3D Printable Hydrogel for Continuous Bioprocessing
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Solution Overview
Problem
Batch processes in the chemical and biotech industries for producing food ingredients, metabolites, and biofuels are inefficient due to the need for strict control of physical parameters and chemical concentrations, and can be detrimental to microbes, while continuous processes are preferred but lack effective catalysts for chemical reactions.
Innovation Solution
Development of hydrogel compositions that are responsive to temperature, pressure, and chemical crosslinking, allowing for the embedding of loading agents and extrusion printing, with crosslinked structures that maintain mechanical robustness and stability in aqueous conditions, enabling continuous chemical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If batch processes are used for chemical reactions, then living organisms can be used as catalysts, but the process efficiency is low and requires strict control of physical parameters and chemical concentrations
Solution Approach 1:
The system segments the reactor into multiple zones with different functions: an anaerobic zone for fermentation where living organisms catalyze reactions, and an aerobic zone for downstream processing. This segmentation allows batch fermentation to occur efficiently while transitioning to continuous processing, resolving the contradiction between using living organisms and maintaining high productivity.
Solution Approach 2:
The invention implements a continuous process where fermented broth flows continuously from the anaerobic zone to the aerobic zone for product recovery. This continuous operation eliminates the downtime between batches while maintaining the use of living organisms as catalysts in the first zone, thereby improving productivity without sacrificing adaptability.
2Productivity
If continuous processes are used for chemical reactions, then process efficiency is improved, but effective catalysts for chemical reactions are lacking
Solution Approach 1:
The continuous process is segmented into two distinct zones: an anaerobic fermentation zone that uses living organisms as catalysts, and an aerobic zone that uses conventional chemical catalysts for product recovery and purification. This segmentation allows each zone to use the most appropriate catalyst type for its function, maintaining both high productivity and catalyst effectiveness.
Solution Approach 2:
The fermented broth acts as an intermediary medium that carries the reaction products from the anaerobic zone to the aerobic zone. This intermediary transport allows the system to combine the advantages of both biological catalysis (in the first zone) and conventional chemical catalysis (in the second zone) within a single continuous process.
3Strength
If hydrogel structures are used in continuous processes, then mechanical robustness is required, but degradation in water under ambient conditions occurs
Solution Approach 1:
The system uses a composite material system consisting of a hydrogel matrix combined with crosslinked polymers. The hydrogel provides the necessary mechanical robustness and water absorption capacity, while the crosslinked polymer network prevents degradation in water. This composite approach resolves the contradiction between achieving mechanical strength and maintaining stability in aqueous environments.
Solution Approach 2:
The invention changes the chemical parameters of the hydrogel by introducing crosslinking functional groups that form covalent bonds between polymer chains. This parameter change transforms the hydrogel from a water-soluble or water-degradable material to a water-stable material with enhanced mechanical properties, simultaneously improving both strength and stability.
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 hydrogel compositions facilitate stable and efficient continuous chemical processes by maintaining mechanical integrity and preventing degradation, allowing for the use of living cells in chemical reactions and improving the production of biofuels and pharmaceuticals.
Implementation Method 1
The crosslinked structure is formed by exposing the printed material to UV light
Implementation Method 2
Hydrogel compositions that are responsive to temperature, applied pressure (shear thinning) and chemical crosslinking
Data Source
AI summary
Hydrogel compositions including a polymer uniformly embedded with a loading agent are provided. Also provided are methods for extrusion printing hydrogel compositions to provide extruded hydrogel compositions, which can be crosslinked to provide crosslinked hydrogel structures. Also provided are methods for using crosslinked hydrogel structures in chemical processes.