HIERARCHICAL MULTISCALE ELECTROSPUN SCAFFOLD FOR THE REGENERATION AND/OR REPLACEMENT OF THE TENDINOUS/LIGAMENTOUS TISSUE AND A METHOD FOR ITS PRODUCTION

Abstract

The present invention relates to a support or a multiscale hierarchical scaffold for the tissue regeneration, in particular for the regeneration or replacement of the tendinous and/or ligamentous and/or muscular and/or nervous tissue. The present invention further relates to the processes for obtaining such support and the uses thereof.

Claims

1. A multiscale hierarchical scaffold for replacing, repairing, regenerating, reconstructing or simulating a tissue, in particular the tendinous and/or ligamentous and/or muscular and/or nervous tissue comprising: (a) a plurality of clusters obtained by electrospinning each one consisting of nanofibers, wherein said plurality of clusters are arranged in order to form one single group; and (b) a porous sheath obtained by electrospinning consisting of nanofibers, wherein said sheath externally coats and compacts said plurality of clusters keeping them aligned with each other.

2. The scaffold according to claim 1 comprising: (a) a plurality of clusters of axially aligned nanofibers (bundles) and/or of clusters of twisted nanofibers (yarns), obtained by electrospinning, consisting of axially aligned and/or twisted nanofibers, respectively, axially arranged so as to form one single group; and (b) a porous sheath obtained by electrospinning consisting of nanofibers, wherein said sheath externally coats and compacts said plurality of clusters keeping them aligned with each other.

3. The scaffold according to claim 1 comprising: (a) a plurality of ring-like clusters of nanofibers (ring bundles), obtained by electrospinning, consisting of axially aligned and/or axially twisted nanofibers, respectively, and/or arranged randomly so as to form one single group; and (b) a porous sheath obtained by electrospinning consisting of nanofibers, wherein said sheath externally coats and compacts said plurality of clusters keeping them aligned with each other.

4. The scaffold according to claim 1 having a mechanical resistance comprised between 2 and 10000 N.

5. The scaffold according to claim 1 having a mechanical resistance comprised between 200 and 500 N and/or an elastic modulus comprised between 30 and 20000 MPa.

6. (canceled)

7. The scaffold according to claim 1 wherein said scaffold has a length comprised between 10 and 1000 mm.

8-9. (canceled)

10. The scaffold according to claim 1 wherein said nanofibers constituting said clusters and/or said sheath have an average diameter comprised between 200 and 1000 nm.

11. The scaffold according to claim 1 wherein the average diameter of said clusters is comprised between 1 and 10000 m.

12. (canceled)

13. The scaffold comprising a plurality of inner scaffolds according to claim 1 further comprising a second porous sheath obtained by electrospinning consisting of nanofibers, wherein said sheath externally coats and compacts said plurality of scaffolds.

14. The scaffold according to claim 1 wherein said porous sheath and/or sheaths consist of randomly arranged nanofibers, axially arranged nanofibers with respect to the scaffold axis, or circumferentially aligned nanofibers with respect to the scaffold axis.

15-17. (canceled)

18. The scaffold according to claim 13 wherein said inner scaffolds are axially aligned with one another.

19. The scaffold according to claim 13 wherein said inner scaffolds are twisted with one another (twisting) and/or arranged randomly.

20. The scaffold according to claim 1 wherein the number of said clusters in said scaffold is comprised between 40 and 1000.

21. The scaffold according to claim 1 wherein said scaffold is made of bioresorbable or biostable and/or inert material.

22. The scaffold according to claim 1 wherein said scaffold is made of a synthetic material selected from polyesters, polyurethanes, polyamides, polyolefins and fluorinated polymers and copolymers thereof or of natural material selected from polysaccharides, proteins, polyesters, polypeptides and copolymers thereof and/or mixtures thereof.

23. (canceled)

24. The scaffold according to claim 1 wherein said scaffold and/or said nanofibers are loaded and/or functionalized with organic and/or inorganic components apt to perform a biological action and/or change in the chemical-physical and/or mechanical properties of said tissue.

25. (canceled)

26. The scaffold according to claim 1 wherein gel or hydrogel are injected into said scaffold.

27. The scaffold according to claim 1 wherein said nanofibers are monophasic or multiphasic.

28. (canceled)

29. The scaffold according to claim 1 wherein said nanofibers are of core-shell type and/or hollow-shell type and/or porous and/or combinations thereof.

30. The scaffold according to claim 1 wherein the nanofibers are of piezoelectric type.

31. The scaffold according to claim 1 wherein said bundles have an axial cavity inside thereof.

32. An implantable prosthetic device comprising a scaffold according to claim 1.

33. A synthetic tendon and/or ligament comprising a scaffold according to claim 1.

34. A synthetic muscle comprising a scaffold according to claim 1.

35. A synthetic nerve comprising a scaffold according to claim 1.

36. A process for preparing a multiscale hierarchical scaffold according to claim 1 comprising the following steps: a) electrospinning a plurality of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles); and b) electrospinning nanofibers so as to coat said clusters with a porous sheath consisting of nanofibers so as to provide an external coating and to compact the plurality of clusters prepared according to step a).

37. The process for preparing a multiscale hierarchical scaffold according to claim 1 comprising the following steps: a) electrospinning a plurality of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles); b) positioning said plurality of clusters prepared according to step a) so as to form one single group; c) clamping the group of clusters obtained according to step b) on a grip, capable of axially rotating rigidly and in line, thus, by keeping the clamped group of clusters in a position suitable for the process of coating with electrospun sheath; and d) electrospinning a sheath external to the group of clusters clamped at step c), in particular by controlling the rotation parameters of the clamped group of clusters, the geometrical parameters of the setup, and process parameters.

38. The process according to claim 36 wherein the nanofibers of the clusters and/or of the sheath are prepared by electrospinning a solution of PLLA dissolved in dichloromethane (DCM) and/or N,N-dimethylformamide (DMF) or nylon 6,6 dissolved in trifluoro-acetic acid (TFA) and/or acetone (AC).

39. The process according to claim 36 wherein during the step of electrospinning the nanofibers an electrical field having a voltage comprised between 10 kV and 30 kV is applied for a time period of at least 5 minutes.

40. The process according to claim 36 wherein during the step a) of electrospinning the nanofibers, said nanofibers are deposited on a collector so as to allow the alignment thereof.

41. The process according to claim 36 wherein during the step of implementing the sheath the nanofibers are deposited on a collector positioned close to the group of clusters to be coated but having no contact with said group of clusters.

42. The process according to claim 36 wherein in said step for preparing the sheath the following process parameters are used: (a) distance between group of clusters and the collector smaller than 5 mm; (b) rotation speed of the group of clusters comprised between about 20 and 25 rpm; (c) stillness periods of the group of clusters comprised between about 3 and 5 minutes; and (d) rotation periods of the group of clusters comprised between 1 and 2 minutes.

43. The process according to claim 36 wherein the grips are made of conductive metallic material and positioned at ground potential to improve the deposition of the sheath of nanofibers arranged randomly on the ends of the scaffold itself.

44. The process according to claim 36 wherein during the step of implementing the sheath the ground collector has a plane geometry.

45. The process according to claim 36 wherein during the step of implementing the sheath the ground collector is a concave, convex or prismatic plate.

46. The process according to claim 36 wherein during the step of implementing the sheath the ground collector consists of two parallel metal rods and/or plates.

47. The process according to claim 36 comprising the following steps: a) spinning on rotating drum collector of a plurality of electrospun nanofibers; b) circumferential winding on the drum of sections of the membrane of electrospun nanofibers to obtain ring-like bundles (ring bundles); and c) removal of the ring-like clusters of nanofibers (ring bundles) from the drum.

48. A process for preparing a multiscale hierarchical scaffold comprising a plurality of inner scaffolds comprising: a) preparing a plurality of scaffolds according to claim 1; and b) electrospinning nanofibers so as to coat said plurality of scaffolds with a porous sheath consisting of nanofibers so as to provide an external coating and to compact the plurality di scaffolds prepared according to step a).

49. A scaffold which can be obtained according to the process of claim 36.

50. A sensor for acquiring and/or transmitting mechanical or physiological signals comprising the scaffold of claim 1.

51. An in vitro sensor for acquiring and/or transmitting mechanical or physiological signals comprising the scaffold of claim 1.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0043] FIG. 1 is a picture of one single cluster of axially aligned nanofibers (bundle) of the multiscale hierarchical scaffold according to a preferred embodiment of the present invention.

[0044] FIG. 2 is a picture showing the multiscale hierarchical scaffold fully, which consists of a plurality of clusters of axially aligned nanofibers (bundles) (FIG. 1) kept together by an outer sheath of randomly arranged fibers according to a preferred embodiment of the present invention.

[0045] FIG. 3 is a picture of the experimental set-up allowing to fix the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) parallelly to each other and one placed side by side in the phase preceding the spinning of the sheath according to a preferred embodiment of the present invention.

[0046] FIG. 4 is a picture of the experimental set-up allowing to coat the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) with an outer sheath of nanofibers according to a preferred embodiment of the present invention.

[0047] FIG. 5 is a tomographic image of the nanofibers of one single cluster of axially aligned nanofibers (bundle) in poly(L)lactic acid (PLLA).

[0048] FIG. 6 is a SEM image of the section of a multiscale hierarchical scaffold in PLLA constituted by 100 clusters of axially aligned nanofibers (bundles) and with electrospun outer sheath.

[0049] FIG. 7 is a picture of one single ring-like cluster of nanofibers (ring bundle) according to a preferred embodiment of the present invention.

[0050] FIG. 8 is a picture showing the multiscale hierarchical scaffold fully, which consists of a plurality of ring-like clusters of nanofibers (ring bundles) (FIG. 7) kept together by an outer sheath of randomly arranged nanofibers according to a preferred embodiment of the present invention, by showing the loops for suturing and/or fixing at their own ends.

[0051] FIG. 9 is a schematic representation of the multiscale hierarchical levels of aggregation of the tendinous and/or ligamentous, muscular and nervous tissue, compared with the hierarchical structure of the multiscale hierarchical scaffold the present invention relates to. In particular: a) Multiscale hierarchical structure of tendons and/or ligaments; b) Multiscale hierarchical structure of muscles; c) Multiscale hierarchical structure of nerves: d) Multiscale hierarchical scaffold structure.

[0052] FIG. 10 is a schematic representation of the multiscale hierarchical levels of aggregation of the tendinous and/or ligamentous, muscular and nervous tissue according thereto further down hierarchical units of the same tissue join together by increasing the multiscale hierarchical level of the same. Such levels are compared with the hierarchical structure of the multiscale hierarchical scaffold. the present invention relates to, according to the embodiment wherein groups of multiscale hierarchical scaffolds are joined together by an additional sheath of electrospun nanofibers, by forming a multiscale hierarchical scaffold with a higher level of hierarchical organization. In particular: a) Multiscale hierarchical structure of tendons and/or ligaments; b) Multiscale hierarchical structure of muscles; c) Multiscale hierarchical structure of nerves; d) Multiscale hierarchical scaffold structure in turn constituted by groups of multiscale hierarchical scaffolds.

DETAILED DESCRIPTION OF THE INVENTION

[0053] The present invention relates to a multiscale hierarchical scaffold, to the processes for the production thereof and the uses thereof.

[0054] In the present description under hierarchical and multiscale it is meant: each device or structure, constituted by sub-structures, having different dimensional scales, which join in a hierarchical order.

[0055] In the present description under the expression support or a multiscale hierarchical scaffold it is meant: a porous anisotropic three-dimensional construct constituted by biomaterials assembled at morphological level at different levels of dimensional scale (from nanometric to micrometric and millimetric), hierarchically organized in a multiscale structure (as defined previously), to mimic as exactly as possible the extracellular matrix of the tissue which one wants to reconstruct in its native state. The scaffolds are typically designed to perform the following functions: (i) promoting the cell-biomaterial interaction, the cell adhesion and the cell proliferation, (ii) allowing the transportation of oxygen, carbon dioxide and nutrients, (iii) if bioresorbable, biodegrading at a speed approximating the tissue regeneration rate under the culture conditions of interest, (iv) not causing in vivo inflammation or toxicity and (v) having mechanical properties similar to the tissue which one wants to reconstruct.

[0056] Even a not bioresorbable material could be selected, but in this case it should not cause in vivo inflammation or toxicity and have mechanical and morphological properties similar to the tissue which one wants to reconstruct and/or simulate and/or replace.

[0057] In the present description under cluster of axially aligned nanofibers (bundle) an electrospun structure is meant, with variable extension and/or section, consisting of nanofibers which arrange with a level of alignment according to the axis of the duster itself, that is along the greater development direction of these constructs. In the present description under cluster of twisted nanofibers (yarn) an electrospun structure is meant, with variable extension and/or section, consisting of nanofibers which arrange with a level of twisting according to the axis of the yarn itself, that is along the longitudinal direction of these constructs. In the present description under ring-like cluster of nanofibers (ring bundle) a ring-shaped electrospun structure is meant, with variable extension and section, consisting of nanofibers, with a level of alignment according to the axis of the ring-like duster or ring bundle itself.

[0058] In the present description under the expression forming one single group the fact of forming one single cluster is meant.

[0059] In an additional embodiment the nanofibers constituting the ring-like cluster could be arranged randomly (random) and/or in a twisted way (twisted) and/or with a level of axial alignment inside the body of the ring-like cluster or ring bundle itself. The multiscale hierarchical scaffold according to the present invention further comprises a porous sheath obtained by electrospinning which coats externally the dusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles), obtained by electrospinning. Said outer sheath (casing) is constituted by nanofibers too. The porosity of the sheath is produced by the superimposition of layers of continuous nanofibers which deposit in the process period of time on a same plane, by forming a three-dimensional structure like the one of a tissue-non-tissue. The porosity of the sheath is then interconnected, in the sense that the pores put into communication the outer layer of the sheath of fibers with the innermost layer, in contact with the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles) and/or sub-groups of multiscale hierarchical scaffolds. The interconnection between the pores allows the cells to filtrate through the outer sheath to reach the inner layers of the multiscale hierarchical scaffold.

[0060] The nanofibers of the sheath could be arranged randomly and/or with a level of axial alignment and/or level of peripheral alignment.

[0061] The average diameter of the nanofibers constituting the multiscale hierarchical scaffold could be comprised between 10 and 100000 nm.

[0062] The length of the multiscale hierarchical scaffold could be comprised between 10 and 1000 mm, in particular between 10 and 500 mm, preferably 20 and 200 mm and it will have an average diameter comprised between 1 and 100 mm, preferably comprised between 2 and 50 mm. According to an embodiment the multiscale hierarchical scaffold will be made of bioresorbable or biostable and/or inert material.

[0063] Examples of bioresorbable or biostable materials of synthetic origin are polyesters, polyurethanes, polyamides, polyolefins, fluorinated polymers and copolymers thereof. Examples of bioresorbable or biostable materials of natural origin are polysaccharides, proteins, polyesters, polypeptides and copolymers thereof. Preferred examples of materials for preparing the nanofibers are poly-(L)-lactic acid (PLLA) and/or collagen and/or nylon 6,6, also other biocompatible polyamides known to the person skilled in the art could be used.

[0064] According to an embodiment the multiscale hierarchical scaffold and/or the nanofibers it consists of, could be loaded and/or functionalized with components of organic and/or inorganic nature which play a biological action and/or change in the chemical-physical and/or mechanical properties of the tissue wherein the multiscale hierarchical scaffold could be used. For example components of organic and/or inorganic nature which could be used are drugs, growth factors, antibacterial agents, peptides, hydroxyapatites, phosphates, bio-glasses, metal oxides, graphene, carbon nanotubes.

[0065] In an embodiment of the nanofibers constituting the multiscale hierarchical scaffold and/or the sheath and/or the clusters of axially aligned nanofibers (bundles) and/or the clusters of twisted nanofibers (yarns) and/or the ring-like clusters of nanofibers (ring bundles) they could be, from the point of view of morphology, classic nanofibers constituted by one single phase (made of one single material and/or by a mixture of materials and/or loaded and/or functionalized materials) and/or nanofibers constituted by two or more phases (for example core-shell nanofibers, wherein, under core-shell, nanofibers are meant made of different materials between central portion and outer portion of the nanofiber itself) and/or hollow-shell nanofibers (wherein, under hollow-shell, nanofibers are meant constituted by an inner central cavity along the axis of the nanofibers themselves) and/or porous nanofibers (under porous nanofibers nanofibers are meant having pores along their surface and/or in their inner volume).

[0066] The procedures for loading and/or functionalizing and/or producing nanofibers with different morphology are known to the person skilled in the art.

[0067] The nanofibers constituting the single clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles) and/or the sheath and/or the sheaths will have an average diameter comprised between 10 and 10000 nm, preferably comprised between 200 and 1000 nm, and in particular between 300 and 1000 nm, whereas the average diameter of the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring to bundles) could be comprised between 10 and 10000 m, in particular comprised between 20 and 10000 m, preferably between 500 and 650 m. The number of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles) will be for example comprised between 2 and 1000, preferably between 40 and 200, for example 100.

[0068] The multiscale hierarchical scaffolds according to the present invention advantageously will have a value of mechanical resistance comprised between 10 and 5000 N preferably between 200 and 500 N and/or an elastic modulus comprised between 20 and 100000 MPa, preferably of about 30-20000 MPa. Such mechanical features were measured by means of monoaxial tensile test with capstan grips (capstan grips) and by cementing the ends as described in the examples.

[0069] The present invention further relates to a process for preparing a multiscale hierarchical scaffold for the replacement and/or repair and/or regeneration and/or reconstruction and/or simulation of a tissue, in particular of the tendinous and/or ligamentous and/or muscular and/or nervous tissue comprising the following steps:

[0070] a) preparing by electrospinning a plurality of dusters of axially aligned nanofibers (bundles) and/or of dusters of twisted nanofibers (yarns)

[0071] b) electrospinning nanofibers so as to coat a plurality of said clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) with a porous sheath consisting of nanofibers so as to provide an external coating and to compact the plurality of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) prepared according to step a) by obtaining a support or a multiscale hierarchical scaffold;

[0072] c) electrospinning nanofibers so as to coat a plurality of said supports or multiscale hierarchical scaffolds according to step b) with an additional porous sheath consisting of nanofibers so as to provide an external coating and to compact the plurality of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or multiscale hierarchical scaffolds according to step b).

[0073] An embodiment of the present invention is a process for preparing ring-like clusters of nanofibers (ring bundles) comprising the following steps:

[0074] a) electrospinning on a ground collector shaped like a drum rotating at different speeds according to the wished alignment level, a plurality of nanofibers;

[0075] b) cutting peripheral strips of membrane of nanofibers obtained by the electrospinning according to step a);

[0076] c) rolling-up the peripheral strips of membrane of nanofibers obtained according to the step b) according to the drum axis;

[0077] d) pulling out the drum the ring-like clusters of nanofibers (ring bundles) obtained according to step c).

[0078] In particular the process for preparing multiscale hierarchical scaffolds with ring-like clusters of nanofibers (ring bundles) will provide the following steps:

[0079] a) preparing by electrospinning a plurality of dusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles);

[0080] b) positioning said plurality of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or clusters of ring-like nanofibers (ring bundles) prepared according to step a) so as to form one single group of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like dusters of nanofibers (ring bundles);

[0081] c) clamping the group obtained according to step b) on grip capable of axially rotating rigidly and in line, thus keeping the group of clusters of nanofibers and/or axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles), clamped in a suitable position for the coating process with electrospun sheath;

[0082] d) implementing an outer sheath on the group of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles) clamped at step c) by electrospinning, in particular by controlling the rotation parameters of the clamped group of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles), the geometrical parameters of the setup, and process parameters, by obtaining a multiscale hierarchical structure or scaffold.

[0083] e) implementing an additional outer sheath on the group of structures or multiscale hierarchical scaffolds obtained according to step d) and clamped as according to step c) by electrospinning, in particular by controlling the rotation parameters of the clamped group of structures or multiscale hierarchical scaffolds, the geometrical parameters of the setup, and process parameters.

[0084] According to an embodiment the nanofibers of the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles) and/or of the sheath could be prepared by electrospinning a solution of PLLA dissolved in suitable solvent, for example in dichloromethane (DCM) and N,N-dimethylformamide (DMF). The solution could be prepared for example with 10-30% (weight/volume) of PLLA for example in 65/35 (volume/volume) (DCM/DMF).

[0085] According to an embodiment the nanofibers of the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles) and/or of the sheath could be prepared by electrospinning a solution of nylon 6,6 dissolved in suitable solvent, for example in trifluoroacetic acid (TFA) and acetone (AC). The solution could be prepared with 10-30% (weight/volume) of nylon 6,6 for example in 50/50 (volume/volume) (TFA/AC).

[0086] According to an embodiment the spinning conditions of the clusters of axially aligned nanofibers (bundles) and/or of the clusters of twisted nanofibers (yarns) and/or of the ring-like dusters of nanofibers (ring bundles) provide the application of an electrical field having a voltage comprised between 10 and 30 kV, preferably 18 kV for an electrospinning time period of at least 5 min, and in particular at least 15 min, preferably one hour, by depositing the fibres on a collector rotating at high speed allowing an alignment degree of the nanofibers. The nanofibers deposited on the collector are subsequently collected together to form clusters of axially aligned nanofibers (bundle) and/or dusters of twisted nanofibers (yarn) and/or a ring-like dusters of nanofibers (ring bundles) with an alignment degree.

[0087] According to an embodiment the electrospinning conditions on the rotating machine for the production of the outer sheath of nanofibers provide the application of an electrical field having a voltage comprised between 10 and 30 kV, for an electrospinning time period of at least 2 hours, preferably 3 hours.

[0088] Advantageously for preparing the sheath the following process parameters will be applied: [0089] distance between the group of clusters and the flat collector smaller than 5 mm; [0090] a rotation speed of the group of clusters of about 20-25 rpm; [0091] stillness periods of the group of clusters of about 3-5 min; [0092] rotation periods of the group of clusters 1-2 min.

[0093] The process for preparing the multiscale hierarchical scaffold according to the present invention has important advantages, in particular the development of the sheath around the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles), which is produced without inserting anything in the body of a multiscale hierarchical scaffold to guide the deposition of fibers.

[0094] Such result is obtained by modulating the shape, the sizes and the position of the collector placed nearby, but not in contact with the group of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like dusters of nanofibers (ring bundles) to be coated and modulating the rotation and stasis time periods of the same, for example it could be positioned at a distance comprised between 1 and 50 mm.

[0095] Making this way, during the stillness time periods the dusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like dusters of nanofibers (ring bundles) will be surrounded by a layer of nanofibers which will have its own ends deposited on the collector. By putting in rotation the group of clusters, the detachment of one end of the layer of nanofibers from the flat collector will take place, by wrapping the group of dusters of nanofibers, favouring the compaction and the pretensioning. Once the whole layer of nanofibers is rolled up around the group of clusters of nanofibers, the end still attached to the flat collector will detach, in turn. Once the detachment is completed, thanks to the combined action of rotation and electrostatic field even the remaining portion of the layer of nanofibers will deposit on the surface of the dusters of nanofibers. The repetition of this process progressively leads to the compaction with consequent reduction in the section of the group of dusters of nanofibers and to the complete formation of the sheath to obtain the complete multiscale hierarchical scaffold.

[0096] Similarly, by repeating the process for producing the sheath of nanofibers on a plurality of multiscale hierarchical scaffolds, produced as previously described, and joined together to form one single group, it will be possible to obtain a multiscale hierarchical scaffold in turn constituted by a plurality of multiscale hierarchical scaffolds, all of them coated and compacted by an electrospun sheath of nanofibers.

[0097] According to an embodiment, the grips for fixing the dusters of axially aligned nanofibers (bundles) and/or twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles), capable of rotating rigidly and in line thus keeping the group of clusters of nanofibers, clamped in suitable position for the coating process with electrospun sheath, could be made of metallic material, preferably stainless steel and/or aluminium. According to an embodiment such grips could have a shape which facilitates the fixing of clusters of nanofibers, for example structures with cylinder arms from 1 to 100, preferably 6, having different and/or equal diameter, preferably between 0.5 and 30 mm of diameter. Such grips could be electrically connected to the ground potential to ease the covering of the ends of the multiscale hierarchical scaffold, during the spinning process, by the sheath of nanofibers according to any embodiments of the herein described process.

[0098] In the state of art, in fact, with such homogeneity level there were implemented 1) sheaths electrospun on clusters of twisted nanofibers (yarns) fixed around a drum put in rotation, or 2) sheaths produced apart, inside thereof in a second moment the clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) are inserted or 3) sheaths produced on groups of clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) fixed with each other by a filler such as for example resins. These procedures do not allow high levels of compaction of the final scaffold, which is fundamental to increase the mechanical properties of the construct, and poses serious design constraints on the number of usable clusters of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles).

[0099] The present invention also relates to the ring-like clusters of nanofibers (ring bundles) obtainable according to any one of the embodiments of the herein described process and the production method thereof.

[0100] The present invention also relates to a multiscale hierarchical scaffold which can be obtained according to anyone of embodiments of the herein described process.

[0101] The herein described multiscale hierarchical scaffold could be used in different applications for example in the biomedical sector in orthopaedic or veterinary field as implantable prosthetic device, in particular if made of biostable material, or for the cellular proliferation and tissue regeneration, in particular if made of bioresorbable material.

[0102] If made of biostable synthetic material it could also be applied in robotics and in the production of actuators and guides or in the production of tendons and/or ligaments and/or muscles and/or synthetic nerves for simulating in vitro surgical procedures.

[0103] A method for the regeneration or replacement of tissues, in particular of the tendinous and/or ligamentous and/or muscular and/or nervous tissue is also herein described, comprising a step of implantation in a subject requiring a multiscale hierarchical scaffold according to anyone of herein described embodiments.

[0104] The herein described multiscale hierarchical scaffold could be used in an ex vivo method for the production of in vitro tendons and/or ligaments and/or muscles and/or nerves, for example a method wherein cells are cultured in vitro with the multiscale hierarchical scaffold.

[0105] According to an embodiment the present invention also relates to a multiscale scaffold for the replacement, repair, reconstruction or simulation of a tissue, in particular of the tendinous and/or ligamentous and/or muscular and/or nervous tissue comprising: [0106] a plurality of clusters obtained by electrospinning consisting of axially aligned nanofibers (bundles) and/or clusters of twisted nanofibers (yarns) and/or ring-like clusters of nanofibers (ring bundles) and wherein said plurality of clusters are arranged in order to form one single group; [0107] a porous sheath obtained by electrospinning consisting of randomly arranged and/or aligned nanofibers, wherein said sheath externally coats and compacts said plurality of clusters keeping them aligned with each other.

[0108] The scaffold according to anyone of herein described embodiments advantageously could also be used as sensor implantable in vivo or in vitro, for example for acquiring and/or transmitting mechanical or physiological signals.

EXAMPLES

Example 1

[0109] 8 prototypes of multiscale hierarchical scaffolds were developed, made of Poly-(L)-lactic acid (PLLA) having length of 100 mm (average diameter 5-6 mm) constituted by 100 clusters of axially aligned nanofibers (bundles) consisting of nanofibers aligned in the direction of the cluster of axially aligned nanofibers (bundle) itself (average diameter of cluster of axially aligned nanofibers (bundles) 550-650 m, average diameter of nanofibers 500-600 nm).

[0110] The sheath was produced thereon by electrospinning the same solution of PLLA used to produce the clusters of axially aligned nanofibers (bundles). The composition is prepared with 13% (weight/volume) of PLLA dissolved in a solvent system of Dichloromethane (DCM) and Dimethylformamide (DMF) in percentage 65/35 (volume/volume). The sheath was produced by electrospinning for 3 hours and by alternating stasis periods of the group of clusters of axially aligned nanofibers (bundles) with rotation periods.

[0111] Spinning conditions for the production of one single cluster of axially aligned nanofibers (bundle): [0112] spinning with 2 metal needles Gauge 20; [0113] syringe pump delivery 1.2 ml/h; [0114] electrical field voltage 18 kV; [0115] rotating collector rotation speed 2900 rpm; [0116] needle-collector distance 200 mm; [0117] useful thickness of produced cluster of axially aligned nanofibers (bundle) 550-650 m

[0118] Once the clusters of axially aligned nanofibers (bundles) are cut into samples, each one having length of 100 mm, they were aligned and fixed on the rotating machine for the production of the outer sheath of random nanofibers, by applying the following conditions: [0119] spinning with needle Gauge 20; [0120] syringe pump delivery 1.2 ml/h; [0121] electrical field voltage 18 kV; [0122] metal collector; [0123] collector-needle(s) distance 200 mm; [0124] distance between group of clusters of axially aligned nanofibers (bundles) and flat collector smaller than 5 mm; [0125] rotation speed of the group of clusters of axially aligned nanofibers (bundles) about 20-25 rpm; [0126] stillness periods of the group of clusters of axially aligned nanofibers (bundles) 2-5 min; [0127] rotation periods of the group of clusters of axially aligned nanofibers (bundles) 1-2 min; [0128] useful thickness of the sheath: 5-10 m

Example 2: Mechanical Tests of the Produced Clusters of Axially Aligned Nanofibers (Bundles) Obtained in Example 1

[0129] Single clusters of axially aligned nanofibers (bundles) were then tested mechanically with a tensile test.

[0130] Synthetically the test was performed by using a tensile breaking test with a strain rate of 100% sec.sup.1 for simulating physiological conditions of strain rate compatible to breaking of the tendinous tissue: [0131] tested samples: 10 [0132] gauge length 16 mm [0133] crosshead speed 16 mm/sec (strain rate: 1/sec); [0134] monotonic ramp to break; [0135] displacement control; [0136] hydration of the samples before the test for 2 min in 0.9% NaCl saline solution; The single clusters of axially aligned nanofibers (bundles) resisted to breaking up to 4-5 N with a ductile behaviour and deformations in the order of 90%, with an elastic modulus of about 80 MPa.

Example 3: Mechanical Tests on Produced Multiscale Hierarchical Scaffolds Obtained in Example 1

[0137] The complete multiscale hierarchical scaffolds were tested mechanically, too, with a tensile test even in this case with a strain rate of 100% sec.sup.1 for simulating physiological breaking conditions of the tendinous tissue: [0138] useful tract 50 mm for 5 tested samples; [0139] the ends of the samples before the test had been cemented in polymethylmethacrylate (PMMA) for a better clamping. Such casts had tapered shape to minimize the stress concentration. [0140] crosshead speed 50 mm/sec (strain rate: 1/sec); [0141] monotonic ramp to break; [0142] displacement control; [0143] hydration of the samples before the test for 2 min in 0.9% NaCl saline solution; The five multiscale hierarchical scaffolds reached force values between 230 and 380 N, with deformations of about 30% and an elastic modulus of about 130 MPa. The breaking of samples took place at the interface between a multiscale hierarchical scaffold and cement: this involves that a stress concentration comes up due to the grips which involved a considerable underestimation of the breaking force value of the multiscale hierarchical scaffold.

Example 4

[0144] 3 prototypes of multiscale hierarchical scaffolds made of nylon 6,6 with length 230 mm (average diameter 4-5 mm) were developed, constituted by 25 ring-like clusters (ring bundles) consisting of nanofibers aligned in the direction of the axis of the ring-like cluster (ring bundle) (average diameter of bundles 550-650 m, average diameter of nanofibers 200-300 nm).

[0145] The ring-like clusters (ring bundles) were fixed at the ends to the rotating system for the production of sheath, through two grips made of stainless steel constituted by 6 symmetrical cylindrical arms with 8 mm diameter.

[0146] On the multiscale hierarchical scaffolds the sheath was produced by electrospinning the same solution of nylon 6,6 used to produce the ring-like clusters (ring bundles). The composition is prepared with 15% (weight/volume) of nylon 6,6 dissolved in a solvent system of Trifluoro-acetic acid (TFA) and Acetone (AC) in percentage 50/50 (volume/volume). The sheath was produced by electrospinning for 12 hours and alternating stasis periods of the group of ring-like bundles (ring bundles) with rotation periods.

[0147] Spinning conditions for the production of the single ring-like clusters (ring bundles): [0148] spinning with 2 metal needles Gauge 20; [0149] syringe pump delivery 0.5 ml/h; [0150] electrical field voltage 20 kV; [0151] rotating collector rotation speed 2900 rpm; [0152] needle-collector distance 160 mm; [0153] useful thickness of produced ring-like bundles (ring bundles) 550-650 m [0154] length of the ring-like bundles (ring bundles): about 470 mm (deriving from the deposition on a drum with 150 mm diameter)

[0155] Once obtained the ring-like clusters (ring bundles), 25 thereof were aligned and fixed at the ends to the arms of the above-described metal grips, on the rotating machine for the production of the outer sheath of random fibers, by applying the following conditions: [0156] spinning with 2 needles Gauge 20; [0157] syringe pump delivery 0.5 ml/h; [0158] electrical field voltage 18 kV; [0159] ground flat metal collector; [0160] collector-needle(s) distance 160 mm; [0161] distance between group of ring-like clusters of nanofibers (ring bundles) and flat collector smaller than 5 mm; [0162] rotation speed of the group of ring-like clusters of nanofibers (ring bundles) about 20-25 rpm; [0163] stillness periods of the group of ring-like clusters of nanofibers (ring bundles) 2-5 min; [0164] rotation periods of the group of ring-like clusters of nanofibers (ring bundles) 1-2 min; [0165] useful thickness of the sheath: 5-10 m [0166] after 10 hours of sheath spinning on flat collector electrically connected to the ground as previously described, even the two metal grips positioned at the ends of the group of ring-like clusters of nanofibers (ring bundles) were placed to ground potential, so as to coat with the sheath of randomly arranged nanofibers (random) even the ends themselves. The spinning parameters are the same shown above.

Example 5: Mechanical Tests of the Produced Ring-Like Clusters (Ring Bundles) Obtained in Example 4

[0167] The single ring-like clusters of nanofibers (ring bundles) were then tested mechanically with a tensile test.

[0168] Synthetically the test was performed by using a tensile breaking test with a strain rate of 100% sec.sup.1 to simulate physiological conditions of strain rate compatible to breaking of the tendinous and/or ligamentous and/or muscular and/or nervous tissue: [0169] tested samples: 5 [0170] gauge length 230 mm

[0171] Crosshead speed 230 mm/sec (strain rate: 1/sec); [0172] monotonic ramp to break; [0173] displacement control; [0174] hydration of the samples before the test for 2 min in 0.9% NaCl saline solution; The single ring-like clusters of nanofibers (ring bundles) resisted to breaking until 20-24 N with a ductile behaviour and deformations in the order of 9-12%, with an elastic modulus of about 600-900 MPa.

Example 6: Mechanical Tests on Produced Multiscale Hierarchical Scaffolds Obtained in Example 4

[0175] The complete multiscale hierarchical scaffolds, too, were tested mechanically with a tensile test even in this case with a strain rate of 100% sec.sup.1 to simulate breaking physiological conditions of the tendinous and/or ligamentous and/or muscular and/or nervous tissue: [0176] gauge length 230 mm per 3 tested samples; [0177] As grips of the samples for the mechanical test, the same metal grips were used therewith the samples were fixed to the machine for the sheath production. Such grips had been planned suitably to deconcentrate the tensions. [0178] crosshead speed 230 mm/sec (strain rate: 1/sec); [0179] monotonic ramp to break; [0180] displacement control; [0181] hydration of the samples before the test for 2 min in 0.9% NaCl saline solution;

[0182] The 3 multiscale hierarchical scaffolds reached force values between 300 and 350 N, with deformations of about 9% and an elastic modulus of about 300 to 400 MPa.

[0183] The breaking of the samples took place both at the interface between a multiscale hierarchical scaffold and grips and in the gauge length: this involves that a partial stress concentration comes up due to the grips which involved an underestimation of the breaking force value of the multiscale hierarchical scaffold.

[0184] The present invention has been sofar described with reference to some preferred embodiments. It is to be meant that other embodiments belonging to the same inventive core may exist, as defined by the protective scope of the here below reported claims.