardiopulmonary bypass procedures. This article reviews theoretical principles of micropore filter technology and outlines the development of a new arterial-line filter concept using computational fluid dynamics analysis. Manufacturer-supplied data of a micropore screen and experimental results taken from an ex vivo test circuit were used to define the inputs needed for numerical modeling of a new filter design. Flow patterns, pressure distributions, and velocity profiles predicted with computational fluid dynamics software were used to inform decisions on model refinements and how to achieve initial design goals of < or = 225 mL prime volume and < or = 500 cm2 of screen surface area. Predictions for optimal model geometry included a screen angle of 56 degrees from the horizontal plane with a total surface area of 293.9 cm2 and a priming volume of 192.4 mL. This article describes in brief the developmental process used to advance a new filter design and supports the value of numerical modeling in this undertaking.