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 further processing steps like tanning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional methods are used to produce synthetic leather, then production simplicity is maintained, but the ability to replicate complex structure and functionality of natural leather is insufficient

Engineering Contradiction:

Improvestructure replication accuracyVSAvoidproduction process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by differentiating fibroblasts and keratinocytes from induced pluripotent stem cells before assembling the layered structure. This pre-differentiation approach ensures that cells are ready to form authentic skin-like structures (dermal layer with fibroblasts and epidermal layer with keratinocytes) when cultured, thereby replicating the complex structure and functionality of natural leather without requiring complex assembly processes later.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs composite materials by creating a multi-layered structure combining different cell types (fibroblasts and keratinocytes) derived from induced pluripotent stem cells. This composite cellular architecture mimics the natural skin structure, providing both structural complexity and functional authenticity that conventional single-material synthetic leathers cannot achieve.

Inventive Principle:

Principle #40Composite materials

2Reliability

If simple production methods are used, then manufacturing ease is maintained, but durability and authenticity of the synthetic leather are compromised

Engineering Contradiction:

Improvesynthetic leather durabilityVSAvoidproduction difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies self-service by utilizing the natural biological functions of differentiated cells to self-organize and form the leather structure. Fibroblasts naturally produce extracellular matrix and collagen in the dermal layer, while keratinocytes form the epidermal layer with appropriate protein structures. This self-organization capability ensures durability and authenticity without requiring complex external manufacturing interventions.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

By pre-differentiating cells into their specific functional types before assembly, the patent ensures that each cell type will perform its natural function (fibroblasts for structural support, keratinocytes for protective layer formation), thereby guaranteeing durability and authenticity while simplifying the overall manufacturing process.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If cell differentiation is not implemented, then production speed is maintained, but the authenticity and natural structure of the leather is lost

Engineering Contradiction:

Improvenatural structure replicationVSAvoidproduction efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent resolves this contradiction by performing cell differentiation as a preliminary action before assembly. Induced pluripotent stem cells are differentiated into fibroblasts and keratinocytes in advance, ensuring that when cells are cultured to form the layered structure, they naturally self-organize into authentic skin-like architectures. This pre-differentiation step enables both high manufacturing precision and maintained productivity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Differentiated cells possess inherent self-organizing capabilities that allow them to automatically form the correct layered structure (dermal and epidermal layers) without requiring complex external guidance. This self-service property ensures authentic structure replication while streamlining the production process.

Inventive Principle:

Principle #25Self-service

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 results in a synthetic leather with improved durability and authenticity, as it incorporates differentiated cells that mimic the natural structure of skin, offering a scalable and reproducible production method for customized tissues with appealing appearance and texture.

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 EffectCellular differentiation:

Implementation Method 2

further processing steps like tanning

Methodology Applied

Scientific EffectTanning:

Data Source

PatentUS10711136B2Engineered skin equivalent, method of manufacture thereof and products derived therefrom

Publication Date: 2020.07.14 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.