A device for evaporating liquid from collagen fibers.

Abstract

An apparatus for evaporating a liquid from collagen fibers includes a fiber forming system configured to form collagen fibers, a fiber collecting system configured to collect collagen fibers from the fiber forming system, and a first fan configured to generate an airflow above the surface of the collagen fibers between the fiber forming system and the fiber collecting system.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 494,931, filed Apr. 7, 2023, the benefit of whose priority is claimed herein and which is hereby incorporated by reference in its entirety.

[0002] (Statement Regarding Government Support) The data presented in this application was supported at least in part by DARPA SBIR 140D0420C0005. The United States Government has certain rights in this invention.

Background Art

[0003] (Field of Disclosure) This disclosure relates to methods for manufacturing collagen fibers, and the incorporation of collagen fibers into scaffolds, and transplantable biocompatible devices prepared using such fibers. In particular, this disclosure relates to an apparatus and method for evaporating liquid from extruded collagen fibers that have excellent mechanical strength, biocompatibility, and immunological properties.

[0004] (Description of Related Art) Collagen is a fibrous insoluble protein composed of bundles of fibrils. Collagen fibrils combine to form white, shiny, inelastic fibers that are a major component of connective tissues including skin, bone, ligaments, and cartilage.

[0005] Much effort has been made to manufacture collagen-containing scaffold-like tissues for use in the body, particularly to replace damaged collagenous body parts, including ligaments and tendons. The manufactured collagen-containing tissues can be considered implantable devices. Such implantable devices can directly replace damaged tissues or facilitate the repair of damaged soft tissues, ultimately functioning to provide a scaffold for replacing damaged soft tissues. Such products function in a variety of challenging biomechanical environments where multiple functional parameters must be addressed. These parameters include, for example, compatibility with body tissues and fluids, strength, flexibility, durability, and biodegradability.

[0006] In this field, there is a need for systems and methods to address the aforementioned shortcomings. [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] In one embodiment, the disclosure points to an apparatus for evaporating a liquid from collagen fibers, the apparatus comprising: a fiber forming system configured to form collagen fibers; a fiber collecting system configured to collect collagen fibers from the fiber forming system; and a first fan configured to generate an airflow between the fiber forming system and the fiber collecting system and above the surface of the collagen fibers. [Means for solving the problem]

[0008] In another embodiment, the disclosure points to an apparatus for evaporating a liquid from collagen fibers, the apparatus comprising a first support member and a plurality of first fans mounted on the first support member, and a second support member and a plurality of second fans mounted on the second support member, wherein the first and second support members form a channel.

[0009] In another embodiment, the present disclosure points to an apparatus for evaporating a liquid from collagen fibers, the apparatus comprising a plurality of manufacturing assemblies arranged parallel to one another, the first support member having a plurality of first openings and a plurality of first ports arranged along the entire length of the first support member, a plurality of first fans attached to the first support member above the first ports, a second support member having a plurality of second openings and a plurality of second ports arranged along the entire length of the second support member, and a plurality of second fans attached to the second support member above the second ports, the plurality of manufacturing assemblies comprising a plurality of manufacturing assemblies including a channel formed between the first support member and the second support member along the entire length of the first support member and the entire length of the second support member.

[0010] Other systems, methods, features, and advantages of the embodiments will be apparent to those skilled in the art upon consideration of the following drawings and detailed description. All such additional systems, methods, features, and advantages are contained within this description and summary, are within the scope of the embodiments, and are intended to be protected by the following claims. [Brief explanation of the drawing]

[0011] The embodiments can be better understood by referring to the following drawings and description. The components in the drawings are not necessarily to scale, and the emphasis is on illustrating the principle of the embodiments. Furthermore, with respect to the drawings, the same reference numerals indicate corresponding parts across different drawings.

[0012] [Figure 1] Figure 1 is a schematic flow diagram of an embodiment for producing biopolymer collagen fibers. [Figure 2] Figure 2 is a schematic diagram of an apparatus for producing biopolymer collagen fibers according to one embodiment. [Figure 3] Figure 3 is a schematic diagram of an evaporation system according to one embodiment. [Figure 4] Figure 4 is a schematic plan view of an evaporation system according to one embodiment. [Figure 5] Figure 5 is a schematic side view of a support member for an evaporation system according to one embodiment. [Figure 6] Figure 6 is a schematic end view of a channel in an evaporation system according to one embodiment. [Figure 7] Figure 7 is a schematic plan view of the channel of an evaporation system according to one embodiment. [Modes for carrying out the invention]

[0013] Exemplary embodiments provide systems and methods for producing biopolymer fibers. Biopolymer fibers may be formed from collagen source materials. Tellocollagen and atelocollagen are hydrogels that can function as collagen source materials. These hydrogels can be obtained from any collagen source tissue (bone, skin, and connective tissue, recombinants, jellyfish, etc.). For example, biocompatible polymers such as silk fibroin, other types of collagen such as type II collagen, fibrin / fibrinogen, basement membrane proteins, hyaluronic acid, polyethylene oxide, polyethylene glycol, polycaprolactone, polyethylene, polyhydroxybutyrate, PDLA, PDLLA and high molecular weight PDLLA, PLGA, and blends thereof can be blended with collagen source materials to form biopolymer fibers.

[0014] As described herein, collagen can be dissolved in an acidic solution to form a collagen solution that can be used as a collagen source material. In one embodiment, the prepared collagen solution can be passed through or injected at a first rate through one or more openings formed in a spinneret having a first diameter. The spinneret may be configured to allow the collagen solution to exit the slit as a plurality of elongated filaments. The spinneret itself is located in a fiber-forming fluid tank, such as a fluid tank containing a forming buffer. For the purposes of this disclosure, the terms “filament” or “fiber line” refer to an acidified collagen solution that is being extruded but has not been sufficiently exposed to the forming buffer tank to accumulate an outer sheath and become a collagen fiber or subfiber.

[0015] The formation buffer tank in the disclosed embodiment is configured as an elongated vertical tank, and the emergence of filaments from the opening may be positioned to occur near or from the bottom of the vertical tank. Thus, once the filaments emerge, they are immersed in the reaction zone for a sufficient time and rate to form collagen subfibers (also referred to herein more simply as “subfibers”). The buoyancy of the filaments and subfibers relative to the surrounding formation buffer allows them to float upward toward the top of the vertical tank. These resulting subfibers can then be collected together at the top of the vertical tank and drawn out. The subfibers may be collectively bonded to form a single collagen fiber, which may be crosslinked and dried. The collagen fiber may be wet or moist when collected. In such cases, the subfibers tend to stick together, especially if they come into contact during collection. Thus, when the subfibers are gathered into a bundle and wound together, they adhere to each other to form a collagen fiber.

[0016] To form a bundle, any number of subfibers may be associated, whether twisted or not, and the bundles may be assembled into larger bundles of multiple fibers. For example, a bundle may include between 2 subfibers and about 10,000 subfibers, or between about 4 subfibers and about 6,000 subfibers, typically between about 8 subfibers and about 4,000 subfibers, and more typically between about 12 subfibers and about 2,000 subfibers. Bundles may be combined by twisting or other means to form larger bundles. The bundles being combined do not need to have an equal number of fibers. Bundles may also be described by the number of fibers in the bundle. For example, 5 fibers may be called a penta fiber, 8 fibers produce an octa fiber, and so on. In some embodiments, such bundles can be produced using systems and apparatus having a different number of nozzles or extruders.

[0017] In various embodiments of this disclosure, collagen or collagen and other suitable biopolymers are prepared into biopolymers or collagen fibers. For ease of understanding, the features of this disclosure will be described in relation to collagen fibers. However, collagen may be blended or combined with suitable biopolymers in various combinations and proportions to obtain the types of fibers disclosed herein. In addition, throughout this specification, steps that are typically performed together in a typical manufacturing process, such as washing and drying or immersion and drying, may be performed or repeated as needed to achieve the desired results. For example, in one embodiment, the composition may be washed and dried before proceeding to the next step. In some embodiments, the material may pass through a vertical bath of forming buffer twice before proceeding to the next processing step. In other embodiments, the first washing or drying step may be optionally omitted. Thus, a material that is normally washed and then dried can proceed directly to the drying step and then to the next processing step. Those skilled in the art will recognize situations in which steps may be repeated or eliminated.

[0018] In different embodiments, constructs such as scaffolds made from fibers allow for internal growth of cells, i.e., various types of cells from the animal tissue into which the fibers (and devices made from the fibers) are implanted grow within the pores of the scaffold and preferably align with the fibers within the scaffold. The constructs and scaffolds can include single - layer and multi - layer articles that can be used as alternatives to known repair mechanisms, such as sutures used to re - attach opposing ends of a body part, e.g., a ruptured Achilles tendon. In addition to providing a support structure for use in repairing torn or damaged tendons, embodiments of the present disclosure are also suitable for ligament repair. Thus, scaffolds or other exemplary ligaments for which the present invention can provide support include the ACL, MCL, PCL, UCL, as well as other human and animal ligaments. Other surgeries for which the products of the present disclosure are useful include, as a treatment option for supraspinatus tendon avulsion, particularly superior capsular reconstruction, where partial or complete avulsion cannot be repaired or is difficult to repair. Similarly, multi - layer sheets may be used to overlay and reinforce repairs.

[0019] In particular, embodiments of the present disclosure can be suitable for the repair of ligaments, tendons, and other soft tissues of all types of animals. The collagen fibers of the present disclosure can be used, for example, to re - attach ligaments and tendons that have only partial tears. Also, multiple fibers can be twisted, bundled, braided, woven together, or otherwise arranged to improve the form factor, which can make the work or manipulation easier during surgery, for example, than a single fiber. Improving the form factor can make it easier to accurately position the fiber or platform. Other shape factors can be constructed to function as reinforcement or internal bracing for torn natural body parts. The brace connects from one bone to another to support a joint. Typically, the brace forms an isometric joint that has restored biomechanics and the isometry of the native joint.

[0020] In embodiments of the present disclosure, the fibers produced may be collagen-containing biopolymer fibers. The biopolymer fibers have one or more of the following properties: (a) an ultimate tensile strength of about 20 MPa to about 300 MPa, (b) an elastic modulus of about 200 MPa to about 3500 MPa, (c) a breaking strain with elongation of about 4 percent to about 12 percent, (d) an average fiber diameter of about 16 μm to about 500 μm or about 75 μm to about 300 μm or about 120 μm to about 160 μm after drying, and (e) retaining at least about 20 to 30% of their strength after immersion in a biological fluid for about 1 hour. The fibers may exhibit an ordered longitudinally oriented structure, and the fibers may allow infiltration of cell proliferation. The manufactured biopolymer collagen fibers can be used to support the repair of soft tissue damage or to develop implantable biopolymer scaffolds for the repair or replacement of body parts, wherein the scaffold comprises at least one biopolymer sheet containing biopolymer fibers. The sheet may contain fibers arranged in a typical manner for ease of handling during use. For example, a single fiber is very difficult to use due to its small diameter. Therefore, it may be necessary or appropriate to form a scaffold, or a structure larger than a single fiber, in order to provide a fiber-containing product suitable for the repair or replacement of body parts. Thus, for example, it may be possible to knit several fibers together to form a strand containing collagen fibers. Such a strand may be useful, for example, for suturing ruptures of ligaments or tendons.

[0021] In embodiments of the present disclosure, clinical-grade atelocollagen and telocollagen are used to form microfluidic extruded collagen microfibers, which can then be crosslinked with biological crosslinking agents such as glyoxal or DL-glyceraldehyde (DLG) and benign crosslinking agents. These crosslinked fibers exhibit a hydrated ultimate tensile strength of about 300 MPa and a modulus of elasticity exceeding about 3 GPa, are significantly stronger than 50 other crosslinking strategies tested, and exceed the strength of native human Achilles tendon and anterior cruciate ligament. Glyoxal crosslinked fibers further retained 50% of their initial load-bearing capacity over 3 to 6 months in culture. Collagen fibers implanted in rats showed biocompatibility, promoted the production of new host-generated aligned collagen growing along the fibers, and in the case of glyoxal crosslinking, promoted an enhanced regenerative M2 macrophage response. Embodiments of the present disclosure demonstrate significant improvements in healing compared to other crosslinked fibers, and embodiments of the present disclosure produce excellent fibers for use as strong collagen sutures or as devices for ligament, tendon, or other soft tissue repair.

[0022] A system and method for manufacturing collagen fibers can be described as comprising a section or manufacturing area. The collagen solution may be prepared in a first section, and the collagen fibers may be formed in a second section. The collagen fibers may be collected in a third section and post-treated in a fourth section, post-treatment, or final treatment to obtain wet or dry collagen fibers. That is, the steps in the system and method shown in FIG. 1 can be grouped into four categories as follows.

[0023] [Table 1]

[0024] As seen in step 105 of Figure 1, the collagen may be combined with an acidic solution and thoroughly stirred in step 110. In some embodiments, the acid may be acetic acid at a concentration of about 0.01 M to about 0.50 M. In other embodiments, the acid may be hydrochloric acid at a concentration of about 0.01 M to about 0.50 M. In step 115, the solution may be degassed. In step 120, the solution may be centrifuged to remove residual bubbles. One or more of steps 105 to 120 may be optionally omitted. For example, centrifugation in step 120 may be optionally omitted.

[0025] The resulting collagen solution can be injected as a filament stream into a forming solution tank in step 125 to form multiple subfibers. The resulting formed subfibers may be fitted with a coaxial sheath (indicated by a cross-section surrounding or encasing the filament) in step 130. The resulting product may be formed collagen subfibers, which can be bonded together to form collagen fibers. In different embodiments, the fibers may be followed by a collection system, which may be passed through an optional alcohol immersion tank in step 135 and optionally dehydrated in step 140. The collagen fibers may be recovered in step 145, collected on a spool in step 150, and air-dried. Post-processing may be performed on the recovered collagen fibers. Some examples of these technologies are described in more detail in U.S. Patent No. 11,020,509, entitled "Microfluidic Extrusion," issued on June 1, 2021, by Francis et al. (hereinafter referred to as the "Francis Application"), the disclosure of which is incorporated herein by reference in its entirety.

[0026] Figure 1 is intended to provide a generalized diagram of a system and method for carrying out embodiments of the present disclosure. Further details and disclosures are included in the following specific embodiments and embodiments described below.

[0027] Figure 2 illustrates an embodiment of the collagen fiber manufacturing apparatus (hereinafter referred to as the "apparatus") 200. In different embodiments, it may be understood that the apparatus 200 includes a plurality of interconnected systems, including a fiber forming system 210, a fiber pulley system 220, an alcohol immersion system 230, an evaporation system 240, and a fiber collection system 250. In one example, the systems are stabilized and held together by a framework 260. The following description will mainly focus on embodiments and features related to the evaporation system 240.

[0028] The appropriate arrangement and operation of the fiber formation system 210 is described in (172-MBDY-037), the entire disclosure of which is incorporated herein by reference. Furthermore, the appropriate arrangement and operation of the fiber pulley system 220 and the alcohol immersion system 230 is described in (172-MBDY-038), the entire disclosure of which is incorporated herein by reference. For clarity, the description refers to the distal and proximal directions (or distal portion and proximal portion) in the context of the collagen fiber production apparatus 200. As used herein, the distal direction is the direction away from the fiber formation system 210 toward the fiber collection system 250, and the proximal direction is the direction toward the fiber formation system 210 toward the fiber collection system 250. The proximal and distal directions may also be understood to refer to directions opposite to the longitudinal axis 262 characterized in Figure 2. Therefore, the term “longitudinal direction” as used throughout this detailed description and claims refers to the direction extending between the proximal side 292 and the distal side 294 of the collagen fiber manufacturing apparatus 200.

[0029] Furthermore, the term “lateral” as used throughout this detailed description and the claims refers to the direction extending along the width of the collagen fiber manufacturing apparatus 200. In other words, the lateral direction may extend between the left side 272 and the right side 274 of the collagen fiber manufacturing apparatus 200, characterized by the transverse axis 264 in Figure 2. Moreover, the term “vertical” as used throughout this detailed description and the claims refers to the direction generally perpendicular to the plane formed by the lateral and longitudinal directions. This may be characterized by the longitudinal axis 266 in Figure 2, extending in the direction between the upper and lower sides of the apparatus 200. For example, if a component has an end closer to the ground surface, the vertical direction may extend upward from the ground surface, as it did along the entire length of each vertical liquid tank. Thus, each of the three axes may be understood to be orthogonal to the other two axes. Furthermore, the term “inside” refers to a portion of a component that is positioned or enclosed by an outer surface, such as the inner chamber of a vertical liquid tank holding a buffer solution. Similarly, the term “outside” refers to a portion of a component that is positioned further away from the inside.

[0030] For clarity to the reader, embodiments can be characterized by various directional adjectives and reference parts. These directional and reference parts can facilitate the description of parts of the system, its components, and / or the entire apparatus. Furthermore, these directional and reference parts may also be used when describing each assembly of the apparatus (e.g., the apparatus, mechanical components, and other structural features). Therefore, for consistency and convenience, directional adjectives are used throughout this detailed description corresponding to the illustrated embodiments.

[0031] As described herein, collagen fibers are aggregates of subfibers gathered together as a single bundle. In some embodiments, the collagen fibers are moist or wet when collected after leaving the fiber-forming system 210. In such cases, the subfibers tend to adhere to one another, especially when in contact during collection. Thus, when the subfibers are gathered into a bundle and wound together, they naturally adhere to one another to form a collagen fiber.

[0032] According to one or more embodiments, the apparatus 200 assists in drying the collagen fibers produced by the fiber-forming system 210. The drying process can reduce the possibility of damage to the collagen fibers during subsequent handling. In some embodiments, the collagen fibers may be dried by exposure to the ambient environment as the collagen fibers are transferred from the fiber-forming system 210 to the fiber-collection system 250.

[0033] The surrounding environment of the apparatus 200 may be a controlled environment in which characteristics such as temperature and humidity are controlled. The drying of the collagen fibers can be controlled according to the characteristics of the surrounding environment. For example, an increase in temperature can accelerate the evaporation rate.

[0034] In some embodiments, the airflow around and through the apparatus 200 can be controlled. For example, the direction and velocity of the airflow can be controlled, and the velocity of the airflow over the collagen fibers can affect the rate at which a liquid, such as water, evaporates from the surface of the collagen fibers. In some cases, a fan, blower, or compressor can be used to control the airflow. For example, a fan may be located above or next to the apparatus 200.

[0035] Drying processes can generally be categorized into convection drying or direct drying, which involves applying heated air directly onto the material and drying it externally; contact drying or indirect drying, which involves transferring heat through the surface to dry the material; dielectric drying, which uses radiation or radio waves to transfer heat into the material and dry it internally; and air drying. Air drying may involve exposure to the ambient environment and the application of unheated forced air in the ambient environment. One or more of these methods may be used by the apparatus 200 to remove water or other liquids from collagen fibers.

[0036] The drying process can be carried out in the ambient environment with the help of an alcohol immersion system 230 or an evaporation system 240. The drying process can be carried out using any combination of the ambient environment, the alcohol immersion system 230, or the evaporation system 240. For example, in some embodiments, the alcohol immersion system 230 and the evaporation system 240 may be omitted, and the collagen fibers may be dried in the ambient environment.

[0037] The distance over which the collagen fibers travel through the surrounding environment can be configured to achieve a desired amount of drying. For example, the fiber collection system 250 can be positioned adjacent to the fiber formation system 210. In other examples, the fiber formation system 210 and the fiber collection system 250 may be positioned several centimeters to several meters apart.

[0038] In some examples, one or more of the alcohol immersion system 230 and the evaporation system 240 may be placed between the fiber forming system 210 and the fiber collection system 250. These components may have lengths of longitudinal distances selected to achieve a desired amount of drying. Thus, different overall lengths of the fiber forming system 210 and the fiber collection system 250 can be implemented. Furthermore, the lengths of the fiber forming system 210 and the fiber collection system 250 may be the same or different.

[0039] In some embodiments, the collagen fibers may be kept under tension by a tensioner as the fibers are dehydrated and / or until the collagen fibers are wound onto the collector of the fiber collection system 250. According to some embodiments, the collagen fibers may be wound by the fiber collection system 250 so that they can be maintained at a desired surface tension or within a desired range of surface tensions. The tension may be induced tension due to winding by the fiber collection system 250. The tension can be controlled by the fiber collection system 250.

[0040] In some embodiments, the collector of the fiber collection system 250 may be a grooved cylinder or a spool. The grooved cylinder or spool may be a collector particularly suitable for wet fibers. For example, the spool at the end of the system can be rotated at a speed that produces a tensile speed to achieve a desired tension. In one example, dry collagen fibers can be stretched onto the spool of the fiber collection system 250 at a speed faster than the injection speed of the prepared collagen solution, which may increase molecular alignment and decrease the diameter of the collagen fibers. The translational speed of the collector may be adjusted to control the separation between the collected fibers on the collector.

[0041] In some embodiments, collagen fibers may be dried by exposure to alcohol, which can bind with water in the collagen and aid in the formation of crosslinks in the collagen. In some examples, the alcohol immersion system 230 includes an ethanol bath. When the collagen fibers pass through the ethanol bath, they may be immersed in ethanol. The ethanol can penetrate the collagen fibers and bind with water in the collagen fibers to form a mixture of ethanol and water (EtOH). In the ethanol-water mixture, hydrogen bonds can be formed between the hydrogen groups of ethanol and the oxygen molecules of water molecules. The formation of the water-ethanol mixture may contribute to the formation of crosslinks in the collagen.

[0042] In some embodiments, exposure to alcohol in an alcohol immersion system 230 strengthens the collagen. The strengthened collagen fibers can then be exposed to a gaseous environment for dehydration, which may further strengthen the collagen fibers. In one example, immersion in alcohol prepares collagen fibers for subsequent exposure to a gaseous drying environment, which may include forced air drying and heating.

[0043] When the alcohol immersion tank system 230 is implemented, the water-ethanol mixture can exhibit different properties depending on the temperature. For example, dielectric constant, viscosity, density, and hydrogen bonding effect can all change with temperature. Therefore, the temperature of the alcohol immersion tank can be controlled to control the properties of the water-ethanol mixture. Similarly, the ambient temperature can be controlled to control the properties of the water-ethanol mixture when the collagen leaves the alcohol immersion tank system 230.

[0044] In some cases, the evaporation system 240 may be implemented to assist in drying the collagen fibers. For clarity, Figure 3 shows a separate view of an embodiment of the evaporation system 240. Once the collagen fibers are dried, they are less likely to adhere to the collagen fibers already collected on the fiber collection system 250.

[0045] In some examples, the evaporation system 240 includes a set of components. Generally, the evaporation system 240 dries collagen fibers. The evaporation system 240 can assist in the evaporation of water from collagen fibers. The evaporation system 240 can also assist in the evaporation of alcohol if an alcohol immersion bath is implemented. At least in part, the evaporation process includes a drying component. Drying can be understood as a process that uses evaporation to remove water from a liquid, gas, or solid. Drying can include removing water from a solution, suspension, solid-liquid mixture, or other substance. That is, the principle of drying may be applied to the circumstances of any material or substance.

[0046] The evaporation system 240 can increase the rate of liquid dehydration from the collagen fibers, thereby removing residual water from the collagen fibers. In some embodiments, the evaporation system 240 can increase the rate of liquid dehydration from the collagen fibers by forced convection using, for example, a fan blower or a compressor.

[0047] According to some embodiments, the evaporation system 240 includes a plurality of support members and a plurality of fans attached to the support members. More generally, in the drawings, the collagen fiber manufacturing apparatus 200 may be observed to include a repeating arrangement of components. For example, the evaporation system 240 can also be understood to comprise a plurality of substantially identical manufacturing assemblies. Each manufacturing assembly may include two opposing support members that form channels through which collagen fibers can pass from the proximal and distal sides of the evaporation system 240. By incorporating more assemblies, the collagen fiber manufacturing apparatus 200 enables mass production of collagen fibers and also enables the maintenance of production continuity in the event of an operational error or malfunction of one of the assemblies.

[0048] For brevity, this description will focus on a single manufacturing assembly of the evaporation system 240, while understanding that there may be multiple such assemblies operating in cooperation or in parallel within the collagen fiber manufacturing apparatus 200, as shown in Figure 2. In Figure 3, the first assembly can be understood to include a first support member 310 and a second support member 311 opposite the first support member 310. The first support member 310 and the second support member 311 form a channel 320 through which collagen fibers 321 can pass longitudinally from the proximal and distal sides of the evaporation system 240.

[0049] According to some embodiments, the evaporation system 240 dehydrates the collagen fibers 321, which can improve the quality and surface finish of the collagen fibers 321. The evaporation system 240 may include one or more fans that can assist in the dehydration of the collagen fibers. For example, a fan can force an airflow around and through the apparatus 200, including over the surface of the collagen fibers 321. The fan may be used to control the direction and speed of the airflow. In some cases, a fan, blower, or compressor may be used to control the airflow. For example, the fan may be positioned above, below, behind, or next to the apparatus 200.

[0050] When fans are arranged along channel 320, the fans may be spaced apart from each other. In some cases, the fans are not spaced apart, but are placed directly next to each other, with no space between them, forming a group of fans along channel 320. In at least one embodiment, different groups of fans may be spaced apart. The space between fans or groups may be regular or irregular.

[0051] The first support member 310 may be located in or on the first base 330. In one embodiment, the first base 330 includes components such as grooves that support the first support member 310. The first base 330 can be connected to the framework 260 by the first base 330. Additional bases can be used to support the first support member 310 along its entire longitudinal length. In some embodiments, the bases may be omitted, and the first support member 310 may be connected directly to the framework 260.

[0052] In some embodiments, the first support member 310 also supports the first fan 340 of a plurality of fans and includes the first opening 350 of a plurality of openings. The openings can establish space between the fans. The openings can have varying widths and heights. In one embodiment, each adjacent pair of fans may be arranged so as to have an opening between them. Thus, the plurality of fans and the plurality of openings may be arranged alternately along the entire longitudinal length of the first support member 310. In another example, the fans may be grouped together, and the groups of fans may be separated by openings. In yet another example, the plurality of openings may be arranged between two adjacent fans or groups of two adjacent fans.

[0053] The first support member 310 can support one or more fans. The fans may be arranged on both sides of the first support member 310.

[0054] In one embodiment, multiple support members for one or more fans are arranged along the sides of the channel 320, replacing a single support member along the entire length of the channel in the longitudinal direction. In yet another embodiment, a support member configured without an opening can connect the fan to the framework 260, where, for example, the support member is connected to the fan housing and does not obstruct the airflow through the fan. In some cases, the fan may be mounted directly to the framework 260, and the support member may be omitted. In yet another embodiment, the fan may be located independently of the device 200.

[0055] The second support member 311 supports the second fan 341 and may include a second opening 351. Similar to the first support member 310, each adjacent pair of fans on the second support member 311 may be arranged with an opening between them. For example, as shown in Figure 5, the second support member 311 may include a second fan 341 and a third fan 541, which are separated by the second opening 351. The fans positioned on both sides of the channel can be arranged in various ways. For example, the fan on one side of the channel may be positioned directly across from another fan on the opposite side of the channel. In another example, the fans may be positioned corresponding to an opening that crosses the channel. In yet another example, the fans crossing the channel may be offset from each other, and some parts of the fans may overlap.

[0056] In some embodiments, the second fan 341 of the second support member 311 faces the first opening 350 of the first support member 310, directly across the channel 320. The first fan 340 of the first support member 310 faces the second opening 351 of the second support member 311, directly across the channel 320. In some examples, each fan generates an airflow. In some embodiments, the airflow achieves forced air convection, which helps dewater the collagen fibers 321.

[0057] In some embodiments, the support member includes a port positioned in conjunction with the fan, so that the fan can push air through the channel onto the surface of the collagen fibers. For example, as shown in Figure 5, a second fan 341 may be mounted above a port 542 of a second support member 311.

[0058] The ports and openings of the support member can have various shapes. In some cases, the ports and openings may be rectangular. In some examples, the ports and openings may be round. For example, as shown in Figure 5, the ports may be round and the openings may be square. The ports and openings can have any shape.

[0059] In some embodiments, the ambient air can be heated, that is, the ambient conditions can be controlled with respect to temperature. In some cases, the ambient air can be dried so that the ambient conditions can be controlled with respect to humidity. In some examples, the apparatus 200 may include a heater for heating the environment in which the collagen fibers are dried. In some cases, the heater may be attached to or located near a support member to raise the temperature of the air around the evaporation system 240.

[0060] In some embodiments, the first support member 310 includes a first heater 370 positioned on or above the fan. The first heater 370 can be positioned at any location that can raise the temperature of the air in and around the channel 320. For example, the first heater 370 can be connected toward the framework 260.

[0061] The first heater 370 can raise the temperature of the air in and around the channel 320. The heated air can enhance the effectiveness of the evaporation system 240. Similarly, as shown in Figure 5, the second support member 311 includes a second heater 570 positioned on or above the fan.

[0062] Although the manufacturing assemblies are described as substantially identical, it should be noted that one or more of the manufacturing assemblies may differ. For example, a manufacturing assembly including a first support member 310 and a first base 330 may include only a single support member, while the other base supports a pair of support members. For example, as shown in Figure 4, a manufacturing assembly including a first support member 310 and a first base 330 may be an end assembly located at the leftmost position of the evaporation system 240.

[0063] Figure 4 is a schematic plan view of an evaporation system according to one embodiment. As shown in Figure 4, the second fan 341 of the second support member 311 and the first fan 340 of the first support member 310 may be offset across the channel 320. Each support member may have any number of fans and any number of openings.

[0064] In at least one example, the collagen fibers 321 may be drawn through the evaporation system 240 by the fiber collection system 250. The fiber collection system 250 draws the collagen fibers 321 at a rate such that a predetermined portion of the collagen fibers 321 remains inside the channel 320 for a predetermined time. The rate can be selected, for example, based on a desired amount of evaporation from the collagen fibers.

[0065] Referring again to Figure 4, upon entering the evaporation system 240, the collagen fibers have an initial state at 401 with a high water content and low tensile strength. As any portion of the collagen fiber moves in the direction of travel, the collagen fiber undergoes a dehydration process at 402, which can improve the tensile strength of that portion. Upon exiting the evaporation system 240, the dehydrated portion of the collagen fiber, due to the action of the evaporation system 240, may have a lower water content and improved tensile strength at 403 compared to the initial conditions.

[0066] Figure 6 is a schematic end view of a channel in an evaporation system according to an embodiment. Figure 7 is a schematic plan view of a channel in an evaporation system according to one embodiment. The channel 600 may be formed between a left support member 610 and a right support member 611. Collagen fibers 601 may be pulled over a fourth fan 660 of the right support member 611. Collagen fibers 601 may be pulled by a fiber collection system 250. A portion of the total length of the collagen fibers 601 may be supported by a guide rod 640. The guide rod 640 may be positioned horizontally to the ground and perpendicular to the total length of the channel 600 and the total length of the collagen fibers 601. Support structures such as the guide rod 640 may be independently supported by the framework 260 or its components. The guide rod 640 can ensure that the collagen fibers 601 are positioned inside the channel 600 and exposed to the turbulence within it.

[0067] The left support member 610 may be supported by the left base 620. The right support member 611 may be supported by the right base 621. The bases are attached to a framework 260 including a first longitudinal frame portion 630 and a second longitudinal frame portion 631. Each base may support one or more support members. For example, the right base 621 supports the right support member 611 and the jointly positioned support member 612. In some embodiments, the support members may be perpendicular to the base. In other configurations, the support members may be angled, for example, about 5 to 10 degrees from the perpendicular (or vertical) direction, as shown in Figure 3.

[0068] According to some embodiments, jointly arranged support members on a common base are positioned such that the fan of one support member aligns with the opening of the other support member. For example, the fourth fan 660 of the right support member 611 may be directly adjacent to the opening 661 of the jointly arranged support member 612. Thus, the airflow 650 may pass through the opening 661, be pulled by the fourth fan 660, and directed towards the collagen fibers 601 in the channel 600. Alternatively, the fourth fan 660 of the right support member 611 may directly face the opening 662 of the left support member 610 across the channel 600.

[0069] At a minimum, because the fans of the opposing support members are offset from each other, the airflow in the channel 600 can become turbulent 651. Turbulent 651 can improve the effectiveness of the evaporation system. As shown in Figure 6, the channel 600 may open above and below the collagen fibers 601. According to some embodiments, the collagen fibers 601 vibrate in the turbulent 651. The vibration of the collagen fibers 601 is amplified by opposing airflows, for example, a first airflow 652 coming out of a fourth fan 660 and a second airflow 653 coming out of a fifth fan 663. The first airflow 652 is in an offset direction opposite to the second airflow 653, which can be observed to enhance the vibration on the collagen fibers 601. According to some embodiments, the vibration of the collagen fibers 601 helps to release liquid from the collagen fibers 601.

[0070] As shown in Figure 7, channel 600 may be one of several channels. For example, channel 600 may be located between the left channel 602 and the right channel 603. The collagen fibers 604 on the left can be dried in the left channel 602, while the collagen fibers 605 on the right can be dried in the right channel 603.

[0071] As illustrated in Figure 6, the heater 670 can heat a portion of the passing airflow. The heater 670 can raise the temperature of the air inside and around the channel 600. The heated air can enhance the effectiveness of the evaporation system 240 in drying the collagen fibers 601. That is, the airflow 650 can be heated by the heater of the evaporation system 240, which increases the capacity of the airflow for evaporating water and drying the collagen fibers 601.

[0072] As described herein, the spool at the end of the system can be rotated at a speed that provides a tensile speed to achieve a desired tension in the collagen fibers. For example, the speed may be about twice the fiber formation speed to about four times the fiber formation speed, or about 2.5 times the fiber formation speed to about 3.5 times the fiber formation speed, or about 2.75 times to 3.25 times the fiber formation speed. In one example, the dried collagen fibers may be drawn onto the spool of the fiber collection system 250 at a speed about twice to about ten times faster than the injection speed of the prepared collagen solution. The tension on the collagen fibers induced by the fiber collection system 250 can increase molecular alignment within the collagen fibers and reduce the diameter of the collagen fibers.

[0073] The tension caused by spooling in the fiber collection system 250 may be used to control the fall of collagen fibers over at least a portion of its entire longitudinal length. The tension may also be used to assist in controlling the thickness of the collagen fibers. For example, the tension can stretch the collagen fibers, resulting in thinning. Furthermore, the tension may be used to control any residual stress that may remain in the collagen fibers once the tension is released, for example, when the collagen fibers are released from the fiber collection system 250.

[0074] In some embodiments, the drying process facilitated by the apparatus 200 can improve the quality and surface finish of the collagen fibers. In some embodiments, the drying process can also help maintain a consistent cross-section (within acceptable limits) and consistent properties over the entire length of the collagen fibers.

[0075] In some embodiments, the drying process can result in the formation of crosslinks in collagen fibers. These crosslinks in collagen fibers may be intramolecular linkages between collagen molecules, or they may be formed when water molecules are removed from the collagen. These intramolecular linkages may be amide bonds.

[0076] The evaporation system 240 can help strengthen collagen fibers by forming crosslinks in the collagen fibers. Specifically, crosslinking can be induced by removing water from the collagen fibers using the evaporation system 240. As described herein, collagen fibers can be made stronger during the drying process due to increased crosslinking between collagen molecules in the collagen fibers as water is removed. More specifically, the tensile strength of the collagen fibers can be increased as the water content of the collagen fibers is reduced and crosslinking is formed.

[0077] Tensile strength is a mechanical strength property. The tensile strength of a material defines the feasibility of the deformation that the material can withstand under applied load. The tensile strength of collagen can be understood as the maximum stress that the collagen can withstand before it breaks when stretched or pulled. Tensile strength may relate, for example, to the maximum elongation before the collagen material tears, on a percentage basis.

[0078] An exemplary embodiment also aims to produce collagen biopolymer fibers using a collagen fiber manufacturing apparatus having a drying function. Drying can be performed simultaneously on multiple collagen fibers by arranging multiple collagen fiber processing steps in parallel. Overall, this method provides simultaneous drying of multiple distinct collagen fibers. The steps described above for a single collagen fiber can be performed for each collagen fiber in a group of collagen fibers. In one embodiment, the group of collagen fibers are each drawn through an evaporation system that can dry or partially dry the collagen fibers.

[0079] The steps and methods of the embodiments described in this detailed description and shown in the figures may be implemented using any type of computing system having one or more central processing units (CPUs) and / or graphics processing units (GPUs). The steps and methods of the embodiments may also be implemented using special-purpose circuits, such as application-specific integrated circuits (ASICs). The steps and methods of these embodiments may also be implemented on a computing system including read-only memory (ROM) and / or random-access memory (RAM), which may be connected to one or more processing units. Examples of computing systems and devices include, but are not limited to, servers, mobile phones, smartphones, tablet computers, notebook computers, e-book readers, laptop computers or desktop computers, all-in-one computers, and various types of digital media players.

[0080] The steps and methods of the embodiments can be stored as instructions and / or data on a non-temporary computer-readable medium. The non-temporary computer-readable medium can include any suitable computer-readable medium, such as memory like RAM, ROM, flash memory, or any other type of memory well known in the art. In some embodiments, the non-temporary computer-readable medium can include, for example, electronic memory, magnetic memory, optical memory, electromagnetic memory, semiconductor memory, or any suitable combination of such devices. More specific examples of non-pass-through computer-readable memory media can include portable computer diskettes, floppy disks, hard disks, magnetic disks or tapes, read-only memory (ROM), random access memory (RAM), static random access memory (SRAM), portable compact disk read-only memory (CD-ROM), erasable memory programmable read-only memory (EPROM, or Flash Memory), electrically erasable memory programmable read-only memory (EEPROM), digital general-purpose disks (DVDs and DVD-ROMs), memory sticks, other types of solid-state drives, and any suitable combination of these exemplary media. Non-transient computer-readable media as used herein should not be construed as transient signals such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through waveguides or other transmission media (e.g., light pulses passing through optical fiber cables), or electrical signals transmitted through wires.

[0081] Instructions stored on a non-temporary computer-readable medium for performing the operation of the present invention may be instruction set architecture (ISA) instructions, assembler instructions, machine instructions, machine-dependent instructions, microcode, firmware instructions, configuration data for integrated circuits, state setting data, or source code or object code written in one or more programming languages, including object-oriented programming languages ​​such as Smalltalk, C++, or a suitable language, and procedural programming languages ​​such as the C programming language or a similar programming language.

[0082] While various embodiments are described, the description is intended to be illustrative rather than restrictive, and it will be apparent to those skilled in the art that many more embodiments and implementations are possible within the technical scope of the disclosed embodiments. Many possible combinations of features are shown in the accompanying drawings and discussed in this detailed description, but many other combinations of the disclosed features are possible. Any feature or element of any embodiment may be used in combination with or in place of any other feature or element of any other embodiment, unless otherwise specified. Furthermore, unless otherwise specified, any step in the method or function of the system may be performed in any relative order in relation to any other step described herein.

Claims

1. A device for evaporating liquid from collagen fibers, A fiber forming system configured to form the aforementioned collagen fibers, A fiber collection system configured to collect collagen fibers from the fiber formation system, A first fan configured to generate airflow between the fiber forming system and the fiber collecting system and above the surface of the collagen fibers, A device equipped with the following features.

2. The apparatus according to claim 1, wherein the first fan is one of a plurality of first fans configured to generate the airflow above the surface of the collagen fibers through the apparatus.

3. The apparatus according to claim 1, wherein the first fan is one of a plurality of first fans arranged on the first side of the collagen fiber, and the apparatus further comprises a plurality of second fans arranged on the second side of the collagen fiber, wherein the plurality of first fans and the plurality of second fans form a channel between the fiber forming system and the fiber collecting system.

4. The apparatus according to claim 3, wherein the arrangement of the plurality of first fans and the plurality of second fans is configured to generate turbulence and cause the collagen fibers to vibrate.

5. A first support member comprising a plurality of first ports arranged along the entire length of the first support member, wherein a plurality of the first fans are mounted on the first support member above the first ports, and the first support member and A second support member comprising a plurality of second ports arranged along the entire length of the second support member, wherein a plurality of the second fans are mounted on the second support member above the second ports, and the second support member and Furthermore, The first support member and the second support member form the channel along the entire length of the first support member and the entire length of the second support member. The apparatus according to claim 3.

6. The first support member comprises a plurality of first openings arranged along the entire length of the first support member, The second support member comprises a plurality of second openings arranged along the entire length of the second support member, The plurality of first fans of the first support member directly face the second opening of the second support member, and the plurality of second fans of the second support member directly face the first opening of the first support member. The apparatus according to claim 5.

7. The apparatus according to claim 3, further comprising a guide rod disposed inside the channel and perpendicular to the entire length of the channel.

8. The apparatus according to claim 1, further comprising a heater configured to heat the airflow between the fiber forming system and the fiber collecting system and above the surface of the collagen fibers.

9. A device for evaporating liquid from collagen fibers, The first support member and A plurality of first fans mounted on the first support member, The second support member, A plurality of second fans mounted on the second support member, Equipped with, The first support member and the second support member form a channel. Device.

10. The apparatus according to claim 9, further comprising a guide rod disposed inside the channel and perpendicular to the entire length of the channel, wherein the guide rod is configured to support the collagen fibers.

11. The apparatus according to claim 9, further comprising a heater configured to heat the air on the surface of the collagen fibers.

12. A first heater arranged along the entire length of the first support member, A second heater arranged along the entire length of the second support member, The apparatus according to claim 9, comprising:

13. The apparatus according to claim 9, wherein the plurality of first fans of the first support member are directly connected to the plurality of second fans of the second support member.

14. The apparatus according to claim 9, wherein the plurality of first fans of the first support member are offset from the plurality of second fans of the second support member.

15. The apparatus according to claim 9, further comprising a fiber collection system configured to pull the collagen fibers through the channel along the entire length of the channel.

16. The apparatus according to claim 9, wherein the arrangement of the plurality of first fans and the plurality of second fans is configured to generate turbulence inside the channel and cause the collagen fibers to vibrate.

17. A device for evaporating liquid from collagen fibers, A plurality of manufacturing assemblies arranged parallel to each other, wherein each manufacturing assembly is The first support member comprises a plurality of first openings and a plurality of first ports arranged along the entire length of the first support member, A plurality of first fans mounted on the first support member above the first port, The second support member comprises a plurality of second openings and a plurality of second ports arranged along the entire length of the second support member, A plurality of second fans mounted on the second support member above the second port, The manufacturing assembly comprises, Each manufacturing assembly includes a channel formed between the first support member and the second support member along the entire length of the first support member and the entire length of the second support member. Device.

18. The plurality of first fans of the first support member face directly opposite the second opening of the second support member inside each of the manufacturing assemblies. The apparatus according to claim 17, wherein the plurality of first fans of the first support member are offset from the plurality of second fans of the second support member inside each of the manufacturing assemblies.

19. The apparatus according to claim 17, wherein the arrangement of the plurality of first fans and the plurality of second fans inside each of the manufacturing assemblies is configured to generate turbulence inside the channel.

20. The apparatus according to claim 17, wherein the arrangement of the plurality of first fans and the plurality of second fans inside each of the manufacturing assemblies is configured to generate turbulence inside the channels of each of the manufacturing assemblies and to vibrate the collagen fibers.

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