Microstructured Film Stack for Cell Cultivation
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Solution Overview
Problem
Existing methods for producing microstructured shaped bodies for biological cell cultivation are inefficient and unsuitable for mass production, as they require precise alignment of films and are not effective in directing liquids to cells in a targeted manner.
Innovation Solution
A method involving a stack of deformable porous and sacrificial films, where the films are pressed into a mold to form cavities, and the sacrificial film is etched to control porosity, allowing for targeted liquid exchange while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a porous film is used to allow liquid penetration through the shaped body, then liquid exchange is facilitated, but liquid cannot be directed to cells in a targeted manner
Solution Approach 1:
The patent applies local quality by creating regions with different porosity characteristics within the same film structure. Specifically, it forms closed cavities (impermeable regions) alongside porous regions, allowing different parts of the film to perform different functions: some areas allow liquid penetration while others direct liquid flow in a controlled manner to specific cell locations
2Manufacturing precision
If precise alignment of films is required during production, then manufacturing precision is improved, but device complexity and production difficulty increase
Solution Approach 1:
The patent merges multiple film layers (first film with pores, second film without pores, and sacrificial film) into a single integrated structure through stacking and simultaneous molding. This combining approach eliminates the need for precise alignment between separate films during assembly, as all layers are formed together in one molding process, thereby reducing production complexity while maintaining the desired structural precision
3Shape
If a deformable first film less than 1 mm thick is molded into recesses to form cavities, then cavity formation is achieved, but the first film becomes too thin and loses structural integrity
Solution Approach 1:
The patent creates a composite structure by stacking multiple films (porous first film, non-porous second film, and sacrificial film) together before molding. This composite construction provides enhanced structural integrity and mechanical strength compared to using a single thin film, while still allowing the formation of deep cavities when the stacked structure is molded into the recesses of the mold
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
This method enables the production of microstructured bodies with regions of limited porosity, suitable for biological cell cultivation, without the need for precise film alignment and is amenable to roll-to-roll operation, facilitating efficient liquid delivery and structural stability.
Implementation Method 1
the deformable first sheet is placed over a second sheet... The first foil is molded into the recesses in the second foil, so that cavities are formed
Implementation Method 2
at least parts of the deformed areas of the second film are etched, as a result of which at least sections in the deformed areas of the second film are chemically dissolved and thus destroyed
Data Source
Figure 1a~1e
Figure 2a~2e
Figure 3a~3c
AI summary
The present invention relates to a method for producing a microstructured molded body, which is particularly intended for the cultivation of biological cells. According to this method, a plastically deformable, porous first film (01) is first provided. Furthermore, a deformable second film (02) and a deformable sacrificial film (03) are provided. The first film (01), the second film (02), and the sacrificial film (03) are stacked to form a film stack (01, 02, 03). Subsequently, the sacrificial film (03) is subjected to pressure to press the film stack (01, 02, 03) into a mold (04). The mold (04) has recesses (06) whereby deformed areas (07, 09) in the form of cavities are formed in the sacrificial film (03), in the first film (01), and in the second film (02), while undeformed areas (08, 11) remain.When the stack of films (01, 02, 03) is pressed into the mold (04), the first film (01) and the second film (02) are bonded together, forming a film composite (01, 02). Subsequently, at least parts of the deformed areas (09) of the second film (02) are etched, chemically dissolving sections of the second film (02). In these sections of the second film (02), sections (12) in the deformed areas (07) of the first film (01) are exposed, thus reopening the pores in these sections (12).