Crane arm pulley system on a horizontal manufacturing plane for microfluidic extrusion

Abstract

A method and system for producing collagen biopolymer fibers involves dissolving clinical-grade collagen in an acidic solution to form a collagen solution, and extruding the collagen solution into a forming buffer tank to form multiple subfibers at a fiber formation rate. The subfibers are assembled together to form the starting end of a collagen fiber, which is attached to a pulley arm positioned above the horizontal processing equipment. The pulley arm feeds the collagen fiber into the horizontal processing equipment by moving across it at a fiber feeding rate equal to the fiber formation rate.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 494,923, 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 and systems for manufacturing collagen fibers. In particular, this disclosure relates to the use of a crane arm pulley in a method for extruding collagen fibers having excellent mechanical strength, biocompatibility, and immunological properties.

[0004] (Description of Related Art) Collagen is a fibrous insoluble protein composed of bundles of small fibrils. Collagen protein molecules bind to form the white, shiny, inelastic fibers of tendons, ligaments, and fascia. Collagen is found in connective tissues such as skin, bone, ligaments, and cartilage.

[0005] In particular, collagen fibrils bind to form strong connective tissues such as ligaments and tendons. Considerable efforts have been made to produce collagen - containing tissues for use in the body to replace damaged collagen body parts, particularly those including ligaments and tendons. Such implantable devices can directly replace damaged parts or function to facilitate the repair of damaged soft tissues such as tendons and ligaments and ultimately provide a scaffold for replacement.

[0006] Such products must function in a variety of challenging biomechanical environments that must address multiple functional parameters. These parameters include, for example, affinity to body tissues and fluids, strength, flexibility, and biodegradability.

[0007] In this field of technology, there is a need for systems and methods to address the shortcomings of the prior art described above. [Overview of the project] [Problems that the invention aims to solve]

[0008] In one embodiment, the present disclosure relates to a method for producing collagen biopolymer fibers, comprising: dissolving collagen, including clinical-grade and non-clinical-grade collagen, to form a collagen solution; extruding the collagen solution into a forming buffer tank to form a plurality of subfibers at a fiber formation rate; combining the plurality of subfibers together to form a starting end of a collagen fiber; attaching the starting end to a pulley arm located above the horizontal processing equipment; and supplying the collagen fiber into the horizontal processing equipment by moving the pulley arm across the horizontal processing equipment at a fiber supply rate equal to the fiber formation rate. [Means for solving the problem]

[0009] In one embodiment, the present disclosure relates to a method for producing collagen biopolymer fibers, comprising: dissolving collagen in a collagen solution to form a collagen solution; extruding the collagen solution into at least one formation buffer tank to form a group of subfibers at a fiber formation rate; combining each subfiber of the subfiber group to form the starting end of each of the group of collagen fibers; attaching each starting end of a pair of starting ends to each pulley arm of a plurality of pulley arms positioned above a horizontal processing facility; and supplying collagen fibers for each starting end of a pair of starting ends to the horizontal processing facility by moving the plurality of pulley arms across the horizontal processing facility at a fiber supply rate equal to the fiber formation rate.

[0010] In one embodiment, the disclosure points to a crane arm pulley system for use in the production of collagen biopolymer fibers. The crane arm pulley system includes a fixed frame positioned above a horizontal processing facility for processing collagen fibers formed at a fiber formation rate by combining groups of subfibers generated by extruding collagen, which was in an acidic solution for forming a collagen solution, into a formation buffer tank. An adjustable assembly is mounted on the fixed frame and includes a movable crane arm. The adjustable assembly is movable inside the fixed frame to position the movable crane arm three-dimensionally relative to the horizontal processing facility. The pulley arm is connected to the movable crane arm at a mounting point and is rotatable relative to the movable crane arm about the mounting point in a plane perpendicular to the horizontal processing facility. The pulley arm comprises a driven pulley rotatably mounted to the pulley arm at the end opposite the mounting point and a driven pulley communicating with the driven pulley and rotating the driven pulley.

[0011] Other systems, methods, features, and advantages of the present invention 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 present invention, and are intended to be protected by the following claims. [Brief explanation of the drawing]

[0012] 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.

[0013] [Figure 1] Figure 1 is a schematic flow diagram of an embodiment for producing biopolymer collagen fibers. [Figure 2] Figure 2 is an explanatory diagram of an embodiment of an apparatus for producing biopolymer collagen fibers, including a crane arm pulley system. [Figure 3] Figure 3 is an explanatory diagram of an embodiment of the pulley arm of a crane arm pulley system located above the horizontal processing equipment. [Figure 4] Figure 4 is an explanatory diagram of an embodiment of a pulley arm that rotates from an upward position to a downward position. [Figure 5] Figure 5 is a flowchart showing an embodiment of a method for producing biopolymer collagen fibers. [Figure 6] Figure 6 is an explanatory diagram of an embodiment of an adjustable assembly positioned relative to a horizontal processing unit. [Figure 7] Figure 7 is an explanatory diagram of an embodiment of collagen fibers attached to the driven pulley of a pulley arm. [Figure 8] Figure 8 is a schematic diagram of an embodiment of a driven pulley that is rotated to be attached to the entire length of a collagen fiber. [Figure 9]Figure 9 shows an embodiment of a pulley arm having attached collagen fibers that are lowered into a horizontal forming buffer for supplying through the horizontal forming buffer. [Figure 10] Figure 10 shows an embodiment of a pulley arm having attached collagen fibers that supplies collagen fibers through an ethanol liquid tank. [Figure 11] Figure 11 shows an embodiment of a pulley arm having attached collagen fibers that supplies collagen fibers through a forced air drying box. [Figure 12] Figure 12 shows an embodiment of a pulley arm having attached collagen fibers, in which collagen fibers are supplied through a fiber integrity monitoring system and the collagen fibers are removed from the driven pulley. [Figure 13] Figure 13 shows an example of an embodiment of collagen fibers attached to a collagen fiber spool. [Figure 14] Figure 14 shows an embodiment of collagen fibers collected on a collagen fiber spool during the collagen fiber formation process. [Modes for carrying out the invention]

[0014] Embodiments provide a system and method for manufacturing biopolymer fibers. An exemplary method for manufacturing biopolymer fibers is described in detail in U.S. Patent No. 11,020,509, issued June 1, 2021, entitled "Microfluidic Extrusion" by Francis et al., the disclosure of which is hereby incorporated by reference in its entirety. Generally, biopolymer fibers are typically formed from collagen. In particular, tropocollagen can be obtained from any source (human, bovine, recombinant, 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 formulated with collagen to form biopolymer fibers.

[0015] In one embodiment, the formation buffer tank of the disclosed embodiment is configured as an elongated vertical tank, and the filaments contain collagen emerging from an opening located near or at the bottom of the vertical tank. Once the filaments emerge, they are immersed in the formation buffer tank and proceed through the reaction zone at a rate that provides sufficient time in the formation buffer tank to form collagen subfibers, more simply referred to herein as “subfibers.” The greater buoyancy of the emerging filaments and subsequent subfibers relative to the surrounding formation buffer tank causes the subfibers to naturally float upward to the top of the elongated vertical tank. These resulting subfibers are then gathered together at the top of the vertical tank and proceed outside the vertical tank and formation buffer. A given set of subfibers are collectively joined to form a single collagen fiber. This single collagen fiber is then crosslinked and dried. In one embodiment, the resulting crosslinked and dried collagen fiber is wound onto a rotating collagen fiber spool that articulates vertically. In one embodiment, the collagen fiber spool is rotated at a spool rotation speed that matches the fiber formation rate spool. In one embodiment, the collagen fiber spool is rotated at a speed approximately 2 to 10 times faster than the injection speed of the collagen solution into the formation buffer tank, thereby increasing molecular alignment and reducing the fiber diameter.

[0016] In various embodiments of this disclosure, collagen, or collagen combined with other suitable biopolymers, is produced into biopolymers or collagen fibers. For illustrative purposes, embodiments are described using collagen. However, these embodiments are also applicable to collagen blended or combined with suitable biopolymers in various combinations and ratios to obtain the types of fibers disclosed herein. In addition, throughout this specification, steps that may be performed together during a typical manufacturing process, such as washing and drying or immersion and drying, may be appropriately performed or repeated to achieve the desired results. For example, in one embodiment, the material may be washed and dried before proceeding to the next step. In some embodiments, the material may pass through a second vertical forming buffer bath before proceeding to the next processing step. In other embodiments, the first washing or drying step may be performed optionally. Thus, a typically washed and then dried material can proceed directly to a 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.

[0017] In different embodiments, constructs made from collagen fibers, such as scaffolds, allow for intracellular growth. Thus, various types of cells from the animal into which the collagen fibers (or devices made from collagen fibers) are implanted grow within the pores of the scaffold and preferably align with the fibers within the scaffold. Constructs and scaffolds include monolayer and multilayer articles used as alternatives to known repair mechanisms, such as sutures used to reattach opposing ends of a ruptured Achilles tendon. In addition to providing a support structure for repairing torn or damaged tendons, collagen fibers manufactured according to exemplary embodiments of the methods disclosed herein are also suitable for use in ligament repair. Ligaments for which scaffolds made from collagen fibers can be used to provide support include the ACL, MCL, PCL, UCL, as well as other human and animal ligaments. Collagen fibers generated according to the exemplary methods disclosed herein can be used in other surgeries, including capsular reconstruction, as an option for treating supraspinatus tendon avulsion, which is otherwise irreparable or difficult to repair with partial or complete rupture. In addition, multilayer sheets containing collagen fibers can be used to stack and reinforce repairs.

[0018] A plurality of collagen fibers can be twisted, bundled, braided, woven together, or otherwise arranged to improve the form factor. This improved form factor produces collagen fibers that are easier to manipulate and handle during surgery, for example, than single fibers. The fact of the improved shape also makes it easier to accurately identify the position of the fiber or platform. Certain form factors may be constructed to function as a reinforcement or internal brace for a torn natural body part. The brace connects from one bone to another to support a joint and typically forms an isometric joint with restored biomechanics and the original isometry of the joint.

[0019] Referring first to Figure 1, one embodiment of a system and method for producing collagen fibers 100 is shown. As shown in the figure, the system includes four sections or production areas. The four sections include a first collagen solution preparation section and a second collagen fiber formation section. The other two sections are a third collagen fiber processing section and a fourth collagen fiber recovery section. As shown in Figure 1, the four sections of the system are associated with one or more steps in the method as follows:

[0020] [Table 1]

[0021] To prepare the collagen solution, collagen is combined with an acidic solution 105, and the combined collagen and acidic solution are thoroughly stirred 110. In one embodiment, the acid is acetic acid at a concentration of about 0.01 M to about 0.50 M. Alternatively, the acid is hydrochloric acid at a concentration of about 0.01 M to about 0.50 M. The resulting stirred collagen and acidic solution is degassed 115, centrifuged 120, and residual bubbles are removed.

[0022] To form collagen fibers, the obtained collagen solution is injected as a filament flow into a buffer solution reservoir to form multiple subfibers 125. The resulting subfibers 130 can incorporate a coaxial sheath (shown in cross-section as surrounding or enclosing the filament). The resulting product is a formed collagen subfiber, in which multiple collagen subfibers are bonded together to form a collagen fiber.

[0023] The resulting collagen fibers are then passed through one or more collagen fiber processing steps. These collagen fiber processing steps include, for example, post-processing, post-treatment, or end-of-process steps that produce wet or dry collagen fibers. As shown in the figure, the collagen fibers continue through a forming buffer solution 135 and emerge from there. After exiting the forming buffer solution, the collagen fibers pass through one or more drying or dehydration steps 140. These drying and dehydration steps include an ethanol solution tank and a forced air drying box. Following the collagen fiber processing steps, the collagen fibers are wound onto a collagen fiber spool 145 or mandrel. The resulting collagen fiber spool is then air-dried 150.

[0024] In one embodiment illustrated and described herein, the collagen fiber processing step includes a series of processes for drying and dehydrating the collagen fibers. These processing steps include an alcohol immersion tank and an air drying section. Thus, the collagen fibers are first passed through the alcohol immersion tank. Preferably, the alcohol immersion tank is an ethanol tank. As the collagen fibers pass through the ethanol tank, they are immersed in ethanol. The ethanol penetrates the collagen fibers and dehydrates them. Dehydration removes residual water from the collagen fibers.

[0025] The collagen fibers exit the alcohol immersion tank and enter an air-drying section. In one embodiment, the air-drying section is a forced-air drying box that includes multiple fans or other air transport devices that direct the flow of air or other gas across the collagen fibers in a direction perpendicular to the direction of propagation of the collagen fibers. The multiple fans are arranged in series along the entire length of the forced-air drying box. In one embodiment, one or more fans may also direct the airflow along the entire length of the collagen fibers. The air-drying section removes residual moisture from the collagen fibers.

[0026] The collagen fiber spool is rotated to wind the collagen fibers onto it. In one embodiment, the collagen fiber spool is rotated at a speed that maintains a desired residual stress along the entire length of the collagen fibers as they pass through the collagen fiber processing step. Thus, as the collagen fibers advance toward the collagen fiber spool, they become stronger as a result of the residual stress imposed by the collagen fiber spool and the dehydration and drying process that removes moisture and moisture content from the collagen fibers.

[0027] Figure 1 provides a generalized diagram of a system and method for carrying out a method for forming collagen fibers. During travel, this method propagates the collagen subfibers through a vertical buffer tank, relying on the buoyancy of the subfibers. The proper arrangement and operation of the vertical buffer tank are described in (172-MBDY-037), the entire disclosure of which is incorporated herein by reference. Once the collagen fibers are mounted on a rotating collagen fiber spool and the spool is rotated, the subfibers and collagen fibers form a continuous strand that passes through all parts of the system to form a long continuous collagen fiber. Buoyancy is used to initially pass or feed the subfibers through the vertical buffer tank, but the resulting collagen fibers also need to be routed through all subsequent processing steps and mounted on a collagen collection spool. This initial routing and mounting is preferably done to maintain a desired rate of collection of the fiber product. In addition, a desired tension is maintained within the collagen fibers, and the collagen fibers are rotated through the collagen fiber processing steps and exposed to the collagen fiber processing steps during the initial routine.

[0028] Exemplary embodiments provide apparatus and methods for producing collagen fibers, achieving a desired initial routing of collagen fibers throughout all collagen fiber processing steps. In one embodiment, a collagen fiber feeder system is provided within the apparatus for producing collagen fibers. The collagen fiber feeder system includes at least one fiber attachment mechanism for detachably attaching the starting end of a collagen fiber to the collagen fiber feeder system. In one embodiment, the collagen fiber feeder system includes a plurality of fiber attachment mechanisms. Any structure that provides detachable securing of fibers can be used. Suitable fiber attachment mechanisms include, but are not limited to, clamps, hooks, spindles, wheels, pulleys, and slits. At least one collagen fiber is attached to the collagen fiber feeder system. Preferably, a plurality of collagen fibers are attached to a collagen fiber feeder assembly, providing simultaneous supply of a plurality of fibers from collagen fiber formation through each collagen fiber processing step to collagen fiber collection.

[0029] The collagen fiber feeder system includes a support structure that supports all elements of the collagen fiber feeder system at desired positions relative to the collagen fiber forming section, the collagen fiber processing section, and the collagen fiber collection section. The positioning structure is provided within the collagen fiber feeder system. The positioning structure is movably mounted and supported by the support structure. The fiber attachment mechanism is connected to the positioning structure. Therefore, the movement of the positioning structure relative to the support structure provides movement of the fiber attachment mechanism, and thus of the collagen fibers attached to the collagen fiber forming section, the collagen fiber processing section, and the collagen fiber collection section. In one embodiment, the fiber attachment mechanism is two-dimensionally movable relative to the collagen fiber forming section, the collagen fiber processing section, and the collagen fiber collection section. Alternatively, the fiber attachment mechanism is three-dimensionally movable relative to the collagen fiber forming section, the collagen fiber processing section, and the collagen fiber collection section.

[0030] To provide the desired movement, the positioning structure includes, for example, a motor, brace, wheel, pulley, belt, cable, framing, and stretchable member. In one embodiment, the positioning structure also includes wiring and a control system for moving the positioning structure. In one embodiment, the control system is incorporated into a control system for an apparatus for producing collagen fibers. Alternatively, the control system is a separate control system. In one embodiment, the control system provides wireless control of the positioning structure. In one embodiment, the collagen fiber feeder system includes a handheld device for wireless communication and control of the positioning structure.

[0031] Referring here to Figure 2, an embodiment of the collagen fiber manufacturing apparatus 200 is shown. As shown, the collagen fiber manufacturing apparatus 200 includes the various interconnected parts or systems described above used to form collagen fibers. A single collagen fiber is manufactured using a given arrangement of interconnected and series-arranged parts. These parts include a fiber forming section 210, a collagen fiber processing section 230, and a collagen fiber collection section 250. As shown, multiple arrangements of these parts are arranged in parallel. Thus, the collagen fiber manufacturing apparatus manufactures multiple collagen fibers simultaneously and in parallel. The collagen fiber manufacturing apparatus includes a framework 251 for supporting all components of the fiber forming section 210, the collagen fiber processing section 230, and the collagen fiber collection section 250.

[0032] As shown in the illustration, the fiber formation unit 210 includes a vertical buffer tank 212 for forming collagen subfibers. The fiber processing unit 230 is arranged as a horizontal processing unit including a plurality of collagen fiber processing steps for processing collagen fibers formed at a fiber formation rate. As shown in the illustration, these collagen fiber processing steps include a horizontal forming buffer stretching unit 214, an ethanol solution tank unit 216, a forced air drying box unit 274, and a fiber integrity monitoring unit 218. A preferred forced air drying box unit is described in (172-MBDY-039), the entire disclosure of which is incorporated herein by reference. Each collagen fiber processing step may have an open top or be openable top to facilitate the initial insertion of collagen fibers into the collagen fiber processing step. The collagen fiber collection unit 250 includes one or more collagen fiber spools 220.

[0033] The collagen fiber manufacturing apparatus 200 also includes a collagen fiber feeder system configured as a crane arm pulley system used for the production of collagen biopolymer fibers. In this embodiment, the crane arm pulley system includes a support structure positioned as a fixed frame 222 located above the horizontal processing equipment. The fixed frame does not move relative to the horizontal processing equipment and includes all the horizontal and vertical support members necessary to support the other components of the crane arm pulley system.

[0034] The crane arm pulley system includes an adjustable assembly 224 mounted on a fixed frame as a positioning structure. The adjustable assembly engages with two parallel top support members 228 of the fixed frame 222. In particular, the adjustable assembly engages with the upper surface 230 of each top support member. The adjustable assembly is movable relative to the fixed frame. In one embodiment, the adjustable assembly is movable or slidable along the upper surface of the top support member. This provides movement of the adjustable assembly and all components of the adjustable assembly in a first dimension as indicated by arrow A. This first dimension is parallel to the horizontal support structure between the fiber forming section 210 and the collagen fiber collection section 250.

[0035] The adjustable assembly includes a movable crane arm 226. The movable crane arm extends downward from a top support member toward a horizontal processing unit. The movable crane arm includes at least one vertical assembly 232 and a horizontal support member 234 attached to one end of the vertical assembly. In one embodiment, the vertical assembly is an extendable or retractable assembly. This allows the movable crane arm and the elements attached to the movable crane arm to move in the direction of arrow C. The movable crane arm is also movable between the top support members in the direction of arrow B. Thus, this adjustable assembly is movable within a fixed frame and positions the movable crane arm three-dimensionally relative to the horizontal processing unit.

[0036] In one embodiment, the adjustable assembly includes one or more motors 236 or actuators that provide the desired movement of the adjustable assembly. These motors are mounted on power and control electronics (not shown) to provide motor operation and control for positioning and movement of the adjustable assembly. In one embodiment, the adjustable assembly provides wireless communication and control. Thus, the collagen fiber manufacturing apparatus 200 includes a handheld device 238 or remote control for wireless control of the adjustable assembly.

[0037] The adjustable assembly includes at least one fiber attachment mechanism, which is arranged as a pulley arm 240. In one embodiment, the adjustable assembly includes a plurality of pulley arms 240. In one embodiment, the adjustable assembly includes a number of pulley arms equal to the number of parallel collagen processing steps in the horizontal processing equipment. Alternatively, the number of pulley arms is less than the number of collagen processing steps. As shown in the figure, the adjustable assembly includes four pulley arms. Referring here to Figure 3, each pulley arm 240 is connected to a horizontal support member 234 of a movable crane arm 226. Thus, the pulley arms extend continuously parallel to the horizontal processing equipment 230. Each pulley arm includes an arm portion 246 rotatably mounted to the horizontal support member 234. Furthermore, each pulley arm includes a driven pulley 244 rotatably mounted to the pulley arm on the end opposite to the mounting point with the horizontal support member, e.g., the distal end. In one embodiment, each pulley arm is equipped with a motor 242 that communicates with a driven pulley and rotates the driven pulley.

[0038] As shown in the figure, the pulley arm is in the raised position together with the driven pulley located above the horizontal support member. Referring here to Figure 4, each pulley arm is attached to the horizontal support member 234 at mounting point 252. The pulley arm is rotatable relative to the movable crane arm and the horizontal support member as indicated by arrow D, and in particular, each pulley arm is rotatable around the mounting point in a plane perpendicular to the horizontal processing equipment. Thus, each pulley arm can be rotated downward toward the horizontal processing equipment and upward away from the horizontal processing equipment in the direction of arrow D. In one embodiment, each pulley arm is rotated independently by hand between the raised position and the downward or lowered position. In the lowered position, the driven pulley is located between the horizontal support member and the horizontal processing equipment. Each driven pulley includes a fiber contact surface 248 and a pulley drive surface 253. The fiber contact surface is used to attach the entire length of the collagen fiber to the driven pulley and thus to the crane arm pulley system. The pulley drive surface is attached to a cable or belt 254, which is also attached to a driven pulley 256 driven by a pulley motor 242. Therefore, the pulley motor can selectively rotate the driven pulley in the direction of arrow E.

[0039] Referring here to Figure 5, an exemplary embodiment of a method (300) for using a collagen fiber manufacturing apparatus having a crane arm pulley system to produce collagen fibers is shown. The formation of the filament flow is initiated in a vertical buffer tank (302). At least one of the pulley arms is rotated downward from an elevated position (304), and an adjustable assembly is used to position a driven pulley adjacent to and above the top of one of the vertical buffer tanks using more of the pulley arms (306). The top of the collagen processing chamber, which was previously closed, is then opened (308).

[0040] As subfibers emerge from the top of the vertical buffer bath, they are formed into collagen fibers (310). In one embodiment, the subfibers are formed into collagen fibers manually. The starting end of the collagen fiber is positioned on the fiber contact surface of the driven pulley (312). In one embodiment, the starting end of the collagen fiber is positioned manually on the fiber contact surface. A pulley motor is operated to rotate the driven pulley in a desired direction of rotation (314). The driven pulley is rotated a number of times sufficient to attach and secure the collagen fiber to the driven pulley. Once the collagen fiber is properly attached, the rotation of the driven pulley is stopped (316). The driven pulley is then lowered into the collagen fiber processing step (318). In one embodiment, this first collagen fiber processing step is a horizontal forming buffer stretching step. Preferably, the driven pulley is lowered a sufficient distance so that the collagen fiber extending from the pulley is fully immersed in or engaged with the first collagen fiber processing step. If necessary, the driven pulley is moved to align with the path through the collagen fiber processing step.

[0041] The driven pulley moves through each collagen fiber processing step in succession (320). The driven pulley is adjusted vertically up and down as needed to pass between adjacent collagen fiber processing steps while keeping the collagen fibers engaged in each processing step. After the driven pulley has passed through the final collagen fiber processing step, the collagen fibers are removed from the driven pulley (322). In one embodiment, the collagen fibers are removed from the driven pulley manually. In one embodiment, the driven pulley is rotated to unwind the collagen fibers. The collagen fibers are then attached to a collagen fiber spool (324), and the top of the collagen fiber processing step is closed (326).

[0042] The collagen fiber manufacturing apparatus can continue to operate to produce collagen fibers to a desired length. The pulley arm is moved upward away from the horizontal processing equipment and manually rotated to the raised position. The collagen fiber manufacturing apparatus is then operated to produce collagen fibers to be collected on the collagen fiber spool. In one embodiment, a remote control device is used to control the movement of the pulley arm and the rotation of the driven pulley.

[0043] An exemplary method for producing collagen biopolymer fibers is described with respect to an embodiment of a collagen fiber production apparatus having a crane arm pulley system. As described herein, collagen, including clinical-grade and non-clinical-grade collagen, is dissolved in an acidic solution to form a collagen solution. The collagen solution is extruded, for example, in a vertical buffer tank into a forming buffer tank. Referring now to Figure 6, an adjustable assembly 224 moves at least one pulley arm 240, which is in an elevated position relative to a horizontal support member 234 above the horizontal processing equipment, as indicated by arrows A and B. This moves the pulley arm toward the top of the vertical buffer tank. In one embodiment, the adjustable assembly moves all of the pulley arms attached to the horizontal support member simultaneously.

[0044] Next, referring to Figure 7, the given pulley arm 240 rotates around the mounting point 252 to the horizontal support member so that the driven pulley 244 is positioned between the horizontal support member and the horizontal processing equipment 230. The adjustable assembly continues to move the pulley arm 240 in the directions of arrows A, B, and C to position the driven pulley 244 above the horizontal forming buffer extension 214 and adjacent to the top of the vertical buffer tank 260.

[0045] Multiple subfibers 262 are formed at the fiber formation rate. As the subfibers emerge from the top of the buffer solution 268, they combine together to form the starting end 266 of the collagen fiber 264. The starting end is then attached to the pulley arm by attaching it to the fiber contact surface 248 of the driven pulley 244.

[0046] Referring now to Figure 8, first, in (a), the starting end 404 of the collagen fiber is attached to a driven pulley 402 which is rotatably mounted on the arm portion 400 of the pulley arm 406. The driven pulley is then rotated in the direction of arrow E. In one embodiment, a remote control device is used to control a motor for rotating the driven pulley. In (b), the first rotation of the driven pulley pulls a collagen fiber onto the driven pulley that is at least equal in length to the circumference of the fiber contact surface 408 of the driven pulley. In (c), the second rotation of the driven pulley pulls another collagen fiber of equal in length to the circumference of the fiber contact surface of the driven pulley onto the driven pulley. Each rotation pulls a length of collagen fiber equal to the circumference of the fiber contact surface, and the driven pulley is rotated to pull one or more windings of the collagen fiber onto the fiber contact surface. Generally, the driven pulley rotates through enough rotations to fix the collagen fiber to the driven pulley, and therefore to the pulley arm. In one embodiment, the driven pulley is rotated at a pulley rotation speed that matches the fiber formation rate. As described herein, another driven pulley, mounted on the pulley arm and in contact with the driven pulley, is used to rotate the driven pulley.

[0047] The driven pulley is rotated so that the collagen fibers extend tangentially from the driven pulley. Once a sufficient amount of collagen fibers are wound onto the driven pulley, the rotation of the driven pulley is stopped before the collagen fibers are fed into the horizontal processing equipment, through the collagen fiber processing process. Next, referring to Figure 9, the collagen fibers 264 extend tangentially from the driven pulley 244 toward the vertical buffer tank 260. This positions the collagen fibers between the driven pulley and the horizontal processing equipment 230, facilitating the stretching of the collagen fibers along and through the collagen fiber processing process. The pulley arm 240 is moved downward in the direction of arrow C until at least a portion of the collagen fibers and the driven pulley are below the height of the buffer solution 268 in the horizontal forming buffer stretching section 214. In one embodiment, this maintains the collagen fibers in the buffer solution and thus continues the processing of the collagen fibers. The pulley arm 240 is then moved in the direction of arrow A relative to the horizontal processing equipment by an adjustable assembly. In one embodiment, the pulley arm is moved simultaneously in both the directions of arrows A and C. In another embodiment, the pulley arm is moved manually using a remote control device. Alternatively, the pulley arm is moved according to a programmed movement initiated, for example, by a remote control device. The programmed movement includes the path and speed of the pulley arm.

[0048] Referring here to Figure 10, the horizontal processing equipment includes at least one, preferably more, collagen fiber processing steps extending across the horizontal processing equipment. The pulley arm and adjustable assembly continue to supply collagen fibers to the horizontal processing equipment by moving the pulley arm across the horizontal processing equipment in the direction of arrow A at a fiber supply rate equal to the fiber formation rate. The pulley arm is moved relative to the horizontal processing equipment to engage in series with the collagen fibers extending from the driven pulley in each collagen fiber processing step. In one embodiment, the movement of the pulley arm is controlled manually, for example, using a remote control device. Alternatively, the pulley arm moves according to a programmed motion that can be initiated by remote control.

[0049] After the horizontal forming buffer stretching section 214, the pulley arm 240 and driven pulley 244 pull the collagen fibers through the ethanol tank section 216. The lid 276 of the ethanol tank section is opened to facilitate the passage of the pulley arm and driven pulley through the ethanol tank section. Furthermore, the pulley arm and driven pulley move up and down in the direction of arrow C as the collagen fiber processing process propagates. This allows the collagen fibers to be lifted onto the support members 270 located at the ends of each section. Suitable support members include glass, stainless steel, or plastic rods that support the collagen fibers as they move from one section to the next. After the support members are removed, the pulley arm 240 and driven pulley 244 are lowered so that at least the collagen fibers extending from the driven pulley are below the level of ethanol 272 in the ethanol tank section.

[0050] Next, referring to Figure 11, the pulley arm 240 and driven pulley 244 move out of and through the ethanol liquid tank, drawing the collagen fibers through the forced air drying box 274. The top 282 of the forced air drying box is open to provide a passage for the pulley arm 240 and driven pulley through the forced air drying box. Forced air for drying is provided by a plurality of fans 280 located along the length of the forced air drying box. The pulley arm 240 and driven pulley 244 are positioned perpendicular to the forced air drying box, and as a result, the collagen fibers 264 are positioned in the flow of forced air.

[0051] Next, referring to Figure 12, after passing through the forced air drying box section 274, the pulley arm 240 and driven pulley 244 draw out the collagen fibers through the fiber integrity monitoring section 218. The top 284 of a given fiber integrity monitor 219 is opened to facilitate the passage of the pulley arm 240 and driven pulley 244 and the supply of collagen fibers 264 to the fiber integrity monitor.

[0052] The pulley arm 240 and driven pulley 244 continue to move in the direction of arrow A until they are separated from the fiber integrity monitoring system 218 and positioned adjacent to the collagen fiber spool 220. The movement of the pulley arm 240 and driven pulley 244 is stopped, and the starting end 266 of the collagen fiber 264 is removed or detached from the driven pulley of the pulley arm. Thus, the collagen fiber is separated after it has been completely fed through the horizontal processing equipment.

[0053] Referring to Figure 13, the starting end of the collagen fiber 264 is attached to the collagen fiber spool 220, which is rotated at a desired speed for the collagen fiber formation process. All lids of the collagen fiber processing unit are closed, and the pulley arm 240 and driven pulley 244 are moved vertically upward from the horizontal processing unit in the direction of arrow C. The adjustable assembly is finally returned to its initial position, as illustrated, for example, in Figure 3. If necessary, the adjustable assembly can be moved into place to supply one or more additional collagen fibers through the collagen fiber processing unit. Thus, the processing unit is repeated for each collagen fiber supplied through the collagen fiber processing unit.

[0054] Referring to Figure 14, the collagen fiber spool 220 rotates at a desired rotational speed and moves vertically to accumulate multiple windings 290 of collagen fibers 264 on the collagen fiber spool. The collagen fiber spool continues to rotate and move vertically until collagen fibers of the desired length have been produced by the collagen fiber formation process and collected on the spool.

[0055] An exemplary embodiment also aims to produce collagen biopolymer fibers using a collagen fiber manufacturing apparatus equipped with a crane arm pulley system to simultaneously supply multiple collagen fibers through multiple parallel-arranged collagen fiber processing steps. Overall, this method provides the simultaneous supply of multiple distinct collagen fibers. The process described above for a single fiber is performed for each fiber in the multiple fibers. In one embodiment, each of the multiple pulley arms is lowered and positioned adjacent to the top of one of the multiple vertical buffer tanks, and the starting end of one collagen fiber is attached to its pulley arm. This process is repeated until multiple collage fibers are attached to the multiple pulley arms. Then, all of the pulley arms are simultaneously moved in a straight line through the collagen fiber processing steps.

[0056] Generally, for this exemplary method, collagen is dissolved in an acidic solution to form a collagen solution, which is then extruded into at least one forming buffer tank at a fiber-forming rate to form multiple subfiber groups. Preferably, the collagen solution is extruded into multiple forming buffer tanks to form groups of subfibers in each forming buffer tank.

[0057] The subfibers in each subfiber group are combined together to form the starting end for each collagen fiber of a group of collagen fibers. Each pulley arm in the group of pulleys is pivotally mounted to a movable crane arm supported above a horizontal processing facility that includes multiple collagen fiber processing steps arranged in series. An adjustable assembly including the movable crane arm is used to move each pulley arm three-dimensionally relative to the horizontal processing facility. The adjustable assembly and movable crane arm position the group of pulley arms and driven pulleys adjacent to the forming buffer tank.

[0058] Each start end in a pair of start ends is attached to one pulley arm of a plurality of pulley arms positioned above the horizontal processing equipment. In one embodiment, a pair of start ends is associated with fewer collagen fibers than the plurality of collagen fibers formed by the extrusion process. Alternatively, a pair of start ends is associated with all of the collagen fibers in the plurality of collagen fibers. In one embodiment, each start end is attached to each pulley arm by positioning each start end on the fiber contact surface of a driven pulley rotatably mounted to each pulley arm. The driven pulley is rotated to pull one or more windings of each collagen fiber onto the respective fiber contact surface.

[0059] An adjustable assembly and a movable crane arm move all the pulley arms and driven pulleys across the horizontal processing equipment. The pulley arms and driven pulleys feed collagen fibers into the horizontal processing equipment for each of a pair of starting ends by moving multiple pulley arms across the horizontal processing equipment at a fiber feed rate equal to the fiber formation rate. Multiple pulley arms move simultaneously across the horizontal processing equipment so that multiple collagen fibers are supplied simultaneously throughout the collagen fiber processing process. This engages the collagen fibers attached to each pulley arm in each collagen fiber processing process. Each collagen fiber is drawn out simultaneously and continuously throughout each collagen fiber processing process.

[0060] Once multiple collagen fibers have passed through all the collagen fiber processing steps, each collagen fiber is separated from its respective pulley arm. Each starting end of a pair of starting ends is attached to each collagen fiber spool of multiple collagen fiber spools, which operate at a spool rotation speed matching the fiber formation rate.

[0061] While various embodiments of the present invention have been 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 scope of the invention. Therefore, the present invention is not limited except in light of the appended claims and their equivalents. Furthermore, various modifications and changes can be made within the scope of the appended claims.

Claims

1. A method for producing collagen biopolymer fibers, Dissolving collagen in an acidic solution to form a collagen solution, The collagen solution is extruded into a forming buffer tank to form multiple subfibers at a fiber formation rate, Multiple subfibers are combined together to form the starting end of a collagen fiber, The starting end is attached to a pulley arm positioned above the horizontal processing equipment, The collagen fibers are supplied to the horizontal processing equipment by moving the pulley arm across the horizontal processing equipment at a fiber supply rate equal to the fiber formation rate. A method for producing collagen biopolymer fibers, including [the specified element].

2. Attaching the aforementioned starting end to the pulley arm means The starting end is positioned on the fiber contact surface of the driven pulley, which is rotatably mounted on the pulley arm. Rotating the driven pulley in order to draw one or more windings of the collagen fiber onto the fiber contact surface, The method according to claim 1, including the method described in claim 1.

3. Rotating the driven pulley further includes rotating the driven pulley through a plurality of rotations, The multiple rotations are sufficient to secure the collagen fiber to the driven pulley, and each rotation attaches the entire length of the collagen fiber, which is equal to the outer circumference of the fiber contact surface. The method according to claim 2.

4. The method according to claim 2, further comprising rotating the driven pulley at a pulley rotation speed that matches the fiber formation rate.

5. The method according to claim 2, wherein rotating the driven pulley includes rotating the driven pulley such that the collagen fibers extend tangentially from the driven pulley between the driven pulley and the horizontal processing equipment.

6. The method according to claim 2, wherein rotating the driven pulley includes using a driven pulley attached to the pulley arm and in contact with the driven pulley in order to rotate the driven pulley.

7. The method according to claim 2, further comprising stopping the rotation of the driven pulley before supplying the collagen fibers to the horizontal processing equipment.

8. The horizontal processing equipment comprises at least one collagen fiber processing step extending across the horizontal processing equipment, The collagen fiber includes clinical-grade collagen fiber, Each collagen fiber processing step further includes moving the pulley arm relative to the horizontal processing equipment to engage the collagen fibers extending from the driven pulley, Supplying the collagen fibers to the horizontal processing equipment includes continuously pulling the collagen fibers through each of the collagen fiber processing steps. The method according to claim 2.

9. The pulley arm is pivotably attached to a movable crane arm supported above the horizontal processing equipment. The further includes using the movable crane arm to move the pulley arm in two dimensions relative to the horizontal processing equipment. The method according to claim 1.

10. The method according to claim 9, wherein the movable crane arm is used to move the pulley arm in three dimensions relative to the horizontal processing equipment.

11. After the collagen fibers have been supplied to the horizontal processing equipment, the collagen fibers are removed from the pulley arm. The starting end is attached to a collagen fiber spool that operates at a spool rotation speed matching the fiber formation rate. The method according to claim 1, further comprising:

12. A method for producing collagen biopolymer fibers, Dissolving collagen in an acidic solution to form a collagen solution, The collagen solution is extruded into at least one formation buffer tank to form groups of multiple subfibers at a fiber formation rate, The subfibers in each group of the subfibers are combined together to form a starting end for a plurality of collagen fibers, Each of the multiple pulley arms positioned above the horizontal processing equipment is fitted with a set of the starting ends at each of the aforementioned starting ends. By moving a plurality of pulley arms across the horizontal processing equipment at a fiber supply rate equal to the fiber formation rate, collagen fibers for each of the starting ends of a set of starting ends are supplied to the horizontal processing equipment. A method for producing collagen biopolymer fibers, including [the specified element].

13. The method according to claim 12, wherein a set of starting ends is associated with fewer collagen fibers than a plurality of collagen fibers.

14. The method according to claim 12, wherein moving the plurality of pulley arms across the horizontal processing equipment includes moving the plurality of pulley arms simultaneously across the horizontal processing equipment.

15. Attaching each of the starting ends to each of the pulley arms is, The starting ends of the driven pulleys, which are rotatably mounted on each of the pulley arms, are positioned on the fiber contact surfaces of the driven pulleys. Rotating the driven pulley in order to pull one or more windings of each collagen fiber onto each fiber contact surface, The method according to claim 12, including the method described in claim 12.

16. The horizontal processing equipment includes at least one collagen fiber processing step extending across the horizontal processing equipment, Each collagen fiber processing step further includes moving each pulley arm relative to the horizontal processing equipment in order to engage the collagen fibers attached to each pulley arm, Supplying each of the collagen fibers to the horizontal processing equipment includes continuously and simultaneously pulling each of the collagen fibers through each of the collagen fiber processing steps. The method according to claim 12.

17. Each of the pulley arms is pivotably attached to a movable crane arm supported on the upper side of the horizontal processing equipment. The further includes using the movable crane arm to move each of the pulley arms in three dimensions relative to the horizontal processing equipment, The method according to claim 12.

18. After each collagen fiber is supplied to the horizontal processing equipment, each collagen fiber is removed from each pulley arm. Each of the starting ends of a set of starting ends is attached to each of the collagen fiber spools of a plurality of collagen fiber spools that operate at a spool rotation speed matching the fiber formation rate. The method according to claim 12, further comprising:

19. A crane arm pulley system used for the manufacture of collagen biopolymer fibers, wherein the crane arm pulley system is To process collagen fibers formed at a fiber formation rate by combining groups of subfibers created by extruding collagen in an acidic solution into a formation buffer tank for forming a collagen solution, a fixed frame positioned above the horizontal processing equipment is used, An adjustable assembly, mounted on the fixed frame and comprising a movable crane arm, wherein the adjustable assembly is movable within the fixed frame to position the movable crane arm in three dimensions relative to the horizontal processing equipment, A pulley arm connected to the movable crane arm at the mounting point, and rotatable relative to the movable crane arm about the mounting point in a plane perpendicular to the horizontal processing equipment, A driven pulley is rotatably attached to the pulley arm at the end opposite to the mounting point, In order to rotate the driven pulley, a driven pulley communicating with the driven pulley, The pulley arm includes, A crane arm pulley system equipped with this system.

20. The crane arm pulley system according to claim 19, comprising a plurality of pulley arms mounted on the adjustable frame and extending in a straight line parallel to the horizontal processing equipment and perpendicular to the plane on which each pulley arm rotates, wherein the collagen fibers include clinical-grade collagen fibers.

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