Sealed Mesh Cell Culture Carriers for Easier Cell Harvesting
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Solution Overview
Problem
Current cell cultivation carriers for anchorage-dependent eukaryotic cells face challenges such as high cell mortality rates due to shearing forces, difficult cell harvesting, contamination susceptibility, and high production costs, particularly with porous carriers like BioNOC® II, which have irregular pore sizes and fiber release issues.
Innovation Solution
Employing netting or mesh structures with consistent pore sizes and sealed edges, forming a multilayered fixed bed system for cell culture, utilizing systems like BelloCell® and TideCell® with TideMotion™ mechanism for nutrient and oxygen supply, ensuring easy cell recovery and minimizing particle release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porous carriers like BioNOC® II are used to provide three-dimensional cavities and protect cells from shear stress, then cell protection and surface area are improved, but cell harvesting becomes difficult and fiber release causes contamination
Solution Approach 1:
The carrier is segmented into a distinct support structure (netting/mesh) with sealed edges that prevents fiber release while maintaining porous functionality. The support structure is separated from the cell growth areas, allowing cells to be harvested without carrying away carrier material.
Solution Approach 2:
The harmful element (loose fibers) is extracted from the carrier structure by using a sealed netting/mesh design. The edges are sealed to prevent fiber release, thereby removing the contamination source while preserving the porous structure needed for cell protection.
2Ease of operation
If smooth surface carriers are used to enable easy cell harvesting, then cell recovery is simplified, but the growth surface area is limited and cell density is reduced
Solution Approach 1:
The carrier transitions from a two-dimensional smooth surface to a three-dimensional porous structure with netting/mesh layers. This dimensional change increases the growth surface area while the sealed edges maintain ease of harvesting by preventing fiber release.
Solution Approach 2:
Multiple netting/mesh layers are nested within the carrier structure, with each layer providing additional growth surface area. The layers are contained within the sealed support structure, maintaining ease of operation while maximizing surface area.
3Reliability
If multiple layers of fibers are used to create porous structure, then cell protection is improved, but the number of layers creates physical obstacles for cell release and increases complexity
Solution Approach 1:
The carrier uses thin netting/mesh films instead of thick fiber layers. These thin films provide the necessary porous structure for cell protection while being less obstructive to cell release and reducing overall structural complexity.
4Reliability
If carriers with irregular pore sizes are used, then cell anchorage is provided, but pore consistency is poor and cell release is hindered
Solution Approach 1:
The netting/mesh structure provides uniform and consistent pore sizes across the carrier surface. This homogeneity ensures reliable cell anchorage while maintaining consistent characteristics that facilitate cell release, unlike irregular fiber-based carriers.
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 solution enables high cell density culture, efficient cell recovery, and reduced particle release, enhancing cellular production efficiency and reducing costs by maximizing surface area and maintaining cell integrity.
Implementation Method 1
The first netting/mesh film is biocompatible and hydrophilic
Implementation Method 2
The edge surrounds of the first netting/mesh film and the second netting/mesh film are sealed together by heat pressing
Implementation Method 3
The edge surrounds of the first netting/mesh film and the second netting/mesh film are sealed together by ultrasonic
Data Source
AI summary
A three-dimensional porous growth surface (carriers) and cell culture devices including the same are provided. The carriers are made by multiple layers of netting or mesh, especially large dimension and area of fabrics that are capable to form a column-type fixed bed by rolling the layers or other shape of fixed bed by stacking or randomly disposed packing the carriers to form a packed-bed for cell culture the layers together, thereby sealing the surrounding of the multilayer nettings or meshes to reduce particle generation during cell harvest, or ease of separation by filtration due to larger wall dimension on the nettings or meshes than cells. The fixed bed make by large dimension of the growth surface can easily to manufacture a fixed bed simply by rolling the multiple layers of sheets, which can reduce the manufacture cost and also facilitate mass production of carriers for fixed bed bioreactors.