MANUFACTURING APPARATUS FOR USE IN LOW-TEMPERATURE HIGH-SPEED MANUFACTURING OF SUPPORT STRUCTURE AND MANUFACTURING METHOD FOR USE IN LOW-TEMPERATURE HIGH-SPEED MANUFACTURING OF SUPPORT STRUCTURE

A manufacturing apparatus for use in the low-temperature high-speed manufacturing of a support structure is introduced. The support structure thus manufactured is for supporting a low-temperature manufacturing scaffold for use in tissue engineering. The manufacturing apparatus includes a frame; a ring-shaped thermally conductive member disposed on the frame; a thermally conductive platform disposed centrally at the ring-shaped thermally conductive member and having an edge in direct contact with an inner wall of the ring-shaped thermally conductive member, wherein a space is defined by and between the thermally conductive platform and the ring-shaped thermally conductive member; a low temperature generating mechanism connected to the ring-shaped thermally conductive member and the thermally conductive platform to cool down the ring-shaped thermally conductive member and the thermally conductive platform; and a spray member disposed above the thermally conductive platform to spray a support material into the space.

CROSS-REFERENCE TO RELATED APPLICATION

This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No(s). 105100100 filed in Taiwan, R.O.C. on Jan. 4, 2016, the entire contents of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to manufacturing apparatuses and, more particularly, to a manufacturing apparatus for use in the low-temperature high-speed manufacturing of a support structure for supporting a low-temperature manufacturing scaffold for use in tissue engineering.

BACKGROUND OF THE INVENTION

A conventional low-temperature manufacturing scaffold for use in tissue engineering is manufactured by depositing a scaffold material layer, wherein the upper layer structure of the scaffold thus manufactured must be fully deposited on its lower layer structure in order to finalize the shape of the scaffold thus manufactured. If the low-temperature manufacturing scaffold for use in tissue engineering has a specific structure, such as a suspended end, the scaffold cannot be directly manufactured but requires an additional support structure (see Ming C. Leu and Diego A. Garcia. Development of freeze-form extrusion fabrication with use of sacrificial material, Journal of Manufacturing Science and Engineering December 2014, Vol. 136/061014-1-9.)

A conventional support structure is made of a support material which is different from that the conventional low-temperature manufacturing scaffold for use in tissue engineering is made of. The low-temperature manufacturing of a support structure, which is effectuated in a way similar to the manufacturing of the low-temperature manufacturing scaffold for use in tissue engineering, entails squeezing out a support material with a nozzle and then depositing it to therefore form a support structure. The aforesaid manufacturing process is not only slow but also unfavorable to the deposition of the scaffold material layer of the low-temperature manufacturing scaffold for use in tissue engineering (see Frances D. Bryant and Ming C. Leu. Modeling and experimental results of concentration with support material in rapid freeze prototyping, Rapid Prototyping Journal 2009, Vol. 15 Iss5 pp. 317-324.)

The conventional support structure supports, from below, the scaffold material layer of the low-temperature manufacturing scaffold for use in tissue engineering. If the scaffold material layer of the low-temperature manufacturing scaffold for use in tissue engineering is misaligned during the deposition process and thus goes beyond the support capacity of a support structure, the scaffold material cannot be supported by the support structure.

Accordingly, it is imperative to provide a manufacturing apparatus for use in the low-temperature high-speed manufacturing of a support structure to effectuate the low-temperature high-speed manufacturing of a support structure, facilitate the deposition of a scaffold material layer of a low-temperature manufacturing scaffold for use in tissue engineering on the support structure, and thus enable the low-temperature manufacturing scaffold for use in tissue engineering to form a specific structure.

SUMMARY OF THE INVENTION

It is an objective of the present invention to provide a manufacturing apparatus for use in the low-temperature high-speed manufacturing of a support structure to effectuate the low-temperature high-speed manufacturing of a support structure, facilitate the deposition of a scaffold material layer of a low-temperature manufacturing scaffold for use in tissue engineering on the support structure, and thus enable the low-temperature manufacturing scaffold for use in tissue engineering to form a specific structure.

In order to achieve the above and other objectives, the present invention provides a manufacturing apparatus for use in the low-temperature high-speed manufacturing of a support structure, and the support structure thus manufactured is for supporting a low-temperature manufacturing scaffold for use in tissue engineering. The manufacturing apparatus comprises: a frame; a ring-shaped thermally conductive member disposed on the frame; a thermally conductive platform disposed centrally at the ring-shaped thermally conductive member and having an edge in direct contact with an inner wall of the ring-shaped thermally conductive member, wherein a space is defined by and between the thermally conductive platform and the ring-shaped thermally conductive member; a low temperature generating mechanism connected to the ring-shaped thermally conductive member and the thermally conductive platform to cool down the ring-shaped thermally conductive member and the thermally conductive platform; and a spray member disposed above the thermally conductive platform to spray a support material into the space.

Regarding the manufacturing apparatus of the present invention, the support material has a water content of 100%.

Regarding the manufacturing apparatus of the present invention, the support material comprises an alcohol solution.

Regarding the manufacturing apparatus of the present invention, the spray member sprays the support material extensively.

Regarding the manufacturing apparatus of the present invention, the spray member is fan-shaped, round or elliptical.

In order to achieve the above and other objectives, the present invention further provides a manufacturing method for use in the low-temperature high-speed manufacturing of a support structure, with the support structure supporting a low-temperature manufacturing scaffold for use in tissue engineering, the manufacturing method comprising the steps of: S100: providing the manufacturing apparatus of any one of claims1-9; S300: injecting a scaffold material layer for use in tissue engineering into a space and then depositing the scaffold material layer on the thermally conductive platform to allow the scaffold material layer deposited on the thermally conductive platform to solidify at low temperature; S500: spraying a support material into the space with the spray member; S700: enabling the support material reaching the thermally conductive platform to be solidified at low temperature until the support material is of a less height than or same height as the scaffold material layer frozen; and S900: injecting and depositing the scaffold material layer on one of the scaffold material layer frozen and the support material frozen, thereby allowing the scaffold material layer to solidify at low temperature.

In conclusion, the present invention provides a manufacturing apparatus for use in the low-temperature high-speed manufacturing of a support structure, facilitate the deposition of a scaffold material layer of a low-temperature manufacturing scaffold for use in tissue engineering on the support structure, and thus enable the low-temperature manufacturing scaffold for use in tissue engineering to form a specific structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1shows a manufacturing apparatus100for use in the low-temperature high-speed manufacturing of a support structure. The manufacturing apparatus100and the support structure thus manufactured are for supporting a scaffold material layer of a low-temperature manufacturing scaffold for use in tissue engineering. The manufacturing apparatus100comprises a frame10, a ring-shaped thermally conductive member20, a thermally conductive platform30, a low temperature generating mechanism40and a spray member50. The manufacturing apparatus100comes with a nozzle1000to thereby manufacture a low-temperature manufacturing scaffold for use in tissue engineering. The nozzle1000injects a scaffold material layer (hereinafter referred to as the scaffold material layer) of the low-temperature manufacturing scaffold for use in tissue engineering such that the scaffold material layer deposits on the thermally conductive platform30of the manufacturing apparatus100or on the support structure manufactured with the manufacturing apparatus100.

The frame10is disposed below the nozzle1000.

The ring-shaped thermally conductive member20is fixedly disposed in the frame10and below the nozzle1000. The ring-shaped thermally conductive member20is of a geometric shape, such as rectangular, round, or elliptical, but the present invention is not limited thereto. Preferably, the ring-shaped thermally conductive member20is made of stainless steel and thus resistant to corrosion and easy to sterilize.

The thermally conductive platform30is disposed centrally at the ring-shaped thermally conductive member20and has an edge in direct contact with the inner wall of the ring-shaped thermally conductive member20. Hence, the ring-shaped thermally conductive member20and the thermally conductive platform30cool down each other. A space31is defined by and between the thermally conductive platform30and the ring-shaped thermally conductive member20.

The low temperature generating mechanism40is connected to the ring-shaped thermally conductive member20to cool down the ring-shaped thermally conductive member20. The low temperature generating mechanism40fits around the outer wall of the ring-shaped thermally conductive member20. The low temperature generating mechanism40is a thermally conductive copper pipe that effectuates cooling by containing a coolant. Referring toFIG. 1, a peristaltic pump circulates a low-temperature alcohol solution within the low temperature generating mechanism40such that the low temperature generating mechanism40cools down the ring-shaped thermally conductive member20, and in consequence the ring-shaped thermally conductive member20cools down the thermally conductive platform30. In a variant embodiment of the present invention, the low temperature generating mechanism40is connected to the thermally conductive platform30to cool down the thermally conductive platform30and thus cool down the ring-shaped thermally conductive member20. In another variant embodiment of the present invention, the low temperature generating mechanism40and the ring-shaped thermally conductive member20are integrated to form a single member. For example, channels are disposed inside the ring-shaped thermally conductive member20to convey a coolant to thereby form the low temperature generating mechanism40, so as to enhance the cooling efficiency and reduce the required volume of the low temperature generating mechanism40.

The spray member50is disposed above the thermally conductive platform to thereby spray a hydrated aerosol into the space31. The hydrated aerosol (hereinafter referred to as the support material) is for use in manufacturing a support structure. Being hydrated, the support material facilitates low-temperature solidification. Being hydrated, the support material renders it easy to be removed from the low-temperature manufacturing scaffold for use in tissue engineering, even though the scaffold has a specific structure formed as a result of the deposition of the scaffold material layer on the support structure. With the spray member50spraying the hydrated aerosol extensively, the support structure can be manufactured quickly and distributed uniformly within the space31. To enable the spray member50to spray the hydrated aerosol extensively, the nozzle of the spray member50is preferably fan-shaped, round or elliptical. In yet another variant embodiment of the present invention, to prevent the support material from remaining on the scaffold material layer, the spray member50sprays the hydrated aerosol with the airflow to thereby remove any residues of the support material from the scaffold material layer.

In a further embodiment of the present invention, the support material is pure water when its water content equals 100%, but the present invention is not limited thereto. Alternatively, the support material has a water content less than 100%, as is the case where the support material contains an alcohol solution, so as to adjust the freezing point.

Regarding the low-temperature manufacturing scaffold for use in tissue engineering and support structure, the low temperature must be low enough to allow the scaffold material layer and support material to freeze quickly. Hence, it is necessary that the low temperature generated from the low temperature generating mechanism40is changed according to the difference in the freezing point and the freeze duration between the scaffold material layer and the support material. The aforesaid cooling process is inevitably accompanied by a loss of cooling energy; hence, the low temperature generating mechanism40is always cooler than the ring-shaped thermally conductive member20. For example, to allow the ring-shaped thermally conductive member20, the thermally conductive platform30and the space31to reach −20□, the low temperature generated from the low temperature generating mechanism40must be lower than −20□.

Referring toFIG. 1, the thermally conductive platform30is movably disposed at the ring-shaped thermally conductive member20and descends when driven by a vertically movable mechanism M, so as to increase the depth of the space31gradually and thus manufacture the low-temperature manufacturing scaffold for use in tissue engineering and the support structure at a constant temperature, as shown inFIG. 2throughFIG. 6. In a further variant embodiment of the present invention, the thermally conductive platform30is fixedly positioned at the ring-shaped thermally conductive member20to facilitate the manufacturing of the low-temperature manufacturing scaffold for use in tissue engineering and the support structure by moving the nozzle1000and the spray member50vertically.

Referring toFIG. 2throughFIG. 8, both the manufacturing apparatus100and the nozzle1000enable the scaffold material layer to be deposited on the support structure at a low temperature such that the low-temperature manufacturing scaffold for use in tissue engineering forms a specific structure.FIG. 8is a flowchart of a manufacturing method for use in the low-temperature high-speed manufacturing of the support structure according to the present invention.

Referring toFIG. 2andFIG. 8, in step S100, the manufacturing apparatus100is provided, and the thermally conductive platform30of the manufacturing apparatus100descends when driven by the vertically movable mechanism M, so as to define the space31. Referring toFIG. 3andFIG. 7, in step S300, in the space31, the scaffold material layer is injected from the nozzle1000, then deposited on the thermally conductive platform30, and eventually solidified at a low temperature, so as to form a first scaffold material layer1; to this end, the nozzle1000moves laterally relative to the platform structure100, as indicated by the arrows shown inFIG. 1andFIG. 2. Referring toFIG. 4andFIG. 7, in step S500, the spray member50sprays the support material into the space31, and the support material moves gradually to the thermally conductive platform30. Referring toFIG. 4andFIG. 7, in step S700, the support material freezes upon arrival at the thermally conductive platform30, and the frozen process of the support material continues until the support material is of a less height than or same height as the scaffold material layer (i.e., the first scaffold material layer1) frozen, thereby forming a first support material layer1a. Referring toFIG. 5andFIG. 7, in step S900, the scaffold material layer is injected from the nozzle1000once again, then deposited on the scaffold material layer frozen, (i.e., the first scaffold material layer1) or the support material frozen, (i.e., the first support material layer1a), thereby allowing the scaffold material layer to solidify, at low temperature and allowing a second scaffold material layer2to form; to this end, the nozzle1000moves laterally relative to the platform structure100.

To allow the support material to be quickly and evenly distributed inside the space31and allow the height of the support material to increase quickly, the spray member50sprays extensively. To allow the support material to freeze quickly without being left on the scaffold material layer, it is necessary to control the temperature in the space31such that the support material efficiently flows to the thermally conductive platform30before getting frozen. To effectively prevent the support material from remaining on the scaffold material layer, the spray member50sprays the support material with the airflow simultaneously such that whatever residues of the support material is removed from the scaffold material layer.

Step S500through step S900are carried out repeatedly to form a tissue engineering-oriented scaffold S of irregular shape as shown inFIG. 6. The tissue engineering-oriented scaffold S has six scaffold material layers and four support material layers. The second scaffold material layer2is deposited on both the first scaffold material layer1and the first support material layer1a. A second support material layer2ais sprayed on the first support material layer1a. The second support material layer2ais of the same height as the second scaffold material layer2substantially. A third scaffold material layer3is deposited on the second scaffold material layer2. A third support material layer3ais sprayed on both the second scaffold material layer2and the second support material layer2a. The third support material layer3ais of the same height as the third scaffold material layer3substantially. A fourth scaffold material layer4is deposited on the third scaffold material layer3. A fourth support material layer4ais sprayed on the third support material layer3a. The fourth support material layer4ais of the same height as the fourth scaffold material layer4substantially. A fifth scaffold material layer5is deposited on the fourth scaffold material layer4and the fourth support material layer4a. A sixth scaffold material layer6is deposited on the fifth scaffold material layer5.

In a further variant embodiment of the present invention, when the support material, namely the first support material layer1a, the second support material layer2a, the third support material layer3aand the fourth support material layer4a, freeze, their surfaces will be coarse so as to facilitate the deposition of the scaffold material layer thereon.

Referring toFIG. 7A, the tissue engineering-oriented scaffold S has a support material (the first support material layer1a, the second support material layer2a, the third support material layer3aand the fourth support material layer4a) which undergoes a freeze-drying process to effectuate the tissue engineering-oriented scaffold S having a scaffold material layer, as shown inFIG. 7B.

In conclusion, the present invention provides a manufacturing apparatus and a manufacturing method for use in the low-temperature high-speed manufacturing of a support structure to effectuate the low-temperature high-speed manufacturing of a support structure, facilitate the deposition of a scaffold material layer of a low-temperature manufacturing scaffold for use in tissue engineering on the support structure, and thus enable the low-temperature manufacturing scaffold for use in tissue engineering to form a specific structure.

The present invention is disclosed above by preferred embodiments. However, persons skilled in the art should understand that the preferred embodiments are illustrative of the present invention only, but should not be interpreted as restrictive of the scope of the present invention. Hence, all equivalent modifications and replacements made to the aforesaid embodiments should fall within the scope of the present invention. Accordingly, the legal protection for the present invention should be defined by the appended claims.