Engineered skin equivalent, method of manufacture thereof and products derived therefrom

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Solution Overview

Problem

Current methods for producing synthetic leather lack the ability to replicate the complex structure and functionality of natural leather, particularly in terms of cell differentiation and layer formation, which affects the material's durability and authenticity.

Innovation Solution

The method involves creating a synthetic leather by differentiating cells from induced pluripotent stem cells to form a layered structure comprising a dermal layer with fibroblasts and an epidermal layer with keratinocytes, which are then processed to achieve a natural leather-like thickness and texture, potentially including a basement membrane substitute and cultivation on a scaffold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If current methods are used to produce synthetic leather, then production is simpler and faster, but the material lacks the complex structure and functionality of natural leather

Engineering Contradiction:

Improvestructure replication accuracyVSAvoidcell differentiation process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The synthetic leather production process is divided into distinct stages: forming a dermal layer with fibroblasts, adding a basement membrane substitute, and then forming an epidermal layer with keratinocytes. This segmentation allows each layer to be optimized independently for structural complexity while maintaining overall production feasibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The basement membrane substitute is incorporated into the dermal layer before the epidermal layer is formed. This preliminary action creates a pre-prepared substrate that guides subsequent cell differentiation and layer formation, enabling complex structure development without requiring simultaneous multi-step processes.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If differentiated cells from induced pluripotent stem cells are used, then durability and authenticity are enhanced, but production time and process complexity increase

Engineering Contradiction:

Improvematerial durabilityVSAvoidcell differentiation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Induced pluripotent stem cells are used to differentiate into specific cell types (fibroblasts, keratinocytes) that self-organize into layered structures. The cells perform their own differentiation and organization functions, reducing the need for external intervention and lengthy processing steps while ensuring authentic tissue structure formation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The differentiation process is controlled by adjusting cultural parameters such as growth factors, substrate composition, and environmental conditions. By optimizing these parameters, cell differentiation is accelerated and directed toward desired cell types, reducing overall production time while maintaining high durability and authenticity.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If multiple layers with differentiated cells are formed, then authenticity and functionality improve, but manufacturing complexity increases

Engineering Contradiction:

Improvelayer formation accuracyVSAvoidproduction process simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The basement membrane substitute serves as an intermediary layer between the dermal and epidermal layers. This intermediary structure provides a defined interface that guides cell attachment and layer formation, simplifying the manufacturing process by creating clear separation zones while maintaining authentic multi-layer structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

Different cell types and structural properties are assigned to specific layers: fibroblasts in the dermal layer for structural support, basement membrane substitute for interface functionality, and keratinocytes in the epidermal layer for protective function. This local quality assignment ensures each layer contributes its specific function while simplifying the overall manufacturing approach.

Inventive Principle:

Principle #3Local quality

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 approach allows for the production of synthetic leather with enhanced durability and authenticity, as it incorporates differentiated cells that mimic the natural structure of skin, enabling the creation of customized tissues with appealing appearance, texture, and durability.

Implementation Method 1

differentiating cells from induced pluripotent stem cells to form a layered structure comprising a dermal layer with fibroblasts and an epidermal layer with keratinocytes

Methodology Applied

Scientific EffectCell differentiation:

Implementation Method 2

tanning at least a portion of a dermal layer, thereby forming a synthetic leather

Methodology Applied

Scientific EffectTanning:

Data Source

PatentUS11377559B2Engineered skin equivalent, method of manufacture thereof and products derived therefrom

Publication Date: 2022.07.05 FAIRCRAFT

AI summary

Disclosed herein are synthetic leathers, artificial epidermal layers, artificial dermal layers, layered structures, products produced therefrom and methods of producing the same.