# US 10,370,505 B2 · Method for making biofabricated composite

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- Number: US 10,370,505 B2
- Document ID: US10370505B2
- Status: Granted
- Kind: B2
- Application number: 15/433,693
- Filed: 2017-02-15
- Published: 2017-08-17
- Granted: 2019-08-06
- Earliest claimed: 2016-02-15
- Assignees: Modern Meadow, Inc.
- Applicants: Modern Meadow, Inc.
- Inventors: Brendan Patrick Purcell; David Thomas Williamson; Suzanne Lee; Amy Congdon
- Web page: https://patentgrep.com/patent/US10370505B2

## CPC

- C08J 3/24: Crosslinking, e.g. vulcanising, of macromolecules (mechanical aspects B29C35/00; crosslinking agents C08K)
- B32B 1/08: Tubular products
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 5/022: {Non-woven fabric}
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 9/025: {comprising leather}
- B32B 15/02: {Layer formed of wires, e.g. mesh}
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 23/10: next to a fibrous or filamentary layer
- B32B 27/12: next to a fibrous or filamentary layer
- B32B 29/02: next to a fibrous or filamentary layer
- C07K 14/78: Connective tissue peptides, e.g. collagen, elastin, laminin, fibronectin, vitronectin or cold insoluble globulin [CIG]
- C08H 1/06: derived from horn, hoofs, hair, skin or leather
- C08L 89/06: derived from leather or skin {, e.g. gelatin}
- C14C 9/00: Impregnating leather for preserving, waterproofing, making resistant to heat or similar purposes
- C14C 9/02: using fatty or oily materials, e.g. fat liquoring
- C14C 13/00: Manufacture of special kinds or leather, e.g. vellum (chamois tanning C14C3/14)
- D01C 3/00: Treatment of animal material, e.g. chemical scouring of wool
- D01F 4/00: Monocomponent artificial filaments or the like of proteins; Manufacture thereof
- D04H 1/00: Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H 1/4382: Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
- D04H 1/43838: {Ultrafine fibres, e.g. microfibres}
- D04H 13/00: Other non-woven fabrics
- D06M 15/05: Cellulose or derivatives thereof
- D06M 15/15: Proteins or derivatives thereof
- D06N 3/00: Artificial leather, oilcloth or {other} material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
- D06N 3/0018: {Collagen fibres or collagen on fibres}
- D06N 7/0097: {Web coated with fibres, e.g. flocked}
- D06P 3/32: leather {skins}
- B32B 2250/02: 2 layers
- B32B 2250/03: 3 layers
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2250/42: Alternating layers, e.g. ABAB(C), AABBAABB(C)
- B32B 2255/02: on fibrous or filamentary layer
- B32B 2255/26: Polymeric coating
- B32B 2262/0207: Elastomeric fibres
- B32B 2262/0261: Polyamide fibres
- B32B 2262/0269: Aromatic polyamide fibres
- B32B 2262/0276: Polyester fibres
- B32B 2262/0292: Polyurethane fibres
- B32B 2262/04: Cellulosic plastic fibres, e.g. rayon
- B32B 2262/062: Cellulose fibres, e.g. cotton
- B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
- B32B 2262/067: Wood fibres
- B32B 2262/08: Animal fibres, e.g. hair, wool, silk
- B32B 2262/10: Inorganic fibres
- B32B 2262/101: Glass fibres
- B32B 2262/103: Metal fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2262/14: Mixture of at least two fibres made of different materials
- B32B 2264/105: Metal
- B32B 2307/202: Conductive
- B32B 2307/208: Magnetic, paramagnetic
- B32B 2307/308: Heat stability
- B32B 2307/4026: within the layer by addition of a colorant, e.g. pigments, dyes
- B32B 2307/422: Luminescent, fluorescent, phosphorescent
- B32B 2307/50: having particular mechanical properties
- B32B 2307/51: Elastic
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/5825: Tear resistant
- B32B 2307/708: Isotropic
- B32B 2307/7265: Non-permeable
- B32B 2437/00: Clothing
- B32B 2437/02: Gloves, shoes
- B32B 2437/04: Caps, helmets
- B32B 2439/46: Bags
- B32B 2451/00: Decorative or ornamental articles
- B32B 2457/00: Electrical equipment
- B32B 2471/00: Floor coverings (B32B2419/04 takes precedence)
- B32B 2479/00: Furniture
- B32B 2519/00: Labels, badges
- B32B 2571/00: Protective equipment
- B32B 2601/00: Upholstery
- B32B 2605/003: Interior finishings
- B32B 2605/08: Cars
- B32B 2605/12: Ships
- B32B 2605/18: Aircraft
- C08J 2389/06: derived from leather or skin
- D06M 23/16: Processes for the non-uniform application of treating agents, e.g. one-sided treatment; Differential treatment
- D06M 2101/06: cellulosic
- D06N 2201/06: Animal fibres, e.g. hair, wool, silk
- D06N 2203/02: Natural macromolecular compounds or derivatives thereof
- C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C07K: PEPTIDES (peptides in foodstuffs A23; obtaining protein compositions for foodstuffs, working-up proteins for foodstuffs A23J; preparations for medicinal purposes A61K; peptides containing beta-lactam rings C07D; cyclic dipeptides not having in their molecule any other peptide link than those which form their ring, e.g. piperazine-2,5-diones, C07D; ergot alkaloids of the cyclic peptide type C07D519/02; macromolecular compounds having statistically distributed amino acid units in their molecules, i.e. when the preparation does not provide for a specific; but for a random sequence of the amino acid units, homopolyamides and block copolyamides derived from amino acids C08G69/00; macromolecular products derived from proteins C08H1/00; preparation of glue or gelatine C09H; single cell proteins, enzymes C12N; genetic engineering processes for obtaining peptides C12N15/00; compositions for measuring or testing processes involving enzymes C12Q; investigation or analysis of biological material G01N33/00)
- C08H: DERIVATIVES OF NATURAL MACROMOLECULAR COMPOUNDS (polysaccharides C08B; natural rubber C08C; natural resins or their derivatives C09F; bituminous materials C10)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C14C: CHEMICAL TREATMENT OF HIDES, SKINS OR LEATHER, e.g. TANNING, IMPREGNATING, FINISHING; APPARATUS THEREFOR; COMPOSITIONS FOR TANNING (bleaching of leather or furs D06L; dyeing of leather or furs D06P)
- D01C: CHEMICAL OR BIOLOGICAL TREATMENT OF NATURAL FILAMENTARY OR FIBROUS MATERIAL TO OBTAIN FILAMENTS OR FIBRES FOR SPINNING; CARBONISING RAGS TO RECOVER ANIMAL FIBRES
- D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- D06M: TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06N: WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06P: DYEING OR PRINTING TEXTILES; DYEING LEATHER, FURS OR SOLID MACROMOLECULAR SUBSTANCES IN ANY FORM

## Abstract

The invention is directed to a composite material comprising a biofabricated material and a secondary component. The secondary component may be a porous material, such as a sheet of paper, cellulose, or fabric that has been coated or otherwise contacted with the biofabricated material. The biofabricated material comprises a uniform network of crosslinked collagen fibrils and provides strength, elasticity and an aesthetic appearance to the composite material.

## Claims

### Claim 1

A method for making a composite material comprising:
dispersing, encapsulating, incorporating, or otherwise introducing at least one biofabricated material into or onto at least one porous, permeable, or absorptive secondary component; wherein said at least one biofabricated material comprises a network of recombinant non-human collagen fibrils produced from isolated or purified recombinant non-human collagen molecules; wherein said material contains no more than 25% by weight water; said material has a collagen density of at least 70 mg/cc; and wherein said material contains at least 1% of a lubricant.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the at least one biofabricated material is produced by a process comprising:
fibrillating an aqueous solution or suspension of isolated or purified recombinant non-human collagen molecules into collagen fibrils,
crosslinking said collagen fibrils by contacting them with at least one crosslinking agent, and
dehydrating the crosslinked collagen fibrils so that they contain less than 25% by weight water, and
further lubricating by incorporating at least 1% by weight of at least one lubricant prior to, during, or after any of said fibrillating, crosslinking, and dehydrating.

### Claim 3 (depends on 2)

The method according to claim 2, wherein said fibrillating, crosslinking, dehydrating and/or lubricating is performed for a time and under conditions that produce no more than 10% by weight of the collagen fibrils in the biofabricated material in the form of collagen fibers having a diameter of 5 μm or more.

### Claim 4 (depends on 1)

The method of claim 1 that comprises introducing the biofabricated material into or onto a top or bottom, or inner and outer, surface of the secondary component.

### Claim 5 (depends on 4)

The method of claim 4, further comprising crosslinking the biofabricated material once introduced.

### Claim 6 (depends on 4)

The method of claim 4 further comprising crosslinking the biofabricated material with at least one compound selected from the group consisting of an amine, carboxylic acid, sulfate, sulfite, sulfonate, aldehyde, hydrazide, sulfhydryl, diazirine, aryl, azide, acrylate, epoxide, phenol, chromium compound, vegetable tannin, and syntan.

### Claim 7 (depends on 4)

The method of claim 4, further comprising dehydrating the biofabricated material once introduced.

### Claim 8 (depends on 4)

The method of claim 4, further comprising dehydrating the biofabricated material once introduced with acetone.

### Claim 9 (depends on 4)

The method of claim 4, further comprising lubricating the biofabricated material once introduced.

### Claim 10 (depends on 4)

The method of claim 4, further comprising lubricating the biofabricated material once introduced with at least one lubricant selected from the group consisting of fat, biological, mineral or synthetic oil, cod oil, sulfonated oil, polymer, and organofunctional siloxane.

### Claim 11 (depends on 4)

The method of claim 4 that comprises introducing the biofabricated material into or onto the secondary component by filtration, dipping, spraying or coating.

### Claim 12 (depends on 4)

The method of claim 4 that comprises applying the biofabricated material to only one side of the secondary component.

### Claim 13 (depends on 4)

The method of claim 4 that comprises applying the biofabricated material to both sides of the secondary component.

### Claim 14 (depends on 4)

The method of claim 4 that comprises layering the biofabricated material between two layers of the secondary component.

### Claim 15 (depends on 4)

The method of to claim 4, wherein the secondary component comprises a fiber, a woven or nonwoven fabric, or other fibrous material.

### Claim 16 (depends on 4)

The method of claim 4, wherein the secondary component comprises paper, cellulose or reconstituted cellulose.

### Claim 17 (depends on 1)

The method of claim 1 that comprises embedding or admixing the at least one secondary component in or with the biofabricated material.

### Claim 18 (depends on 17)

The method according to claim 17, wherein the secondary component comprises at least one resin, polymer, or plastic.

### Claim 19 (depends on 17)

The method according to claim 17, wherein the secondary component comprises at least one particle, bead, wire, mesh, fiber, woven or nonwoven fabric, or other three dimensional object.

### Claim 20 (depends on 17)

The method according to claim 17 that comprises uniformly distributing at least one filler in the biofabricated material, wherein the concentration by weight of the filler in or on identical unit volumes of the material varies by no more than 20%.

### Claim 21 (depends on 1)

The method according to claim 1, wherein the collagen contains substantially no 3-hydroxyproline.

### Claim 22 (depends on 1)

The method according to claim 1, wherein the collagen contains substantially no hydroxylysine.

### Claim 23 (depends on 1)

The method according to claim 1, wherein said material comprises no more than 1% of actin.

### Claim 24 (depends on 1)

The method according to claim 1, wherein said method is performed for a time and under conditions that produce a material having a tensile strength of at least 1 MPa, a flexibility determined by elongation at break of at least 1%, a softness as determined by ISO 17235 of at least 2 mm, and a thickness of at least 0.05 mm.

### Claim 25 (depends on 1)

The method of claim 1, wherein said recombinant non-human collagen molecules are isolated from cells that are cultured in vitro.

### Claim 26 (depends on 1)

The method of claim 1, wherein said recombinant non-human collagen molecules are purified.

### Claim 27

A method for making a composite material comprising:
dispersing, encapsulating, incorporating, or otherwise introducing at least one biofabricated material into or onto at least one porous, permeable, or absorptive secondary component; wherein said at least one biofabricated material comprises a network of recombinant collagen fibrils produced from isolated or purified recombinant collagen molecules; wherein said material contains no more than 25% by weight water and no more than 1% of actin; said material has a collagen density of at least 70 mg/cc; and wherein said material contains at least 1% of a lubricant.

### Claim 28 (depends on 1)

The method according to claim 1, wherein said material contains at least 10% by weight water.

### Claim 29 (depends on 1)

The method according to claim 1, wherein said material has a collagen density of at least 100 mg/cc.

### Claim 30 (depends on 1)

The method according to claim 1, wherein said material has a collagen density of 100 mg/cc to 500 mg/cc.

### Claim 31 (depends on 27)

The method of claim 27, wherein said recombinant non-human collagen molecules have a degree of purity of at least 40% by weight based on its total protein content.

### Claim 32 (depends on 27)

The method according to claim 27, wherein the at least one biofabricated material is produced by a process comprising:
fibrillating an aqueous solution or suspension of isolated or purified recombinant collagen molecules into collagen fibrils,
crosslinking said collagen fibrils by contacting them with at least one crosslinking agent, and
dehydrating the crosslinked collagen fibrils so that they contain less than 25% by weight water, and
further lubricating by incorporating at least 1% by weight of at least one lubricant prior to, during, or after any of said fibrillating, crosslinking, and dehydrating.

### Claim 33 (depends on 27)

The method according to claim 27, wherein said material contains at least 10% by weight water.

### Claim 34 (depends on 27)

The method according to claim 27, wherein said material has a collagen density of at least 100 mg/cc.

### Claim 35 (depends on 27)

The method according to claim 27, wherein said material has a collagen density of 100 mg/cc to 500 mg/cc.