Highly Oriented Collagen Fibril Bundle Production
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Solution Overview
Problem
Existing methods fail to produce highly oriented collagen fibrils of significant length and controlled diameter, limiting their application in medical scaffolding and tissue engineering, particularly for artificial tendons and joint surgery materials.
Innovation Solution
A method involving continuous introduction of a collagen sol into a temperature-controlled flow path with controlled shear stress and shear rate to orient collagen fibrils, resulting in a uniaxially oriented collagen fibril bundle with a length of 1 m or more and a refractive index difference of 3×10−4 or more, allowing for the production of a collagen gel with enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If collagen fibrils are oriented using conventional shear stress methods (spin coater, microflow path), then some orientation is achieved, but the total length of collagen fibrils is limited to less than 1 meter
Solution Approach 1:
The continuous collagen fibril production is achieved by segmenting the process into controlled stages: collagen solution preparation, controlled shear application in a flow path, and continuous extraction. This allows the fibrils to be progressively oriented over an extended period and length without losing orientation uniformity.
Solution Approach 2:
The collagen solution is pre-prepared with specific viscosity and concentration parameters before entering the shear stress application zone. This preliminary preparation ensures that when the shear stress is applied, the fibrils orient uniformly from the beginning of the flow path, enabling continuous production of fibrils longer than 1 meter while maintaining orientation precision.
2Volume of moving object
If the diameter of string-like collagen gel is increased to 1-10 mm for medical applications, then the molded component becomes thicker and more useful, but continuous spinning with controlled orientation becomes difficult
Solution Approach 1:
The invention transitions from two-dimensional disk orientation (spin coater) or short path orientation (microflow) to a three-dimensional continuous flow path system. This allows the collagen gel to be extruded as a string-like structure with controlled diameter (1-10 mm) while maintaining orientation along the entire length, enabling both large volume and continuous manufacturing.
Solution Approach 2:
The flow path system serves multiple functions simultaneously: it provides the shear stress for orientation, defines the diameter of the extruded gel (1-10 mm), and enables continuous spinning operation. This multi-functionality resolves the contradiction between producing thick gel structures and maintaining continuous manufacturing capability.
3Manufacturing precision
If collagen fibrils are oriented in a batch type molding technique, then some orientation is achieved, but productivity is low and cannot satisfy industrialization requirements
Solution Approach 1:
The invention implements continuous spinning by maintaining a steady flow of collagen solution through the shear stress application zone. The orientation process is not interrupted or batched but continues uninterrupted, producing collagen fibrils at a rate that satisfies industrialization requirements while maintaining high orientation precision throughout the entire production run.
4Length of moving object
If the flow path length is increased to produce longer collagen fibrils, then the total length increases, but uniform laminar flow can only be maintained up to several cm from inlet
Solution Approach 1:
The collagen solution is pre-conditioned with specific viscosity and flow characteristics before entering the main flow path. This preliminary preparation ensures that laminar flow is established from the very beginning of the flow path, allowing the uniform flow condition to be maintained over the entire extended length required to produce fibrils longer than 1 meter.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of highly oriented collagen fibril bundles and gels with improved mechanical properties, such as increased Young's modulus and breaking stress, suitable for medical applications like artificial tendons and joint surgery materials.
Implementation Method 1
a method involving continuous introduction of a collagen sol into a temperature-controlled flow path with controlled shear stress and shear rate to orient collagen fibrils
Implementation Method 2
collagen fibrillogenesis under a shear force
Implementation Method 3
collagen fibrils are oriented uniaxially
Implementation Method 4
A molded component of collagen fibrillar gel with crosslinked collagen
Data Source
AI summary
The present invention relates to a highly oriented collagen fibril bundle having a length in a major axis direction of 1 m or more.