Macroporous particles

Abstract: Particles which enclose cavities can be produced by adding a water-insoluble solid, liquid or gaseous cavity gene­ rating compound to an aqueous solution of the matrix mate­ rial. Subsequent to forming particles by dispersion in a water-­ insoluble dispersion medium, the matrix is renderend insoluble in water by cooling, by covalent cross-linking or by polymerization. The cavity generating compound is washed out, whereafter the particles can be used as ion exchangers in gel filtration processes, in hydrophobic chromatography or in affinity chromatography, optionally subsequent to derivatiz­ ing the particles. The particles can also be used to advantage as microcarriers in the cultivation of anchorage dependent cells.

Description: The present invention concerns macroporous particles, processes to produce these particles and the use of the particles as ion exchanger in gel filtration, hydrophobic chromatography, affinity chromatography or as microcarriers in cell cultivation processes. The separation of molecules is effected to a large extent with the aid of matrices which have connected thereto ligands which interact with the molecules concerned. These ligands may be ionic, hydrophobic or affinity ligands. Electrically neutral matrices of mutually different porosity are used when separating molecules in accordance with size, i.e. gel filtration. These matrices are normally spheroidal in shape, in order to afford good flow properties. The flow properties of the separation system are also determined by the size of the particles present; the smaller the particles the higher the pressure drop, which results in a lower rate of flow. It is desirable in industrial applications to achieve high rates of flow, so that the molecules can be separated quickly. Another important parameter with regard to the particles used is the total specific surface area presented by the particles. The larger the specific surfaces are the more quickly the molecules are able to penetrate the matrix and interact with the ligands. The specific surface area can be increased by reducing the sizes of the particles. This antithesis is usually solved by taking a middle path, i.e. by using a relatively large particle size which is not optimum with regard to either the flow properties of the separation system or the specific surface area. The present invention overcomes the antithesis by manufacturing particles which enclose a large number of cavities, so that the particles can be given a size which while enabling a high rate of flow to be achieved also present a very large specific surface area. In addition to the separation of molecules, the extremely large surface area of the particles provided enables the particles to the used for cultivating anchorage dependent cells. In this technique, the anchorage dependent cells are allowed to grow on the surfaces of particles, microcarriers, suspended in a nutrient. Because the interiors of the particles can now also be used in cell cultivation processes, the surface area available is much larger and mechanical protection is also afforded to the cells during the process of cultivation. Thus, the invention concerns macroporous particles which are characterized in that they have a particle size of 10-500 µm and consist of a polymer matrix enclosing a large number of cavities having a diameter of 1-50 µm, which particles have been produced by mixing a solution of a matrix material, prepared by dissolving a polymer and/or polymerizable monomers in an aqueous solvent for the matrix material and addition of a water-soluble emulsifier, with a solid cavity generating compound to make a suspension of the solid compound in the solution; forming particles of the polymer matrix by dispersion of the suspension in a water-insoluble dispersion medium containing a water-insoluble emulsifier and solidifying the suspension droplets obtained in the medium; and washing out the solid cavity generating compound from the particles. The invention also concerns macroporous particles which are caracterized in that they have a particle size of 10-500 µm and consist of a polymer matrix enclosing a large number of cavities having a diameter of 1-50 µm, which particles have been produced by mixing a solution of a matrix material, prepared by dissolving a polymer and/or polymerizable monomers in an aqueous solvent for the matrix material and addition of a water-soluble emulsifier, with a water-insoluble dispersion medium containing a water-insoluble emulsifier to make a dispersion of the medium in the solution; forming particles of the polymer matrix by dispersing the dispersion in a further amount of the dispersion medium and solidifying the dispersion droplets obtained in the medium; and washing out the dispersion medium from the particles. These macroporous particles are produced by (A) dissolving a matrix material, selected from a water-soluble polymer and/or polymerizable monomers, in an aqueous solvent for the matrix material; (B) adding a water-soluble emulsifier; (C) forming cavity containing droplets of the matrix material by: a) adding a solid cavity generating compound which is insoluble in the aqueous solution while stirring the system to form a suspension of the cavity generating compound in the aqueous solution; and b) adding the suspension to a water-insoluble dispersion medium containing a water-insoluble emulsifier which dissolves in the dispersion medium while stirring to form a dispersion of droplets of the suspension in the dispersion medium; D) solidifying the dispersed droplets by cooling, covalent crosslinking or by polymerizitation to form beads of the polymer matrix each bead having a large number of pores containing the solid cavity generating compound; and E) washing out the solid cavity generating compound from the pores of the beads to form the macroporous particles with a large number of cavities; or by (A) dissolving a matrix material, selected from a water-soluble polymer and/or polymerizable monomers, in an aqueous solvent for the matrix material; (B) adding a water-soluble emulsifier; (C) forming cavity containing droplets of the matrix material by: a) adding a liquid cavity generating material consisting of a water-insoluble dispersion medium containing a water-insoluble emulsifier which dissolves in the dispersion medium, while stirring the system until the dispersion medium forms droplets in the aqueous solution and an emulsion is obtained; and b) adding additional dispersion medium to saturate the aqueous solution with the dispersion medium and to form droplets of the emulsion in the dispersion medium; D) solidifying the dispersed droplets by cooling, covalent crosslinking or by polymerizitation to form beads of the polymer matrix each bead having a large number of pores containing the dispersion medium ; and E) washing out the dispersion medium from the pores of the beads to form the macroporous particles with a large number of cavities. Subsequent to the removal of the solid or liquid cavity generating compound, the resultant microporous particles can either be derivatized or used directly for their intended purposes. The matrix forming compound is selected from proteins, polysaccharides or synthetic polymers. Examples of compounds which can be used are: proteins - gelatin, albumin polysaccharides - dextran, agarose synthetic polymers - polyacrylamide. An example of a solid cavity generating compound is calcium carbonate, which after the particles have been produced by dispersing the mixture in a water-insoluble dispersion medium and the matrix has been made insoluble in water, can be removed by treating the system with an acid. When the cavity generating compound used is in liquid form, it is necessary to add emulsifiers. The aqueous solution of the matrix is admixed with a water soluble emulsifier (characterized by an HLB-value greater than 9). Droplets of the cavity generating compound are formed by continuously adding the liquid cavity generating compound admixed with a water-insoluble emulsifier (characterized by a HLB-value lower than 8) to the aqueous solution of the matrix while stirring the system; the more vigorous the agitation the smaller the droplets formed. When the cavity generating compound has been added in an amount sufficient to saturate the aqueous solution of the matrix material, further addition will cause the matrix solution to form droplets in the excess of the cavity generating compound. By selecting emulsifiers which result in stable dispersions, particles of the matrix material which contain droplets of the cavity generating compound are obtained, subsequent to rendering the matrix insoluble in water. The cavity generating compound is then washed out with a solvent. The majority of organic solvents (water insoluble) can be used as the liquid cavity generating compound, as can also vegetable oils or mineral oils. Examples of suitable emulsifiers are Span® 85, Arlacel® 83 (water insoluble) and Tween® 80, Triton® X-100 (water soluble). Example 1 Thermal gelation (liquid cavity generating compound). Gelatin was dissolved by heating the same in water to a concentration of 10 % (w/v). 6 g of emulsifier (Tween® 80) were added to 100 ml of the gelating solution. 500 ml of toluene containing 30 g emulsifier (Span® 85) were then stirred into the solution. When beads of the desired size had formed, the dispersion was cooled to a temperature beneath the solidification temperature of the gelatin. The aforedescribed process results in the formation of gelatin beads which are saturated with droplets of toluene. These toluene droplets can be removed by washing the beads with ethanol and acetone, therewith providing a gelatin bead which is filled with cavities. The gelatin beads can then be cross-linked with, for example, glutardialdehyde, in order to further increase stability. Example 2 Thermal gelation (solid cavity generating compound). 10 g of calcium carbonate were added to 100 ml of gelatin solution (10 % w/v), whereafter beads were produced in accordance with Example 1. The beads were treated with acid, so as to dissolve the calcium carbonate and therewith form cavities in the beads. Example 3 Polymerization. Acrylamide (17 g) and bisacrylamide (1.2 g) were dissolved in a Tris-buffer (100 ml 0.05M, pH 7). Ammonium persulphate (0.5 g/ml, 0.25 ml) and emulsifier (Triton® x-100, 6 g) were added to the monomer solution. 500 ml of toluene containing an emulsifier (Span® 85, 30 g) were then stirred into the system. TEMED (co-catalyst, 1.3 ml) was then added to the system. The organic solvents were washed out with ethanol and acetone, upon termination of the polymerization process. Example 4 Covalent cross-linking. Sodium hydroxide (0.7 g) and emulsifier (Tween® 80, 6 g) were added to an aqueous solution of dextran (10 %, w/v, 100 ml). Toluene (500 ml) having an emulsifier (Span® 85, 30 g) and epichlorohydrin (1.5 g) dissolved therein was then added to the solution while stirring the system. The temperature of the system was raised to 40°C over a period of 2 hours, and then to 70°C over a further period of 12 hours. The resultant beads were washed with ethanol and acetone, in order to remove organic solvent. The properties of the beads formed can be varied, by varying the quantity of dextran and the quantity of epichlorohydrin used. Example 5 Covalent cross-linking. Chitosan was dissolved in formic acid (5 %, w/v) to a concentration of 30 g/l. 100 ml of solution were admixed with emulsifier (Tween® 80, 6 g) and, while stirring the system, with toluene (500 ml) containing an emulsifier (Span® 85, 30 g). Subsequent to obtaining beads of the desired size, formaldehyde (20 ml) was added to the system. The resultant beads were washed with methanol after a time lapse of one hour.

Claims: Macroporous particles to be used as ion exchanger in gel filtration, hydrophobic chromatography, affinity chromatography or as microcarriers in cell cultivation processes, characterized in that they have a particle size of 10-500 µm and consist of a polymer matrix enclosing a large number of cavities having a diameter of 1-50 µm which particles have been produced by mixing a solution of a matrix material, prepared by dissolving a polymer and/or polymerizable monomers in an aqueous solvent for the matrix material and addition of a water-soluble emulsifier, with a solid cavity generating compound to make a suspension of the solid compound in the solution; forming particles of the polymer matrix by dispersion of the suspension in a water-insoluble dispersion medium containing a water-insoluble emulsifier and solidifying the suspension droplets obtained in the medium; and washing out the solid cavity generating compound from the particles. Macroporous particles to be used as ion exchanger in gel filtration, hydrophobic chromatography, affinity chromatography or as microcarriers in cell cultivation processes, characterized in that they have a particle size of 10-500 µm and consist of a polymer matrix enclosing a large number of cavities having a diameter of 1-50 µm which particles have been produced by mixing a solution of a matrix material, prepared by dissolving a polymer and/or polymerizable monomers in an aqueous solvent for the matrix material and addition of a water-soluble emulsifier, with a water-insoluble dispersion medium containing a water-insoluble emulsifier to make a dispersion of the medium in the solution; forming particles of the polymer matrix by dispersing the dispersion in a further amount of the dispersion medium and solidifying the dispersion droplets obtained in the medium; and washing out the dispersion medium from the particles. Particles according to Claim 1 or 2, characterized in that the particles have a size of approximately 200 µm and that the cavities have a diameter of approximately 10-20 µm. Particles according to any of Claims 1-3 , characterized in that the polymer matrix comprises a protein, a polysaccharide or a synthetic polymer. A method of producing macroporous particles to be used as ion exchanger in gel filtration, hydrophobic chromatography, affinity chromatography or as microcarriers in cell cultivation processes, having a particle size of 10-500 µm and comprising a polymer matrix which encloses a large number of cavities of a diameter of 1-50 µm, characterized in (A) dissolving a matrix material, selected from a water-soluble polymer and/or polymerizable monomers, in an aqueous solvent for the matrix material; (B) adding a water-soluble emulsifier; (C) forming cavity containing droplets of the matrix material by: a) adding a liquid cavity generating material consisting of a water-insoluble dispersion medium containing a water-insoluble emulsifier which dissolves in the dispersion medium, while stirring the system until the dispersion medium forms droplets in the aqueous solution and an emulsion is obtained; and b) adding additional dispersion medium to saturate the aqueous solution with the dispersion medium and to form droplets of the emulsion in the dispersion medium; D) solidifying the dispersed droplets by cooling, covalent crosslinking or by polymerizitation to form beads of the polymer matrix each bead having a large number of pores containing the dispersion medium ; and E) washing out the dispersion medium from the pores of the beads to form the macroporous particles with a large number of cavities. A method of producing macroporous particles to be used as ion exchanger in gel filtration, hydrophobic chromatography, affinity chromatography or as microcarriers in cell cultivation processes, having a particle size of 10-500 µm and comprising a polymer matrix which encloses a large number of cavities of a diameter of 1-50 µm, characterized in (A) dissolving a matrix material, selected from a water-soluble polymer and/or polymerizable monomers, in an aqueous solvent for the matrix material; (B) adding a water-soluble emulsifier; (C) forming cavity containing droplets of the matrix material by: a) adding a solid cavity generating compound which is insoluble in the aqueous solution while stirring the system to form a suspension of the cavity generating compound in the aqueous solution; and b) adding the suspension to a water-insoluble dispersion medium containing a water-insoluble emulsifier which dissolves in the dispersion medium while stirring to form a dispersion of droplets of the suspension in the dispersion medium; D) solidifying the dispersed droplets by cooling, covalent crosslinking or by polymerizitation to form beads of the polymer matrix each bead having a large number of pores containing the solid cavity generating compound; and E) washing out the solid cavity generating compound from the pores of the beads to form the macroporous particles with a large number of cavities. A method according to Claim 5 or 6, characterized in that the water-insoluble dispersion medium is an organic solvent, a vegetable oil or a mineral oil. A method according to claim 6, characterized in that the solid cavity generating compound is calcium carbonate. A method according to any of Claims 5-8, characterized in binding negative groups, positive groups, hydrophobic groups or affinity ligands to the matrix of the produced particles. A method according to any of Claims 5-9, characterized in selecting the matrix material from the group of proteins, polysaccarides or polymerizable monomers. The use of macroporous particles according to Claim 1 or 2 with a particle size of 10-500 µm and comprising a polymer matrix enclosing a large number of cavities having a diameter of 1-50 µm as an ion exchanger in gel filtration, hydrophobic chromatography, affinity chromatography or as microcarriers in cell cultivation processes.

Inventors: MOSBACH KLAUS H, NILSSON KJELL G C, MOSBACH, KLAUS H., NILSSON, KJELL G.C.
Applicants: MOSBACH KLAUS H, NILSSON KJELL G C, MOSBACH, KLAUS H., NILSSON, KJELL G.C.
Application year: 1986
Main classification: C08J3
IPC codes: C08J9, C08J3, B01J20