Thermosetting Cell Culture Membrane Fixation via Substrate Bulges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cell culture devices using thermoplastic resins for both membranes and substrates face issues with additive elution and membrane deformation during welding, leading to variability in culture conditions and reduced membrane accuracy.
Innovation Solution
A cell culture device featuring a thermosetting resin membrane with open pores and a thermoplastic resin substrate, where the substrate is melted and extended into the membrane's pores to form bulges, enhancing fixation strength and maintaining membrane flatness without welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If both the cell culture membrane and substrate are made from thermoplastic resins and welded to each other, then the fixation strength between membrane and substrate is improved, but the cell culture membrane deforms due to swelling and contraction during heating, reducing membrane accuracy
Solution Approach 1:
The patent changes the material parameter of the cell culture membrane from thermoplastic resin to thermosetting resin. This parameter change allows the membrane to withstand welding temperatures without deforming, as thermosetting resins do not melt or soften at welding temperatures. The substrate remains made from thermoplastic resin to enable welding, while the thermosetting resin membrane maintains its shape and membrane accuracy during the welding process.
2Ease of manufacture
If adhesive tape or adhesive agent is used to fix the cell culture membrane to the substrate, then the fixation process is simplified, but additives in the adhesive are eluted into the culture solution, affecting cell culture
Solution Approach 1:
The patent replaces the chemical bonding method (adhesive) with a mechanical bonding method (welding). Instead of using adhesive agents that can elute additives into the culture solution, the patent uses ultrasonic vibration or heat to weld the thermoplastic resin substrate directly to the thermosetting resin membrane. This mechanical/physical bonding method eliminates the harmful additive elution problem while maintaining effective fixation.
3Manufacturing precision
If the cell culture membrane is made from thermosetting resin, then deformation during fixation is suppressed and membrane accuracy is maintained, but the fixation strength compared to thermoplastic-thermoplastic welding may be reduced
Solution Approach 1:
The patent creates a composite structure combining thermosetting resin (membrane) and thermoplastic resin (substrate). The thermosetting resin membrane provides dimensional stability and prevents deformation during welding, while the thermoplastic resin substrate enables effective welding through melting and bonding. This composite material approach allows both the thermosetting resin's shape stability and the thermoplastic resin's weldability to coexist, achieving both strong fixation and maintained membrane accuracy.
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 configuration reduces additive elution, maintains membrane accuracy, and minimizes deformation, thereby ensuring consistent culture conditions and improved fixation strength between the membrane and substrate.
Implementation Method 1
the substrate is melted and extended into the membrane's pores to form bulges
Implementation Method 2
the substrate is melted and extended into the membrane's pores
Data Source
AI summary
A cell culture device comprises a cell culture membrane and a substrate fixed to the cell culture membrane. The cell culture membrane is made from a thermosetting resin and has a plurality of pores that are open to at least one surface including a surface on a side that is in contact with the substrate. The substrate is made from a thermoplastic resin. In a contact region between the cell culture membrane and the substrate, part of the substrate is extended to form bulges in the pores of the cell culture membrane that are open in the contact region. This configuration suppresses reduction of the strength of the cell culture membrane and reduction of the flatness of the cell culture membrane (membrane accuracy) in the cell culture device in which the cell culture membrane and the substrate are fixed to each other.