PEVA Film Surface Modification for Bioreactor Gas Barrier
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Solution Overview
Problem
Single-use bioreactor bags require a gas barrier layer but often contain phthalates and need multilayer films with tie layers, which are costly and difficult to modify, and can contaminate the cell culture medium.
Innovation Solution
A polymer film with a base composition of poly(ethylene-vinyl acetate) and a surface composition modified to include hydroxy groups through conversion of acetate groups to alcohol groups, allowing for the formation of a gas barrier layer without tie layers, using methods like saponification or plasma treatment, and enabling customization for bioreactor applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a multilayer film with PEVOH barrier layer is used to provide gas barrier capability, then gas barrier performance is improved, but device complexity and manufacturing cost increase due to required tie layers and multilayer construction
Solution Approach 1:
The patent combines the gas barrier function and the structural integrity function into a single layer by integrating PEVOH barrier material with tie layer chemistry in one homogeneous film, eliminating the need for separate barrier layers and tie layers while maintaining both gas barrier performance and layer adhesion
Solution Approach 2:
The modified PEVA film serves multiple functions simultaneously: it provides the structural base layer, contains the gas barrier capability through integrated PEVOH, and provides tie layer adhesion through its chemical composition, replacing the need for multiple specialized layers
2Reliability
If commercial multilayer films are used for single-use bioreactor bags, then gas barrier capability is achieved, but manufacturing cost increases and customization becomes difficult
Solution Approach 1:
The patent modifies the chemical parameters of the PEVA film by incorporating PEVOH and specific tie layer chemistries to achieve the desired gas barrier properties and adhesion characteristics, allowing customization without requiring complete multilayer constructions
Solution Approach 2:
The gas barrier capability and tie layer adhesion are built into the film during manufacturing as preliminary features, allowing the film to be used directly without additional processing or assembly steps that would be required for commercial multilayer films
3Strength
If tie layer chemistries are added to enhance multilayer compatibility, then interlayer adhesion is improved, but contamination risk from extractables and leachables increases
Solution Approach 1:
The adhesion function and barrier function are merged into a single integrated layer structure, eliminating the additional tie layer materials that could potentially leach or extract into the cell culture medium while maintaining interlayer compatibility
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 modified film provides a thin, customizable gas barrier layer that reduces contamination from extractables and leachables, is cost-effective, and allows for controlled release of metabolites and biologics, enhancing cell growth and bioprocess control.
Implementation Method 1
The process converts an acetate functional chemistry of a portion of a PEVA film to an alcohol functional chemistry through saponification
Implementation Method 2
The process converts an acetate functional chemistry of a portion of a PEVA film to an alcohol functional chemistry through saponification, radiation oxidation
Implementation Method 3
The process converts an acetate functional chemistry of a portion of a PEVA film to an alcohol functional chemistry through saponification, radiation oxidation, plasma treatment
Implementation Method 4
The process converts an acetate functional chemistry of a portion of a PEVA film to an alcohol functional chemistry through saponification, radiation oxidation, plasma treatment, laser ablation/oxidation
Implementation Method 5
The second composition is attached to the surface layer by ester bonds between carboxyl groups of the copolymer of glycerol and sebacic acid and the hydroxy groups
Data Source
AI summary
In some embodiments, a polymer film includes a base composition of poly(ethylene-vinyl acetate) and a surface composition comprising hydroxy groups. In some embodiments, a polymer film includes a base layer of a first composition of poly(ethylene-vinyl acetate), a surface layer at a surface of the base layer, and a coating layer of a second composition of a copolymer of glycerol and sebacic acid. The surface layer includes surface hydroxy groups converted from acetate groups of the poly(ethylene-vinyl acetate). The second composition is attached to the surface layer by ester bonds between carboxyl groups of the copolymer and the hydroxy groups. A single-use bioreactor bag includes a polymer film including a base composition of poly(ethylene-vinyl acetate) and a surface composition comprising hydroxy groups. A method of modifying a poly(ethylene-vinyl acetate) film includes converting acetate groups at a first surface of the poly(ethylene-vinyl acetate) film to hydroxy groups.