Tangential Flow Filtration for Continuous Functional Exosome Processing
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Solution Overview
Problem
Conventional methods for producing functional exosomes are limited to concentration, purification, and buffer exchange, and require separate reactors, stirring facilities, and repetitive washing processes, making them unsuitable for large-scale production and increasing process time and cost.
Innovation Solution
A method using a tangential flow filtration (TFF) device to simultaneously perform reaction, filtration, and washing steps, eliminating the need for separate reactors and stirring facilities, and a continuous concentration system for ultra-high concentration of exosomes, which involves mixing exosomes with functional materials such as biocompatible polymers, protein drugs, and labeled molecules, and chemical drugs, and labeled molecules, and chemical drugs, and labeled molecules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separate batch reactors and stirring facilities are used for exosome modification, then reaction can be performed, but the process becomes time-consuming and inefficient with low productivity
Solution Approach 1:
The patent merges the reaction step, filtration step, and washing step into a single tangential flow filtration device. The exosome modification reaction occurs within the TFF device while simultaneously performing filtration and washing operations, eliminating the need for separate batch reactors and multiple transfer steps between different equipment.
Solution Approach 2:
The tangential flow filtration device is designed to perform multiple functions simultaneously: it serves as both the reaction vessel for exosome modification and the filtration/washing system. This multi-functional approach consolidates what were previously separate unit operations into a single integrated system.
2Reliability
If separate washing facilities are used for removing unreacted functional materials, then purification can be achieved, but the process complexity and time increase
Solution Approach 1:
The washing function for removing unreacted functional materials is merged into the TFF device's filtration system. The tangential flow filtration simultaneously separates exosomes from unreacted functional materials and performs washing in the same operational cycle, eliminating the need for separate washing facilities.
Solution Approach 2:
The TFF system performs continuous filtration and washing operations without interrupting the exosome modification process. The tangential flow continuously removes unreacted functional materials while maintaining the reaction environment, achieving purification as a continuous rather than discrete step.
3Reliability
If repetitive washing processes are performed to remove unreacted functional materials, then purification is improved, but productivity decreases and costs increase
Solution Approach 1:
The TFF system performs continuous washing and filtration in a single uninterrupted process. The tangential flow continuously removes unreacted functional materials throughout the reaction period, eliminating the need for multiple discrete washing cycles and associated time losses.
Solution Approach 2:
The TFF device is prepared with appropriate filtration membranes and washing buffers before the exosome modification reaction begins. This preliminary setup ensures that purification can occur continuously during the reaction without requiring subsequent repetitive washing steps.
4Quantity of substance
If conventional concentration methods are used for exosome solutions, then exosomes can be concentrated, but achieving ultra-high concentration requires multiple steps and large volumes
Solution Approach 1:
The multiple TFF devices are configured to perform continuous concentration operations in series. Exosome solution flows continuously through multiple filtration stages, with each stage further concentrating the solution. This continuous multi-stage process achieves ultra-high concentration more efficiently than conventional batch methods.
Solution Approach 2:
The concentration process is divided into multiple sequential TFF stages, each contributing to the overall concentration factor. By segmenting the concentration into discrete but continuous steps across multiple devices, the system achieves cumulative concentration effects while maintaining continuous flow operation.
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
Enables efficient, large-scale production of functional exosomes with higher yield and productivity by integrating reaction, filtration, and washing steps using a tangential flow filtration device, and continuous concentration system for ultra-high concentration of exosomes, reducing process time and cost.
Implementation Method 1
a filtration and concentration step of removing unreacted functional materials
Implementation Method 2
a multiple TFF continuous concentration system for ultra-high concentration of exosomes
Data Source
AI summary
The present disclosure relates to a new use of a tangential flow filtration device and a continuous concentration system for producing an ultra-high concentration medical exosome solution.