Implantable device for retaining live cells and providing nutrients thereto

An implantable medical device, a method of manufacturing, and a method of use are described. The implantable medical device includes an absorption bag connected by a cannula to a discharge bag. The implantable medical device also includes a reservoir external to the discharge bag and attached to a surface of the discharge bag. At least a portion of the absorption bag and at least a portion of a bottom surface of the reservoir are permeable to a predefined class of small molecules, such as molecular oxygen. The reservoir can retain live cells that rely on the small molecules for survival and growth. Based on concentration of the small molecules, the small molecules permeate into the absorption bag and are transported to the discharge bag for permeation into the reservoir, thereby providing a supply of the small molecules to the live cells.

BACKGROUND

1. Field of the Art

Generally, embodiments of the present invention relate to methods and devices for implanting live cells within a body and providing nutrients to the live cells. The nutrients can be transported from an environment external to the body or from within the body.

2. Description of the Related Art

Diabetes is a group of widespread diseases in which there are high blood sugar levels over a prolonged period. If left untreated, diabetes can cause many complications. Acute complications can include diabetic ketoacidosis, nonketotic hyperosmolar coma, or death. Serious long-term complications include heart disease, stroke, chronic kidney failure, foot ulcers, and damage to the eyes. Diabetes is due to either cells in the pancreas not producing insulin (type-I diabetes) or not responding properly with the insulin production and release (type-II diabetes).

Pancreatic islets or islets of Langerhans, referred to herein as islets, are clusters of cells, containing mostly beta cells that secrete insulin. In people suffering from type-I diabetes, the islets are destroyed. One of medical solutions is to implant islets. In islet transplantation, cells are isolated from a donor pancreas and transplanted into type I diabetic patients. Once implanted, the transplanted islets begin to make and release insulin, thereby helping patients potentially avoiding the need of daily insulin injections.

Islet transplantation into the liver of diabetic patients has been studied for decades as a long-term treatment of type-I diabetes by normalizing blood sugar levels and preventing life-threatening hypoglycemic episodes. However, this “intrahepatic” islet transplantation results in chronic decline of islet function due to inflammation, immune response, and toxic environment to islets.

Attempts have been made to transplant islets into sites outside the liver. For example, the subcutaneous site (e.g., under the skin) is promising as it provides a large area and easy access for transplantation. However, low oxygen supply to implanted islets within the subcutaneous microenvironment is detrimental to islet survival. Specifically, the survival of islets depends on sufficient supply of oxygen to the islets at the site of implantation. Inadequate flow of oxygen, and/or of other nutrients, leads to the death of the islets, thereby negating any benefits of the implantation.

For a period of time after a subcutaneous implantation, a risk for ischemia exists. Ischemia is caused by inadequate blood flow due to the lack of adequate vascular structure in the subcutaneous implantation site. Oxygen supply to the implanted islets is not proper until sufficient vascular growth is achieved around the islets. Accordingly, for the islets to survive during the period of time between implantation and vascular growth, oxygen should be adequately supplied from other sources. No solutions exist currently for the adequate oxygen supply in islet transplantation outside of the liver.

Therefore, current treatments of diabetes based on islet implantation have a number of distinct disadvantages that need to be overcome.

BRIEF SUMMARY

Generally described is a microfabricated, implantable medical device with two bags connected by an impermeable cannula in the middle, where one of the bags is configured to retain live cells on its external surface. The implantable medical device is used to implant the live cells, such as islets, in an implantation site, such as a subcutaneous site and provide nutrients to the live cells, thereby enabling their survival.

In an embodiment, one of the bags is fully or partially permeable to a predefined class of small molecules of interest, such as diatomic oxygen (O2) or other “drugs.” The small molecules generally provide nutrients to the live cells. This bag is referred to herein as an absorption bag. Specifically, the permeability of the absorption bag enables permeation of the small molecules from a surrounding environment into the absorption bag. The other bag is partially permeable to the small molecules, where the permeation is at a specific location of the bag. This bag is referred to herein as a discharge bag. Specifically, the live cells are retained on an external surface of the discharge bag, where the external surface corresponds to (e.g., includes or consists of) the permeation area of the discharge bag. The small molecules are transported from the absorption bag to the discharge bag via the cannula and permeates through the permeation area to the live cells.

The bags can be sized to collect and disburse an estimated amount of the small molecules and transfer them by passive means, that is, by virtue of there being a higher concentration of the molecules in one region than another region. Proteins to assist in the capture and transport of the target small molecule can also be included within the device.

The cannula can include a tube or strip of pliable, bendable material, such as metal, so that a surgeon can bend the cannula and keep it bent in order to align the device in the body. For example, the device can be mounted so that its cannula enters the subcutaneous site and bends back so that the discharge bag sits below the skin. Suture holes can be included to assist implantation.

Also described are methods of microfabrication of the device from biocompatible silicone and parylene. Microfabrication can include using custom molds. Cavities in the molds can define the bags, cannula, and reservoir. The reservoir-related molds can be customized to retain a certain amount of the live cells for implantation. The bag and/or cannula-related molds can be customized based on an estimated consumption of small molecules by the live cells, such that adequate amounts of the small molecules can be provided to the live cells during a period of time. Not only can the size be customized depending on the estimated consumption, but the thickness and/or permeability of the bags can also be customized.

In an embodiment, the implantable medical device includes an absorption bag, a cannula, a discharge bag. At least a portion of the absorption bag is permeable to a predefined class of small molecules, such as molecule oxygen. A first portion of the discharge bag is permeable to the small molecules, whereas a second portion (e.g., the remaining portion) of the discharge bag is impermeable to the small molecules. The cannula includes a lumen. The lumen is impermeable to the small molecules and connects an interior of the absorption bag to an interior of the discharge bag. The implantable medical device also includes a means for retaining live cells and for providing the small molecules to the live cells based on permeation through the first portion of the discharge bag. Permeable and impermeable portions can be defined by using specific materials. Various materials are available and are biocompatible and/or biodegradable. For instance, silicone is used to define permeable portions. A coating of parylene is used to reduce the permeability and, thus, define impermeable portions. The absorption bag and the discharge bag have approximately a same shape, such as cylindrical shape or a torus with a mesh connecting opposite points of the torus. For cylindrical shapes, internal diameters in the range of 2 mm to 30 mm and internal heights in the range of 200 μm to 2 mm can be used.

For example, the means includes a reservoir. The reservoir is external to the discharge bag and that includes a wall, an opening, and a bottom. The wall is impermeable to the small molecule and is attached to the first portion of the discharge bag. The bottom is defined by the first portion of the discharge bag. The reservoir is configured to retain live cells received through the opening and to provide the small molecules (e.g., oxygen) to the live cells based on permeation of the small molecules through the first portion of the discharge bag. The discharge bag and the absorption bag are dimensioned based on an expected consumption of the small molecules by the live cells. The reservoir can have a cylindrical shape. Its internal diameters is in the range of 1 mm to 20 mm. Its height falls in the range of 100 μm to 1 mm.

In another example, the means includes an irregular array of corrugations that are disposed on an external side of the first portion of the discharge bag. In yet another example, the means includes a pattern of corrugations that are disposed on an external side of the first portion of the discharge bag. In a further example, the live cells are included in a culture, such as a hydrogel. The means includes an adhesion layer between the first portion of the discharge bag and the hydrogel.

In addition, the culture is added to the means and the small molecules (e.g., oxygen) permeates to the culture through the first portion of the discharge bag.

In an example, the live cells include islets and the culture includes hydrogel. In this example, the hydrogel includes vinyl sulfone and cysteine.

In an embodiment, a method of manufacturing an implantable medical device is described. The method includes spreading a uncured, biocompatible silicone on half molds. The method also includes partially curing the uncured, biocompatible silicone on the half molds to create partially cured silicone halves. The method also includes aligning and joining the partially cured halves to create a partially cured silicone workpiece. The partially cured silicone workpiece defines an absorption bag connected by a cannula to a discharge bag. The method also includes aligning and joining at least one partially cured silicone piece with an external surface of the discharge bag to add a reservoir to the partially cured silicone workpiece. The method also includes curing the partially cured silicone workpiece to create a silicone workpiece. The method also includes masking at least a portion of the absorption bag and the reservoir of the silicone workpiece. The method also includes depositing parylene on the absorption bag, the cannula, the discharge bag, and the reservoir based on the at least portion of the absorption bag and the reservoir being masked.

In an example, the method further includes estimating a consumption of oxygen by live cells. The reservoir is configured to retain the live cells. The cavities in the half molds are dimensioned based on the estimated consumption of the oxygen. Additionally or alternatively, thickness of the silicone defining the absorption bag and the discharge bag is set based on the estimated consumption of oxygen.

In an embodiment, a method of using an implantable medical device is described. The method includes providing the implantable medical device. The implantable medical device includes an absorption bag and a discharge bag connected by a cannula. The implantable medical device also includes a reservoir. The reservoir is external to the discharge bag and has a bottom defined by a portion of the discharge bag, where the portion is permeable to oxygen. The method also includes adding live cells to the reservoir. The method also includes placing at least the reservoir retaining the live cells, the discharge bag, and a portion of the cannula inside a body of a subject. The method also includes securing the implantable medical device in place.

In an example, the method further includes placing the absorption bag at an external surface of a skin of the subject and suturing the absorption bag to the skin. Alternatively, the absorption bag is placed inside the body of the subject and can be sutured to tissue.

In an example, the live cells include isles. The method further includes determining vascular growth around the islets after a period of time and removing the implantable medical device from the body of the subject after the period of time.

A further understanding of the nature and the advantages of the embodiments disclosed and suggested herein may be realized by reference to the remaining portions of the specification and the attached drawings.

DETAILED DESCRIPTION

Implantable medical devices, their methods of manufacture, and methods for their use are described. The implantable medical devices facilitate implanting live tissues in the body and providing nutrients to the live tissues for their survival. The implantable medical devices capture the nutrients from an environment external to the body and/or from within the body and deliver the nutrients to the live tissues.

In an embodiment, an implantable medical device is used to implant islets in a subcutaneous site. The implantable medical device is secured in place for a period of time. A reservoir of the implantable medical device retains the islets and is placed in the subcutaneous site through an incision. Based on a natural concentration gradient of oxygen, the implantable medical device transports oxygen from an oxygen-rich zone into the subcutaneous site, which is an oxygen deficient zone. The transported oxygen is permeated to the islets, thereby providing adequate oxygen flow for their survivals. Over time, vascular growth is achieved around the islets, thereby creating another source of oxygen. When the vascular growth is sufficient for the survival of the islets, the implantable medical device may be removed, whereas the islets may remain in the subcutaneous site.

U.S. Patent Application Publication No. US 2015/0366707, titled “small molecule transport device for drug delivery or waste removal” describes a passive device that facilitates the transportation of small molecules between two locations.

In contrast, embodiments of the present disclosure include an implantable medical device that facilitates implantation of live cells in a body of a subject and targeted supply of small molecules to the live cells for their survival. Specifically, the implantable medical device includes, among other components, a discharge bag. The discharge bag has a particular portion permeable to the small molecules. The live cells are retained at a location that is external to the discharge bag and that corresponds to the particular portion. The small molecules are supplied to the live cells in part through the permeation from the particular portion of the discharge bag. Because the retention location corresponds to the particular portion, the supply is targeted. Further, prior to the implantation, a determination may be made as to the desired amount of the live cells. The consumption of the small molecules by such an amount can be estimated. The estimated consumption can be correlated to a particular size and/or permeation of the implantable medical device such that the appropriate implantable medical device can be obtained and implanted.

In the interest of brevity, an implantable medical device is referred to as a device in the present disclosure. In other words, unless context dictates otherwise, a device as used herein represents a medical device that can be implanted in a body of a subject. The implantation need not be permanent and, instead, can be temporary. The device can be secured in place for the period of the implantation using different techniques, as further described in the next figures.

In the interest of clarity of explanation, embodiments of the present disclosure are described in connection with a device for implanting islets and supplying oxygen to the implanted islets. However, the embodiments are not limited as such. Instead, the device is also usable for implanting other types of live cells and for supplying other types of nutrients to the live cells. Generally, a live cell can be any cell that relies on a nutrient for survival. A nutrient represents a molecule that the cell can consume through cellular metabolism, alone or in combination with other molecules, to survive. Islets are one example of live cells. Oxygen is one example of nutrients.

FIG. 1illustrates an example of a device100in accordance with an embodiment. The device100includes an absorption bag110, a cannula120, a discharge bag130, and a means140for retaining live cells142and providing small molecules150to the live cells142. In an example, the live cells142are islets including pancreatic beta cells and the small molecules150are molecular oxygen (O2). The small molecules150are passively captured by the absorption bag110and transported to the discharge bag130through the cannula120. The small molecules150are then permeated into the means140for consumption by the live cells142.

In an example, the absorption bag110is partially or fully permeable to the small molecules150. For instance, the entire membrane that forms the absorption bag110or only a portion of the membrane is permeable to the small molecules150. The small molecules150permeates to an interior of the absorption bag150through the permeable membrane or permeable portion thereof. The absorption bag110may also be foldable, rollable, and/or stretchable depending on the membrane.

The cannula120includes a thin lumen that connects the interior of the absorption bag110to an interior of the discharge bag130. The cannula120is impermeable to the small molecules150such that the small molecules150are transported between the two interiors through the lumen and without permeation at the cannula120. For example, the cannula120is formed by a membrane coated with a material that renders the cannula120impermeable to the small molecules150. Based on natural concentration gradient of the small molecules150, transportation occurs from the absorption bag110to the discharge bag130. That is the case when the absorption bag110is placed in a region that has a higher concentration of the small molecules150relative to the concentration in a region where the discharge bag130is placed.

The discharge bag130includes a particular portion132(e.g., a first portion) that is permeable to the small molecules150. The remaining portion134of the discharge bag130(e.g., a second portion) is generally impermeable such the permeation of the small molecules150is targeted to occur through the particular portion132. The discharge bag130may also be foldable, rollable, and/or stretchable depending on membrane that forms the discharge bag130.

The means140is external to the discharge bag130, retains the live cells142, and supplies the small molecules150to the live cells142based on the permeation from the permeable portion132of the discharge bag130. Different types of the means exist including, for instance, a reservoir, irregular array of corrugations, an adhesion layer as further described in connection with the next figures. Generally, the live cells142belong or are included in a culture144retained by the means140. The culture144represent a solution in which the live cells can be placed and that provides a suitable environment for their survivability. A hydrogel is an example of the culture144. The supply of the small molecules150to the live cells142can be targeted by properly locating the means140relative to the permeable portion132of the discharge bag130. For example, the means140is placed on top of the permeable portion132and has a bottom surface that is formed by the permeable portion132, that surrounds the permeable portion132, or that is approximately surrounded by the permeable portion132(e.g., the permeable portion surrounds the bottom surface by a margin that does not exceed 10% (or some other relevant percentage) the total area of the bottom surface)).

Various materials are available and are biocompatible and/or biodegradable. In an example, the absorption bag110, the cannula120, the discharge bag130, and the means140are made of biocompatible silicone that has been cured together, i.e., integrally formed. Parylene C coating surrounds cannula120, the remaining portion134of the discharge bag130(but not the permeable portion132), and, optionally, a portion (but not the entire) absorption bag110. Parylene C is a biocompatible polymer with a permeability rate that is five orders of magnitude lower than silicone. The coating renders the coated portions impermeable to the small molecules150.

“Permeability” of a material is typically in relation to a size of substance of interest. A Stokes-Einstein radius or a Stokes diameter is a measure of the diffusion properties of a substance. A “Stokes diameter” is an equivalent diameter of a hard sphere that a molecule possesses in terms of its diffusion rate. A molecule can pass through thin materials with pores that have a Stokes diameter that is about 1 to about 5 times the Stokes diameter of the molecule.

The small molecules150diffusion out of the discharge bag130into the means140lowers the device's100internal concentration, and this in turn pulls additional small molecules from a small molecule rich region (e.g., where the absorption bag110is located) into the device100. The concentration gradient will continue to transport small molecules from the rich region into the means140, thereby providing an adequate flow of the small molecules to the live cells142.

Dosing and targeted release can be controlled by material properties of the device100. Controlling the thickness of silicone can determine the permeation rate (dosing). As the absorption bag110, cannula120, and discharge bag130are integrally formed with the same thickness of silicone, a single adjustment to how much silicone is distributed on a mold can determine permeation rates. Applying impermeable coating to specific portions of the device100allows control over the permeation rates and/or locations of the permeations.

The dimensions of the absorption bag110and discharge bag130can also be adjusted to alter the permeation rate. Generally, the larger the permeable surface area, the larger the permeation rate is (given a same concentration of small molecules). The dimensions and permeable surface areas are application dependent and can be designed for the specific task the device100is to perform. For instance, a desired amount of live cells142can be determined. The means140is dimensioned to hold that amount. An estimated consumption of the small molecules150by the amount of the live cells142is estimated. The dimensions and permeable surface areas of the absorption bag110and discharge bag130are set to provide a flow of the small molecules150adequate for the estimated consumption. The device100is manufactured accordingly.

In addition to controlling the thickness, one may inject into the interior of the device100a substance with a high diffusion constant such as perfluorocarbons, air, etc. For example, a perfluorocarbon within the absorption bag110and device100can increase oxygen solubility (e.g., in the case when the small molecules150are oxygen). A hemeprotein, such as a natural, artificial, or autologous hemoglobin or myoglobin, can be added inside the device100to increase oxygen transport. A chlorocruorin or a hemocyanin can be added into the absorption bag110and other portions of the device100to increase oxygen transport. Other substances natural or synthetic that have beneficial properties for small molecule storage or transport may be used.

Other small molecules besides diatomic oxygen can also be captured and transported. The device100can be targeted for carbon dioxide (CO2), nitrous oxide (N2O), or other gases. Small molecule proteins and other drugs can be specifically targeted. Any of these ‘drugs’ may be transported, whether they are classified as a therapeutic agent, waste product, or otherwise.

FIG. 2illustrates an example of a device200that includes an absorption bag210having suture holes212, in accordance with an embodiment. In addition to the absorption bag210, the device200includes a cannula220, a discharge bag230, and a reservoir240.

As illustrated, the absorption bag210has a cylindrical shape. Other shapes are possible, including a spheroid, a toroid, and the like. A top surface211, a bottom surface213, and a side surface215define the cylindrical shape. These surfaces are generally, but need not, made of the same material to form an integral membrane that defines the structure of the absorption bag210. The material is generally permeable to a predefined class of small molecule, such as molecule oxygen (O2). In an example, the material includes NuSil Technology LLC (of Carpinteria, Calif., U.S.A.) MED4-4210, two-part, medical grade silicone in which base and curing agent are mixed at a 10:1 ratio by weight.

Optionally, the bottom surface213, the side surface215, and/or other surface areas of the absorption bag210are coated with thick parylene (e.g., 2 μm or more of parylene C), rendering these surfaces impermeable to the small molecules. The coating is applied to a surface when, for example, the permeation of the small molecules into the absorption bag210is not expected through the surface. For instance, if the absorption bag210is attached to the skin of a subject, the bottom surface213may sit against the skin and oxygen is not expected to properly diffuse through that surface accordingly, the coating of the thick parylene is applied to the bottom surface213, rendering that surface impermeable to oxygen.

The device200also includes a number of tabs214. The tabs are made of the same material as the absorption bag210(e.g., silicone). In an example, the tabs214are spaced symmetrically around the side surface215. Each of the tabs214includes a through hole212. Through holes212are sized for sutures and thus are sometimes called suture holes. These holes can be used to attach and secure the absorption bag210to tissue of the subject.

The cannula220is also made of the same material as the absorption bag210(e.g., silicone). The external surface of the cannula220is covered in a thick parylene coating222(2 μm or more of parylene C), rendering that surface impermeable to oxygen and/or other small molecules. Enclosed inside the cannula220is pliable metal strip224, such as a biocompatible type three hundred and four stainless steel tube. The tube is pliable so that it can be bent and keep its bent shape. Or it can be re-bent to be straight and then keep its straight shape. In other embodiments, the metal strip224may be a thin metal foil, sheet, or solid rod. The metal strip224can be bent by a surgeon's hands or by surgical instruments.

The discharge bag230has the same or substantially the same shape (a cylindrical shape as illustrated inFIG. 2) and dimensions as the absorption bag210. The discharge bag230is also made of the same material as the absorption bag210(e.g., silicone). A top surface231, a bottom surface233, and a side surface235are made of the material to form an integral membrane that defines the structure of the discharge bag230.

To allow targeted permeation, the bottom surface233and the side surface235are covered in a thick parylene coating (2 μm or more of parylene C), rendering these surfaces impermeable to oxygen and/or other small molecules. Further, the top surface231is divided into two portions: a first portion232and a second portion234, each defining a surface area. The first portion232is not covered with the thick parylene coating and, thus, is permeable to oxygen and/or other small molecules. In contrast, the second portion234represents a remaining portion of the top surface231, is coated with the thick parylene coating, and, thus, is impermeable to oxygen and/or other small molecules.

The reservoir240is an example of a means for retaining live cells and for providing oxygen and/or other small molecules to the live cells. The reservoir240sits on top of the first, permeable portion232of the discharge bag230. The reservoir includes an opening242, one or more walls244, and a bottom surface246. The opening242allows the addition of the live cells into the interior of the reservoir240. The wall(s)244and the bottom surface246retain the live cells within that interior. Although a cylindrical shape is illustrated, other shapes and geometries are possible for the reservoir240, such as a rectangular shape. Oxygen and/or other small molecules to the live cells are supplied through permeation from the bottom surface246. For example, the bottom surface246can be made of the same permeable material as the absorption bag210(e.g., silicone). In another example, the bottom surface246is formed by the of the first, permeable portion232of the discharge bag230, as opposed to being made with a separate permeable material. In both examples, oxygen and/or other small molecules permeates from the discharge bag230into the interior of the reservoir240through the first, permeable portion232of the discharge bag230and the bottom, permeable surface246of the reservoir240.

FIG. 3illustrates an example of a device300that includes, in addition to a cannula320, an absorption bag310and a discharge bag330having a particular configuration, in accordance with an embodiment. Each of these bags has substantially a cylindrical shape. However, and unlike the plain cylindrical shape illustrated inFIG. 2, the cylindrical shape includes a grill-like configuration. In each of the cylinders, the outer perimeter340has a shape that is a torus or a ring. A mesh342connects opposite points that belong to the outer perimeter340. The mesh342defines a three dimensional grate for the flow of the oxygen and/or other small molecules. This grate has openings344from between top and bottom surfaces of the mesh342(or the cylinder) but not into the body of the mesh342(or the cylinder). In this configuration, a larger surface area can be achieved given the same footprint of a cylinder relative to the plain cylinder ofFIG. 2. Accordingly, a relatively higher permeation rate into and/or out from the device300can be achieved.

Although an absorption bag and a discharge bag are illustrated in each ofFIGS. 2 and 3as having the same shape, dimension, and geometry, the embodiments of the present disclosure are not limited as such. Instead, the configurations can differ. For example, the absorption bag can be larger. In another example, while a plain cylindrical shape is used for the discharge bag, a grill-like shape is used for the absorption bag. Generally, the specific configuration for each bag is dependent on the application, such as the type and amount of live cells to be retained, the estimated nutrients consumption for a period of time, among other application parameters.

FIG. 4illustrates a plan view and cross sectional views of an example of a device400, in accordance with an embodiment. In the exemplary embodiment, the absorption bag410is 10 mm in diameter with 500 μm (micron) walls. The internal height is 720 μm with a ceiling and a floor thickness of 360 μm each, for a total thickness of 1440 μm. The cannula420is 10 mm long with a width of 1.5 mm. Like the absorption bag410, the cannula420has an internal height of 720 μm with a ceiling and a floor thickness of 360 μm each, for a total thickness of 1440 μm. The side walls are 400 μm thick.

A tube422is placed inside the cannula420. The tube422has an internal diameter of 406.4 μm (0.016 inches) and an outside diameter of 508 μm (0.02 inches). The discharge bag430has similar dimensions as the absorption bag410. Specifically, the discharge bag430is 4 is 10 mm in diameter with 500 μm (micron) walls. The internal height is 720 μm with a ceiling and a floor thickness of 360 μm each, for a total thickness of 1440 μm. The absorption bag410, cannula420, and discharge bag430have squared edges and are all approximately the same height is an indication that they were fabricated together using lithographic techniques.

Permeable material460, which forms the absorption bag410, cannula420, and discharge bag430is silicone. A particular silicone that has been shown to be effective is NuSil Technology LLC (of Carpinteria, Calif., U.S.A.) MED4-4210, two-part, medical grade silicone in which base and curing agent are mixed at a 10:1 ratio by weight. To limit permeability, a coating462of parylene is applied to specific portions of the absorption bag410, cannula420, and discharge bag430. Specifically, a layer of 10 μm parylene C is applied to the sides and bottom surfaces of the absorption bag410, thereby forming an envelope that is impermeable to molecular oxygen (O2) and other small molecules. Likewise, a layer of 10 parylene C is applied around the cannula420and to sides and bottom surfaces of the discharge bag430.

Tabs426with holes428are integrally formed with the device400. That is, the silicone of these appurtenances are at least partially co-cured with that of absorption bag410, cannula420, and discharge bag430. As will be detailed below, a thin layer of uncured silicone470is spread between partially-cured halves of the device400before fully curing the device's silicone material. Further, uncured silicone470is spread in cannula420before the metal tube422is placed therein. The metal tube422keeps lumen424free from flowing silicone while curing.

In addition, a reservoir440is attached to a top surface of the absorption bag410. The reservoir440has a cylindrical shape, with an internal diameter of 6.35 mm and a height of 500 μm. The wall442of the reservoir440is about 1.825 mm thick. The reservoir440centered around the center of the top surface of the discharge bag430. Its wall442is attached to the top surface absorption bag410via the uncured silicone470and ends at the edge of the top surface. The bottom surface of the reservoir440is formed by the top surface of the absorption bag410and, thus, is made of silicone, which is permeable to molecular oxygen (O2) and other small molecules. The wall442is coated with a layer of 10 μm parylene C.

The reservoir has volume of 15.27 mm3suitable for retaining about 1,500 IEQ of islets in hydrogel, where one IEQ is considered equivalent to a pancreatic islet with a diameter of 150 μm. The dimensions and permeability of the absorption bag410, cannula420, and absorption bag430provides sufficient oxygen for the 1,500 IEQ of islets such that the islets survive and grow over a period of at least two weeks given the oxygen flow through the device400.

Other dimensions of the medical device400are possible. The specific shape, geometry, membrane thickness, and permeation of the absorption bag410, cannula420, discharge bag430, and reservoir440are application dependent. Generally, the internal diameter of the reservoir440is in the range of 1 mm to 20 mm and the height of its wall falls in the range of 100 μm to 1 mm. Similarly, each of the absorption bag410and the discharge bag430has an internal diameter in the range of 2 mm to 30 mm and having an internal height in the range of 200 μm to 2 mm. The cannula420is sized such that the width of its lumen424is smaller than the diameter of the absorption bag410. For instance, this width falls in the range of 0.1 mm to 5 mm.

FIG. 5illustrates examples of retaining live cells on an external surface of a discharge bag, in accordance with an embodiment. WhereasFIG. 4illustrates a reservoir440as one exemplary embodiment,FIG. 5illustrates additional exemplary embodiments for the retaining and for providing nutrients to the live cells.

InFIG. 5, a device500includes an absorption bag510, a cannula520, and a discharge bag530. A means540is located on a top surface532of the discharge bag530. The means540retains an amount of the live cells and provides oxygen and/or other small molecules as nutrients to the live cells based on permeation through the top surface532. Three specific configurations of the means540are illustrated.

In a first configuration, the means540includes a pattern of corrugations550that are disposed on the top surface532. Specifically, the corrugations550are formed on an external surface of the first portion of the discharge bag530(e.g., on the external side of the top surface532). The pattern is regular (e.g., repetitive as a function of height, width, and/or length) and has a specific geometry.FIG. 5illustrates a repetitive cuboid geometry. Each cuboid has a square base and a length. The width (and height) of the square is in the range of one eight to one half of the thickness of the top surface532(e.g., range of 45 μm to 180 μm for a 360 μm thickness). The length of the cuboid is in the range of one fourth to three fourth of the diameter of the discharge bag530(e.g., range of 180 μm to 540 μm for a 720 μm diameter). Other repetitive, three dimensional geometries are also possible. Geometries having squared edges and approximately the same height (e.g., such as cuboids) are an indication that the corrugations550were fabricated using lithographic techniques. Specifically, the half molds for creating the absorption bag include corresponding cavities to form the corrugations550.

In a second configuration, the means540includes array of corrugations560that are disposed on the top surface532. Like the first configuration, the corrugations560are formed on an external surface of the first portion of the discharge bag530(e.g., on the external side of the top surface532). However, the array here has an irregular pattern, such as one with random heights, widths, and/or lengths. Generally, the overall dimensions of the array have a length and width in the range of one fourth to three fourth of the diameter of the discharge bag530, and a height in the range of one eight to one half of the thickness of the top surface532. Using a random pattern may simplify, relative to the first configuration, the process of creating the corrugations560.

In a third configuration, the means540includes an adhesion layer570that is disposed on the top surface532. Generally, the live cells are included in a culture, such as hydrogel. The adhesion layer570is disposed between a first portion of the discharge bag530(e.g., on the external side of the top surface532) and a second portion of the culture (e.g., on the external side of the bottom surface of the hydrogel). The adhesion layer570provides bonding, such as covalent bonding, between the top surface532and the culture and is permeable to the oxygen and/or small molecules. Depending on the type of the material that forms the top surface532and/or the hydrogel, the adhesion layer570can be defined and can be separate or integrated with the external side of the top surface532and/or the hydrogel. For instance, fibroblasts, a type of cells found in connective tissue, are cultured and stretched, and then applied as a coating between the two external sides.

In the above configurations, the means540mainly consists of an interface (e.g., corrugations or adhesion layer) for retaining the culture of the live cells, whereas the reservoir440FIG. 4defines a well. In such configurations, the culture itself needs to have a solid-like state such that it remains attached to the top surface through the interface of the means540. In an example, the culture includes equal parts of vinyl sulfone (VS) functionalized saccharide-peptide copolymer and cysteine (Cys) functionalized saccharide-peptide copolymer. When these two parts are initially mixed, the culture is liquid and can be deposited on the means540(and/or the reservoir440). Shortly thereafter, the culture solidifies into a hydrogel.

FIG. 6illustrates an example of a subcutaneous implantation, in accordance with an embodiment. The implantation is subcutaneous in the abdomen of a subject. An incision650is made in the abdomen. An absorption bag610of a device600sits on the exterior of the abdomen, such as on external side of the epidermis652. A cannula620and a discharge bag630of the device600are inserted in the subcutaneous area654through the incision650. A reservoir640attached to and external to the discharge bag630retains hydrogel that contains islets. The reservoir640is positioned such that its opening is towards the epidermis652. Hence, the device600absorbs oxygen from the ambient air external to the abdomen (at about 160 mmHg, depending on the external environment). The oxygen is transported to the islets retained in the reservoir640.

Simulation of the subcutaneous implantation demonstrates that oxygen can be provided to the islets at a partial pressure (ρO2) of 55.04 mmHg on average, which is sufficient for the islet survival. In comparison, absent the device600, the oxygen would be provided at an average of 3.70 mmHg of partial pressure, which is insufficient for the islet survival.

Further, in lab experimentation, the device600is tested by immersing the hydrogel containing the islets to an anoxic culture medium. An oxygen sensor was inserted in the hydrogel. The lab experimentation demonstrated a steady ρO2 at the center of top surface of the discharge bag630(e.g., the center of the bottom surface of the reservoir640) to be between 118 mmHg and 126 mmHg, which demonstrated that the device600is highly efficient in terms of extra oxygen supply.

FIGS. 7A-7Gillustrate an example of a manufacturing process, in accordance with an embodiment.

InFIG. 7A, a half mold700includes silicon substrate742with a dry film photoresist744patterned in the shape (e.g., half cylinders connected by a half cuboid) of the final device.

The photoresist was masked and exposed to visible or ultraviolet (UV) light or other electromagnetic radiation and then developed to create the half molds. Because such masks can be easily altered, a device can be custom made using custom molds. The molds include cavities sized to create a specific configuration of the device. In turn, the specific configuration can be set to retain a particular amount of live cells over a time period and expected consumption of nutrients by the live cells, where the nutrients are to be supplied through the device.

The illustrated half mold700defines the top half of the device. A mirror half mold can be used for the bottom half of the device. The half mold700is coated entirely with coating746of parylene C in order to reduce adhesion between silicone and the mold and thus increase the mold's releasability. Although not illustrated, a section of the half mold700can also include additional cavities to define corrugations on an external side of a top surface of a discharge bag.

InFIG. 7B, uncured silicone748is dabbed and brushed upon the half mold700so as to coat the bottom and sides. It is then partially cured at 65° C. for 30 minutes. A similar application is made for the mirror, bottom half mold.

InFIG. 7C, partially cured silicone748is peeled from the half mold700. Its joining edges are then coated with uncured silicone750. A pliable tube of malleable, ductile metal is cut to a desired length and inserted in the cannula, “handle section” of the device.

InFIG. 7D, a mold760includes silicone substrate762with dry film photoresist764and is patterned to define a wall of a reservoir. The reservoir can be adjoined to a top surface of a discharge bag of the device. The photoresist is masked, exposed, and developed similarly to that of the photoresist for the half mold700. The half mold760is also coated with parylene C766.

InFIG. 7E, uncured silicone768is dabbed and brushed upon the mold760so as to coat the bottom and sides. It is then partially cured at 65° C. for 30 minutes.

InFIG. 7F, partially cured silicone768is peeled from the mold760. Its joining edges are then coated with uncured silicone750.

InFIG. 7G, the complementary partially cured silicone are joined along the joining edges. For example, the top and bottom partially cured silicones halves are aligned and joined, with the metal tube in between the halves to form an assembly that includes sections for an absorption bag, cannula, and discharge bag. The partially cured silicone wall768is aligned and joined to a top surface of the section corresponding to the discharge bag. The assembly is fully cured at 100° C. for 8 hours. A portion of or the entire absorption bag and the bottom of the reservoir are then masked, and the assembly is placed in a chemical vapor deposition (CVD) chamber for depositing parylene around the unmasked portions of the device. A layer770of parylene C (e.g., about 10 μm) ensures that the cannula is impermeable to oxygen and/or other small molecules.

FIG. 8is a flowchart illustrating an example method of manufacturing800, in accordance with an embodiment

In operation802, consumption of small molecules by live cells is evaluated. For example, the oxygen consumption of the live cells for their survival and growth over a period of time is estimated. The estimation can involve utilizing a lookup table. The lookup table correlates consumption to quantity of the live cells. For example, the lookup table documents the oxygen rate needed to grow 1,500 IEQ of live cells for a period of two weeks. The lookup table can be developed through experimentation and/or modeling. In experimentation, different quantities of live cells can be cultured. Oxygen sensors can be added to the cultures and used to determine the necessary oxygen rate. In modeling, the consumption rate can be modeled following Monod kinetics, where

μ=μm⁢SKs+S,
where “μ” is the growth rate, “μm” is the maximum growth rate (an empirical value), “Ks” is the Monod constant (an empirical value) of the substrate (e.g., the culture), and “S” is the limiting growth of the substrate. For oxygen, “μ” can be also expressed as

μ=CDOKDO+CDO,
where “CDO” is the concentration of dissolved oxygen and, “KDO” is the Monod constant of the dissolved oxygen.

In operation804, half molds are obtained based on the estimated consumption of the small molecules (e.g., the estimated oxygen consumption). For example, a particular oxygen consumption may dictate a particular configuration (e.g., shape, size, and/or geometry) of a device that includes an absorption bag, a cannula, a discharge bag, and a reservoir (or other means for retaining live cells and providing nutrients thereto). The cannula connects the absorption bag and the discharge bag. Half molds are created using lithography other techniques, where the half molds correspond to the absorption bag, cannula, and discharge bag. Molds are similarly created for the reservoir. Cavities in the half molds and molds are defined to meet the particular configuration of the device. Additionally or alternatively, the thickness of material applied to the half molds and molds to define permeable and impermeable membranes is controlled according to the particular configuration.

In operation806, the half molds are coated with parylene C. Similarly, the molds of the reservoir are also coated with parylene C.

In operation808, uncured, biocompatible silicone is spread on the half molds. Similarly, uncured, biocompatible silicone is spread on the molds.

In operation810, the silicone on the half molds is partially cured to create partially cured silicone halves. The silicone halves will define the absorption bag, cannula, and discharge bag. Similarly, the silicone on the molds is partially cured to create partially cured silicone pieces. The silicone pieces will define the reservoir.

In operation812, one of the partially cured halves is peeled from one of the half molds. The peeling is facilitated by the coating of parylene C. Similarly, one of the partially cured silicone pieces is peeled from on the molds.

In operation814, uncured, biocompatible silicone is applied to the peeled, partially cured silicone halves. For example, the uncured, biocompatible silicone is applied to joining edges of the peeled silicone half. Similarly, uncured, biocompatible silicone is applied to joining edges of the peeled, partially cured silicone piece.

In operation816, a metal tube is added to the peeled silicone half. Thereafter, the peeled silicone half is aligned and joined with a corresponding partially cured silicone half to create a partially cured silicone workpiece. The joining edges are used. The partially cured silicone workpiece defines the absorption bag, cannula, and discharge bag. The cannula contains the metal tube.

In operation818, the peeled, partially cured silicone piece is aligned and joined with an external surface of the discharge bag to add, to the partially cured silicone workpiece, the reservoir (e.g., a silicone reservoir having a silicone wall defined by the peeled, partially cured silicone piece and having a bottom surface defined by the external surface of the discharge bag). The joining edges of the peeled, partially cured silicone piece are used.

In operation820, the partially cured silicone workpiece is further cured to create a silicone workpiece. The silicone workpiece includes the absorption bag, cannula, discharge bag, and reservoir.

In operation820, at least a portion of the absorption bag and a bottom surface of the reservoir of the silicone workpiece are masked. For example, a top surface of the absorption bag may be desired to remain permeable to the small molecules (e.g., the oxygen). Similarly, the bottom surface of the reservoir interfaces with the top surface of the discharge bag and may be desired to remain permeable such that the small molecules permeate from the discharge bag into the reservoir through that interface. Accordingly, these portions are masked.

In operation822, parylene is deposited on the unmasked portions of absorption bag, cannula, discharge bag, and reservoir. The coating reduces permeability of these portions.

FIG. 9is a flowchart illustrating an example method of use 900, in accordance with an embodiment.

In operation902, a device is provided, where the device includes an absorption bag, a cannula, a discharge bag, and a reservoir. The cannula includes a metal tube and connects the absorption bag and the discharge bag. The reservoir is external to the discharge bag and is attached to a surface of the discharge bag.

In operation904, live cells are added to the reservoir of the device. For example, parts of vinyl sulfone (VS) functionalized saccharide-peptide copolymer and cysteine (Cys) functionalized saccharide-peptide copolymer are mixed to form a culture. The live cells are added to the culture. The culture is then moved to a syringe. The syringe is used to add the culture to the reservoir.

In operation906, an incision is cut in a body of a subject. For example, a ten millimeter incisions is cut into the abdomen of the subject.

In operation908, the cannula with the pliable metal tube is bent into position.

In operation910, at least the reservoir retaining the live cells, the discharge bag, and a portion of the cannula are placed inside the body. In an example, the reservoir, discharge bag, and portion of the cannula are pulled through the incision. For instance, these components of the device are placed in a subcutaneous site in the abdomen area.

In operation912, the device is secured in place. In an example, the absorption bag is placed outside of the body. In another example, the absorption bag in subcutaneous site, but at a location with relatively higher oxygen concentration (or a relatively higher concentration of other small molecules usable as nutrients for the live cells). In both example, the device can be secured in place by suturing the absorption bag to surrounding skin or tissue.

In operation914, vascular growth around the live cells can be determined after a period of time. In an example, the vascular growth can be expected over time. In another example, a probe is used to determine the vascular growth.

In operation916, the device is removed from the body after the period of time. For example, if the vascular growth is satisfactory (e.g., provides adequate oxygen flow or an adequate source of nutrients to the live cells), the device is removed. Removing the device includes removing the absorption bag, the cannula, and the discharge bag. Optionally, the reservoir is removed. However, the live cells are not removed and are retained in the body. A surgical tool can be used to cut an incision in the body and remove any of the desired components of the device.

Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain. “About” includes within a tolerance of ±0.01%, ±0.1%, ±1%, ±2%, ±3%, ±4%, ±5%, ±8%, ±10%, ±15%, ±20%, ±25%, or as otherwise known in the art. “Substantially” refers to more than 66%, 75%, 80%, 90%, 95%, or, depending on the context within which the term substantially appears, value otherwise as known in the art.