Classifications

• • C—CHEMISTRY; METALLURGY
  • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
  • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
  • C12M23/00—Constructional details, e.g. recesses, hinges
  • C12M23/02—Form or structure of the vessel
  • C12M23/08—Flask, bottle or test tube
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01L—CHEMICAL OR PHYSICAL LABORATORY APPARATUS FOR GENERAL USE
  • B01L3/00—Containers or dishes for laboratory use, e.g. laboratory glassware; Droppers
  • B01L3/08—Flasks
• • C—CHEMISTRY; METALLURGY
  • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
  • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
  • C12M27/00—Means for mixing, agitating or circulating fluids in the vessel
  • C12M27/16—Vibrating; Shaking; Tilting
• • C—CHEMISTRY; METALLURGY
  • C12—BIOCHEMISTRY; BEER; SPIRITS; WINE; VINEGAR; MICROBIOLOGY; ENZYMOLOGY; MUTATION OR GENETIC ENGINEERING
  • C12M—APPARATUS FOR ENZYMOLOGY OR MICROBIOLOGY; APPARATUS FOR CULTURING MICROORGANISMS FOR PRODUCING BIOMASS, FOR GROWING CELLS OR FOR OBTAINING FERMENTATION OR METABOLIC PRODUCTS, i.e. BIOREACTORS OR FERMENTERS
  • C12M27/00—Means for mixing, agitating or circulating fluids in the vessel
  • C12M27/18—Flow directing inserts
  • C12M27/20—Baffles; Ribs; Ribbons; Auger vanes

Definitions

• This invention relates generally to laboratory ware and, more particularly, to a cell culture flask.
• Shaker flasks otherwise referred to as cell culture flasks, are commonly used in a laboratory setting to cultivate biological organisms.
• a quantity of biological organisms such as any one of prokaryotic, mammalian, yeast, or insect cells, for example, are placed in a cell culture flask containing a cell culture medium to thereby grow the biological organisms into significantly more organisms as quickly as possible.
• the growth of the biological organisms, or cells is dependent on exposure of the cell culture medium and thus the biological organisms to adequate levels of oxygen. That is, cell growth increases with aeration of the cell culture medium, resulting in a continuous exchange of oxygen and removal of carbon dioxide therefrom.
• the shaker flask is typically agitated using a laboratory shaker. To this end, shaking of the flask creates a vortex that exposes more liquid surface to the oxygen in the headspace of the flask.
• OTR in shaker flasks is determined by the flask size and geometry, agitation speed, fill volume, and ambient conditions.
• baffles can be used to create turbulent flow to improve aeration and oxygen transfer during agitation.
• increasing the shaking speed can also increase aeration of the cell culture medium and thus oxygen transfer.
• baffles and agitation speed can improve aeration during shaking operations
• baffles in particular can cause cells to experience higher levels of shear stress (e.g., hydrodynamic stress) which can be detrimental to cell viability.
• aggressive baffles can cause foaming of the cell culture medium which hinders oxygen transfer.
• the present invention overcomes the foregoing and other shortcomings and drawbacks of cell culture flasks. While the present invention will be discussed in connection with certain embodiments, it will be understood that the present invention is not limited to the specific embodiments described herein.
• a cell culture flask having a flask body defining a cavity for receiving a cell culture medium.
• the flask body includes an elongate neck that defines an opening to the cavity; a base; a sidewall that extends from the elongate neck to the base of the flask body, the sidewall including a circumferential beveled portion that extends from an outermost periphery of the flask body to the base of the flask body at a constant angle relative to a central axis of the flask to define a sidewall angle.
• the flask having the circumferential beveled portion also includes at least one baffle formed in the flask body so as to extend in a radially inward direction relative to the central axis of the flask to form an indent in the flask.
• the at least one baffle includes six baffles spaced equidistantly apart and distributed circumferentially about the flask body.
• the at least one baffle includes a first pair of baffles spaced 60° apart from each other about the central axis of the flask and a second pair of baffles spaced 60° apart from each other about the central axis of the flask, wherein the first pair of baffles are diametrically opposed from the second pair of baffles about the central axis of the flask.
• the flask body includes an elongate neck that defines an opening to the cavity; a base; a sidewall that extends from the elongate neck to the base of the flask body, the sidewall including a circumferential faceted portion that extends from an outermost periphery of the flask body to the base of the flask body that is defined by a plurality of facets distributed circumferentially about the flask body.
• the flask having the circumferential faceted portion also includes at least one baffle formed in surfaces of one facet of the plurality of facets and the base of the flask body so as to extend in a radially inward direction relative to a central axis of the flask.
• the at least one baffle includes six baffles spaced equidistantly apart and distributed circumferentially about the flask body with each baffle being formed on surfaces of a different one of the plurality of facets and the base.
• the at least one baffle includes a first pair of baffles spaced 60° apart from each other about the central axis of the flask so as to be formed on surfaces of a different one of the plurality of facets and the base, and a second pair of baffles spaced 60° apart from each other about the central axis of the flask so as to be formed on surfaces of a different one of the plurality of facets and the base, wherein the first pair of baffles are diametrically opposed from the second pair of baffles about the central axis of the flask.
• method of culturing cells that includes providing a cell culture flask as described herein, introducing a cell culture medium and one or more cells into the cavity; and culturing the cells under conditions to support growth and/or expansion of the one or more cells.
• methods of expressing a protein of interest that includes providing a cell culture flask as described herein, introducing a cell culture medium and one or more cells configured to express the protein of interest into the cavity; and culturing the cells under conditions to support expression of the protein of interest.
• the method further comprises isolating the protein of interest from the cell culture medium and/or the one or more cells.
• a virus vector in another embodiment, includes providing a cell culture flask as described herein, introducing a cell culture medium and one or more cells configured to express the virus vector into the cavity; and culturing the cells under conditions to support expression of the virus vector.
• the method further comprises isolating the virus vector from the cell culture medium and/or the one or more cells.
• FIG. 1 is a front plan view of a cell culture flask according to one embodiment of the present invention.
• FIG. 2 is a cross-sectional view of the shaker flask taken along line 2-2 in FIG. 1.
• FIG. 3 is an enlarged cross-sectional view of the base of the shaker flask of FIGS. 1 -2, illustrating details of a small baffle.
• FIG. 4 is a bottom perspective view of the base of the shaker flask of FIGS. 1 - 3, illustrating the base isolated from the shaker flask.
• FIG. 5 is a partial bottom view of the base of the shaker flask of FIG. 4, illustrating details of a small baffle.
• FIG. 6 is a bottom plan view of the base of the shaker flask of FIGS. 1-5.
• FIG. 7A is a view similar to FIG. 6, illustrating a first and a second pair of baffles.
• FIG. 7B is a bottom plan view of a base of a shaker flask having small baffles in accordance with an embodiment of the present invention.
• FIGS. 8A-8C are bottom plan views of embodiments of a base of a shaker flask having large baffles in accordance with embodiments of the present invention.
• FIG. 9 is a front plan view of a cell culture flask in accordance with another embodiment of the present invention.
• FIG. 10 is a cross-sectional view of the shaker flask taken along line 10-10 in FIG. 9.
• FIG. 11 is an enlarged cross-sectional view of the base of the shaker flask of FIGS. 9-10, illustrating details of a facet.
• FIG. 12 is a bottom perspective view of the base of the shaker flask of FIGS. 9-11 , illustrating the base isolated from the shaker flask.
• FIG. 13 is a partial bottom plan view of the base of the shaker flask of FIG.
• FIGS. 14 is a bottom plan view of the base of the shaker flask of FIG. 12.
• FIG. 15 is a front plan view of a cell culture flask in accordance with another embodiment of the present invention.
• FIG. 16 is a cross-sectional view of the shaker flask taken along line 16-16 in FIG. 15.
• FIG. 17 is an enlarged cross-sectional view of the base of the shaker flask of FIGS. 15-16, illustrating details of a small baffle.
• FIG. 18 is a bottom perspective view of the base of the shaker flask of FIGS. 15-17, illustrating the base isolated from the shaker flask.
• FIG. 19 is a partial bottom plan view of the base of the shaker flask of FIG.
• FIGS. 20 is a bottom plan view of the base of the shaker flask of FIG. 15.
• FIG. 21 A is a view similar to FIG. 20, illustrating a first and a second pair of baffles.
• FIG. 21 B is a bottom plan view of a base of a shaker flask having small baffles in accordance with an embodiment of the present invention.
• FIGS. 22A-22C are bottom plan views of embodiments of a base of a shaker flask having large baffles in accordance with embodiments of the present invention.
• FIG. 23 is a diagrammatic view showing a cell culture flask positioned on a laboratory shaker within an incubator.
• FIG. 24 is a front plan view of a cell culture flask according to one embodiment of the present invention.
• FIG. 25 is a cross-sectional view of the shaker flask taken along line 24-24 in FIG. 1.
• FIG. 26 is an enlarged cross-sectional view of the base of the shaker flask of FIGS. 24-25, illustrating details of the beveled portion.
• FIG. 27 is a bottom perspective view of the base of the shaker flask of FIGS.
• FIG. 28 is a partial bottom view of the base of the shaker flask of FIG. 27.
• FIG. 29 is a bottom plan view of the base of the shaker flask of FIGS. 24-28.
• FIG. 30 is a graph depicting growth performance of Expi293 cells cultured in faceted-bottomed flasks at varying end volumes and control 30 mL cultures.
• FIG. 31 is a graph depicting growth performance of ExpiSf9 cells cultured in an beveled-bottom flask and a faceted-bottom flask at a 2-liter end volume.
• FIG. 32 is a graph depicting growth performance of ExpiCHO cells cultured in a beveled-bottom flask at a 2-liter end volume and control 30 mL volume.
• FIG. 33 is a bar graph depicting antibody expression levels from transfected Expi293 cells cultured at a 2.25-liter end volume and control 30mL volume.
• FIG. 34 is a bar graph depicting GFP expression levels from baculovirus infected Expi293 cells cultured at a 2-liter end volume and control 30m L volume.
• FIG. 35 is a bar graph depicting protein expression levels from transfected ExpiCHO cells cultured at a 2-liter end volume and control 30mL volume following the Max Titer protocol for expression.
• FIG. 36 is a bar graph depicting protein expression levels from transfected ExpiCHO cells cultured at a 2-liter end volume and control 30mL volume following the Standard protocol for expression.
• the cell culture flask 10 includes a flask body 12 that defines a cavity 14 for receiving a cell culture medium for culturing one or more biological organisms (i.e. , cells).
• a cell culture medium for culturing one or more biological organisms (i.e. , cells).
• the cell culture flask 10 is configured to be placed on a laboratory shaker and agitated at various agitation frequencies and movements to express a protein of interest into the cavity 14.
• the flask body 12 includes an elongate neck 16 that defines an opening 18 to the cavity 14, a base 20, and a sidewall 22 that extends from the elongate neck 16 to the base 20.
• the cell culture flask 10 further includes at least one baffle 24 formed in the flask body 12 that is configured to increase oxygen exchange during agitation of the cell culture medium contained in the cell culture flask 10, particularly for cell types sensitive to shear stress, to thereby increase cell titer and protein expression while minimizing cell shear and foaming, as will be described in further detail below.
• the exemplary cell culture flask 10 may be a 5-liter (L) flask, by way of example, having a minimum of a 5L fill volume below the elongated neck 16.
• the cell culture flask 10 may have a total cavity 14 fill volume of 5.5L, for example.
• the preferred working volume of the cell culture flask 10 may be within the range of between 2.5L to 3.5L.
• embodiments of the invention can also be applied to the design and manufacture of lower or higher volume cell culture flasks (e.g., 10L), and particularly to flasks having a fill volume within the range of between 125mL to 28000mL, for example.
• the drawings are not intended to be limiting.
• the elongate neck 16 of the flask body 12 defines the opening 18 to the cavity 14 through which cell culture medium and cells may be introduced into, and removed from, the cell culture flask 10.
• the elongate neck 16 includes a threaded portion 26 configured to threadably receive a closure device (not shown) and a collar 28 that defines an abutment surface for the closure device.
• the elongate neck 16 may further include a groove 30 configured to receive an O-ring (not shown) used to form a seal between the elongate neck 16 and the closure device.
• the closure device is configured to close the opening 18 to prevent spilling of the cell culture medium held in the cell culture flask 10, for example.
• the closure device may be a vented cap to allow air exchange, such as oxygen to enter the cavity and carbon dioxide to leave the cavity.
• the threaded portion 26 may include size 83B threads configured to receive an 83B threaded closure device, for example.
• the base surface 32 comprises a generally flat annular disk having an outer circumferential edge 36 that defines an outer diameter of the base surface 32 and an inner circumferential edge 38 that defines an inner diameter of the base surface 32.
• the base surface 32 is configured to support the cell culture flask 10 in an upright position on a support surface, such as a laboratory shaker, for example.
• the sidewall of the flask body 12 includes a first circumferential beveled portion 40 that extends upward from the base 20 of the flask body 12 to an outermost periphery 42 of the flask body 12 in a radially outward direction relative to an central axis A1 of the cell culture flask 10.
• the outermost periphery 42 of the cell culture flask 10 is defined as a portion of the flask 10 where a diameter of the flask body 12 is the greatest.
• the first beveled portion 40 extends radially outwardly and upwardly at a constant angle relative to the central axis A1 (i.e., a vertical axis) of the cell culture flask 10 to define a sidewall angle 01, as shown in FIG. 3.
• the sidewall angle 01 may be within a range of between 30° to 60°, for example. In a preferred embodiment, the sidewall angle 01 is 45°.
• the sidewall 22 of the flask body 12 further includes a second circumferential beveled portion 44 that extends from the outermost periphery 42 of the flask body 12 to a shoulder 46 of the flask body 12.
• the shoulder 46 and the second beveled portion 44 of the sidewall 22 may be generally symmetrical about the central axis A1 of the cell culture flask 10.
• the second beveled portion 44 extends from the outermost periphery 42 of the flask body 12 to the shoulder 46 in a radially inward direction relative to the central axis A1 of the cell culture flask 10.
• the second beveled portion 44 may extend at an angle of between 2° to 5° from vertical toward the central axis A1 of the cell culture flask 10.
• the second beveled portion 44 extends radially inwardly at an angle of 3.8° from vertical.
• the shoulder 46 extends upwardly from the second beveled portion 44 to the elongated neck 16 at an angle of between 15° to 20° from horizontal (i.e., a horizontal plane transverse to the central axis A1 of the cell culture flask 10).
• the shoulder 46 extends from the second beveled portion 44 to the elongate neck 16 at an angle of 16.164° from horizontal.
• the overall height of the cell culture flask 10 (i.e., a distance measured between the base 20 of the flask body 12 and an apex of the elongate neck 16) may be 10.8 inches. That way, the cell culture flask 10 effectively fits within a standard tabletop incubator having a laboratory shaker and a cover or hood (e.g., FIG. 23), yet provides clearance between the opening 18 in the elongate neck 16 and the cover for a pipette or other tools used to add/remove fluids, such as cell culture medium and cells, to/from the cell culture flask 10. To this end, the elongate neck 16 may have an inner diameter (ID) of 2.57 inches and a height of 3.3 inches to accommodate 50 mL serological pipettes, for example.
• ID inner diameter
• the cell culture flask 10 further includes at least one baffle 24 formed in the flask body 12.
• the cell culture flask 10 includes four baffles symmetrically spaced apart about the central axis A1 of the cell culture flask 10.
• each baffle 24 is formed in the flask body 12 so as to extend in a radially inwardly direction relative to the central axis A1 of the cell culture flask 10 to form an indent 48 in the flask body 12.
• each baffle 24 is generally V-shaped to define a pair of flattened sidewalls 50 that join together along an edge 52 which defines a peak for each baffle 24 within the cavity 14 of the flask body 12 (e.g., FIG. 2).
• each baffle 24 is generally triangular in transverse cross-sectional shape with the edge 52 forming an apex of the triangle.
• the edge 52 is curved in transverse cross-section (i.e., radiused) to facilitate a smooth transfer of cell culture medium over the baffle 24 to minimize shear stress and cell damage during agitation of the cell culture medium.
• the pair of sidewalls 50 of each baffle 24 extend between the first beveled portion 40 of the sidewall 22 and the base 20 of the flask body 12 such that the edge 52 extends in a radially inward direction relative to the central axis A1 of the cell culture flask 10.
• the edge 52 extends from a first terminal end 54 located on the first beveled portion 40 of the sidewall 22 and a second terminal end 56 located on the base surface 32 of the base 20 of the flask body 12.
• the edge 52 of each baffle is angled relative to the central axis A1 (i.e., a vertical axis) of the cell culture flask 10 to define a baffle angle 02.
• the baffle angle 02 may be within a range of between 45° to 70° (or 20° to 45° from a horizontal base plane), for example. In a preferred embodiment, the baffle angle 02 is 60° (or 30° from a horizontal base plane).
• each baffle sidewall 50 is generally triangular in shape to define a first leg edge 58 and a second leg edge 60 with a hypotenuse being the common edge 52 shared by the pair of sidewalls 50.
• Each first leg edge 58 extends along the first beveled portion 40 of the sidewall 22 and between the first terminal end 54 of the edge 52 and the outer edge 36 of the base surface 32.
• Each second leg edge 60 extends along the base surface 32 and between the outer edge 36 of the base surface 32 and the second terminal end 56 of the edge 52.
• each baffle 24 is generally V-shaped in transverse cross-section as a result of the angled relationship between the pair of sidewalls 50. More particularly, as shown in FIG.
• the pair of sidewalls 50 are angled relative to each other to form a baffle sidewall angle 03 therebetween.
• the baffle sidewall angle 03 may be within a range of between 90° to 110°, for example.
• the baffle sidewall angle 03 is 100°. To this end, it is important to have a wide baffle sidewall angle 03 (i.e., 100°) minimize the steepness of the baffle to thereby reduce shear stress and cell damage during agitation of the cell culture medium.
• each baffle 24 extends along the first beveled portion 40 of the flask body 12 a greater distance compared to the base surface 32.
• a length of each first leg edge 58 is greater than a length of each second leg edge 60.
• the first beveled portion 40 of the sidewall 22 includes a length L measured as a distance between the outer edge 36 of the base surface 32 and the outermost periphery 42 of the flask body 12.
• Each first leg edge 58 may extend a distance from the outer edge 36 of the base surface 32 to locate the first terminal end 54 of the edge 52 within an area on the first beveled portion 40 of the sidewall 22 that is between 40% to 60%, and preferably 45% to 50%, of the length L of the circumferential beveled portion 40 of the sidewall 22 measured from the outer edge 36 of the base surface 32 of the flask body 12. To this end, the location of the first terminal end 54 of the edge 52 along the first beveled portion 40 of the sidewall 22 influences the baffle angle 02.
• the base surface 32 includes a width W measured as a distance between the inner edge 38 and the outer edge 36 of the base surface 32 of the flask body 12.
• each second leg edge 60 extends a distance from the outer edge 36 of the base surface 32 to locate the second terminal end 56 of the edge 52 within an area on the base surface 32 that is between 50% to 70%, and preferably 60% to 65%, of the width W of the base surface 32 measured from the outer edge 36 of the base surface 32 of the flask body 12.
• the location of the second terminal end 56 of the edge 52 along the base surface 32 also influences the baffle angle 02.
• the cell culture flask 10 includes a first pair 64, or grouping of baffles 24 and a second pair 66, or grouping of baffles 24 diametrically opposed from the first pair of baffles 64 about the central axis A1 of the cell culture flask 10.
• the baffles 24 that form the first pair 64 of baffles 24 are spaced 60° apart from each other about the central axis A1 of the cell culture flask 10 and the baffles 24 that form the second pair 66 of baffles 24 are also spaced 60° apart from each other about the central axis A1 of the cell culture flask 10.
• baffles 24 that form the first and second pair 64, 66 of baffles 24 may be spaced further or closer apart from each other about the central axis A1 of the cell culture flask 10, such as within a range of between 50° to 70° apart, for example.
• FIG. 7B illustrates a cell culture flask 10a having six baffles 24 in accordance with an embodiment of the present invention. As shown, the baffles 24 are spaced apart from each other in a symmetrical arrangement about the central axis A1 of the cell culture flask 10a with the baffles 24 being spaced equidistantly apart in 60° increments about the central axis A1 of the cell culture flask 10a.
• the cell culture flask 10a may include fewer or more baffles 24 spaced apart in different increments about the central axis A1 of the cell culture flask 10a, such as four baffles 24 spaced 90° apart about the central axis A1 of the cell culture flask 10a, for example.
• FIGS. 8A-8C wherein like numerals represent like features, cell culture flasks 10b, 10c in accordance with additional embodiments of the present invention are shown and will now be described.
• the primary differences between the cell culture flasks 10b, 10c of these embodiments and the cell culture flask 10 of the previously described embodiment is the configuration of the baffles 24b.
• the baffles 24b are larger compared to the baffles 24 of the previously described embodiment.
• the baffles 24b of FIGS. 8A-8C may be referred to as “large” baffles 24b and the baffles 24 of FIGS. 1 -7B may be referred to as “small” baffles 24.
• each first leg edge 58b may extend a distance from the outer edge 36 of the base surface 32 to locate the first terminal end 54b of the edge 52b within an area on the first beveled portion 40 of the sidewall that is between 85% to 99%, and preferably 95% to 99%, of the length L of the circumferential beveled portion 40 of the sidewall 22 measured from the outer edge 36 of the base surface 32 the flask body 12.
• each second leg edge 60b extends a distance from the outer edge 36 of the base surface 32 to locate the second terminal end 56b of the edge 52b within an area on the base surface 32 that is between 85% to 99%, and preferably 95% to 99%, of the width W of the base surface 32 measured from the outer edge 36 of the base surface 32 of the flask body 12.
• the baffle angle 02b is steeper compared to the baffle angle 02 of the previously described embodiment, as shown in FIG. 8C.
• the baffle angle 02b is 52° (or 38° from a horizontal base plane).
• FIG. 8A illustrates a cell culture flask 10b having four large baffles 24b according to an embodiment of the present invention, with the baffles 24b being spaced apart in a symmetrical arrangement about the central axis of the cell culture flask.
• the cell culture flask 10b includes a first pair 64b, or grouping of large baffles 24b and a second pair 66b, or grouping of large baffles 24b diametrically opposed from the first pair 64b of baffles 24b about the central axis A1 of the cell culture flask 10b.
• baffles 24b that form the first pair 64b of baffles 24b are spaced 60° apart from each other about the central axis A1 of the cell culture flask 10b and the baffles 24b that form the second pair 66b of baffles 24b are also spaced 60° apart from each other about the central axis A1 of the cell culture flask 10b.
• the baffles 24b that form the first and second pair 64b, 66b of baffles 24b may be spaced further or closer apart from each other about the central axis A1 of the cell culture flask 10, such as within a range of between 50° to 70° apart, for example.
• FIG. 8B illustrates a cell culture flask 10c including six large baffles 24b according to an embodiment of the present invention.
• the baffles 24b are spaced apart from each other in a symmetrical arrangement about the central axis A1 of the cell culture flask 10c.
• the baffles 24b are spaced equidistantly apart in 60° increments about the central axis A1 of the cell culture flask 10c.
• FIGS. 24-29 wherein like numerals represent like features compared to the embodiment of the cell culture flask 10 described above with respect to FIGS. 1 -6, a cell culture flask 10i in accordance with another embodiment of the present invention is shown and will now be described.
• the primary difference between the cell culture flask 10i of this embodiment and the cell culture flask 10 of the previously described embodiment is that the flask body 12i includes a circumferential beveled portion 40i without at least one baffle.
• the circumferential beveled portion 40i provides minimal turbulence during agitation of the cell culture medium contained in the cell culture flask 10i to effectively culture certain cell types sensitive to shear stress.
• the cell culture flask 10i includes a flask body 12i that defines a cavity 14i for receiving a cell culture medium for culturing one or more cells, and an elongate neck 16 that defines an opening 18 to the cavity 14i.
• the flask body 12i further includes a base 20i and a sidewall 22i that extends from the elongate neck 16 to the base 20i.
• the base 20i of the flask body 12i includes a base surface 32i and a central concave portion 34 that is curved gently upward and into the cavity 14i from the base surface 32i.
• the base surface 32i comprises a generally flat annular disk having an outer circumferential edge 36i that defines an outer diameter of the base surface 32i and an inner circumferential edge 38 that defines an inner diameter of the base surface 32 i .
• the sidewall 22i includes the circumferential beveled portion 40i and a second circumferential beveled portion 44 that extends from the outermost periphery 42 of the flask body 12i to a shoulder 46 of the flask body 12i.
• the base 20i of the flask body 12i includes a base surface 32 and a central concave portion 34 that is curved gently upward and into the cavity 14i from the base surface 32.
• the profile of the central concave portion 34 serves to create a vortex of cell culture medium during agitation of the cell culture flask 10.
• the base surface 32 comprises a generally flat annular disk having an outer circumferential edge 36i that defines an outer diameter of the base surface 32i and an inner circumferential edge 38 that defined an inner diameter of the base surface 32.
• the base surface 32 is configured to support the cell culture flask 10 in an upright position on a support surface, such as a laboratory shaker, for example.
• the sidewall of the flask body 12i includes a first circumferential beveled portion 40i that extends upward from the base 20i of the flask body 12i to an outermost periphery 42 of the flask body 12i in a radially outward direction relative to a central axis A1 of the cell culture flask 10i.
• the outermost periphery 42 of the cell culture flask 10i is defined as a portion of the flask 10 where a diameter of the flask body 12i is the greatest.
• the first beveled portion 40i extends radially outwardly and upwardly at a constant angle relative to the central axis A1 (i.e., a vertical axis) of the cell culture flask 10i to define a sidewall angle 0i, as shown in FIG. 26.
• the sidewall angle 01 may be within a range of between 30° to 60°, for example. In a preferred embodiment, the sidewall angle 01 is 45°.
• the cell culture flask 10i does not include a baffle formed in the flask body 12.
• the lack of baffles can be advantageous particularly for cell types sensitive to shear stress to minimize shear stress and cell damage during agitation of the cell culture medium.
• the beveled only cell culture flask 10i greatly reduces the risk of foaming. Use of the beveled only culture flask 10i thereby increases cell titer and protein expression while minimizing cell shear and foaming.
• the base surface 32 i includes a width W measured as a distance between the inner edge 38 and the outer edge 36 of the base surface 32i of the flask body 12i.
• FIGS. 9-1 wherein like numerals represent like features compared to the embodiment of the cell culture flask 10 described above with respect to FIGS. 1 -7A, a cell culture flask 10d in accordance with another embodiment of the present invention is shown and will now be described.
• the flask body 12d includes a circumferential faceted portion 70 rather than the circumferential beveled portion 40.
• the circumferential faceted portion 70 extends radially upwardly and outwardly between the base 20d of the flask body 12d and the outermost periphery 42 of the flask body 12d.
• the circumferential faceted portion 70 is defined by a plurality of facets 72 distributed circumferentially about flask body 12d. As described in further detail below, the circumferential faceted portion 70 provides sufficient turbulence needed to increase the oxygen exchange during agitation of the cell culture medium contained in the cell culture flask 10d to effectively culture certain cell types sensitive to shear stress.
• the cell culture flask 10d includes a flask body 12d that defines a cavity 14d for receiving a cell culture medium for culturing one or more cells, and an elongate neck 16 that defines an opening 18 to the cavity 14d.
• the flask body 12d further includes a base 20d and a sidewall 22d that extends from the elongate neck 16 to the base 20d.
• the base 20d of the flask body 12d includes a base surface 32d and a central concave portion 34 that is curved gently upward and into the cavity 14d from the base surface 32d.
• the base surface 32d comprises a generally flat annular disk having an outer circumferential edge 36d that defines an outer diameter of the base surface 32d and an inner circumferential edge 38 that defines an inner diameter of the base surface 32d.
• the sidewall 22d includes the circumferential faceted portion 70 and a second circumferential beveled portion 44 that extends from the outermost periphery 42 of the flask body 12d to a shoulder 46 of the flask body 12d.
• the circumferential faceted portion 70 extends upwardly from the base 20d of the flask body 12 to the outermost periphery 42 of the flask body 12d in a radially outwardly direction relative to the central axis A1 of the cell culture flask 10d.
• an angle of the circumferential faceted portion 70 is defined by an angle of each facet 72 relative to the central axis A1 (i.e. , a vertical axis) of the cell culture flask 10d.
• each facet 72 is angled at a constant angle relative to the central axis A1 of the cell culture flask 10d to define a facet angle 94.
• the facet angle 04 may be within a range of between 30° to 60° (or 30° to 60° from a horizontal base plane), for example. In a preferred embodiment, the facet angle 94 is 45°.
• the facets 72 provide a flat surface to support the cell culture flask 10d at an angle (equal to the facet angle 04) relative to a support surface on which the cell culture flask 10d sits to facilitate the recovery of cells from the cell culture flask 10d.
• the cell culture flask 10d includes 12 facets 72 arranged symmetrically about the central axis A1 of the cell culture flask 10d (e.g., FIG. 14).
• the 12-facet 72 configuration is particularly suitable for culturing cells sensitive to shear stress, however, it is possible that the cell culture flask 10d include fewer or more facets 72, as desired.
• each facet 72 defines a base edge 74 along the outer circumferential edge 36d of the base surface 32d, a rounded edge 76 at the outermost periphery 42 of the flask body 12d, and a pair of side edges 78 that extend between the base edge 74 and the rounded edge 76.
• the facet base edges 74 define the outer circumferential edge 36d of the base surface 32d.
• agitation of the cell culture flask 10d with a laboratory shaker causes a vortex of the cell culture medium to flow over the plurality of facets 72, and in particular the side edges 78.
• the side edges 78 form a low point, or valley between each facet 72 that creates turbulent flow during agitation of the cell culture flask 10d by a laboratory shaker.
• the faceted only cell culture flask 10d greatly reduces the risk of foaming.
• FIGS. 15-21 A wherein like numerals represent like features compared to the embodiment of the cell culture flask 10d described above with respect to FIGS. 9-14, a cell culture flask 10e in accordance with another embodiment of the present invention is shown and will now be described.
• the cell culture flask 10e includes at least one baffle 24 formed in the flask body 12e that is configured to increase oxygen exchange during agitation of the cell culture medium contained in the cell culture flask 10e, particularly for cell types sensitive to shear stress, to thereby increase cell titer and protein expression while minimizing cell shear and foaming.
• FIGS. 15-20 illustrate the cell culture flask 10e with four “small” baffles 24 formed in the flask body 12e, like the embodiment of the cell culture flask 10 described above with respect to FIGS. 1 -7A.
• the pair of sidewalls 50 of each baffle 24 extend between the circumferential faceted portion 70e of the sidewall 22e and the base surface 32e of the flask body 12e such that the edge 52 extends in a radially inward direction relative to the central axis A1 of the cell culture flask 10e.
• the edge 52 extends from a first terminal end 54 located on a facet 72 of the circumferential faceted portion 70e of the sidewall 22e and a second terminal end 56 located on the base surface 32e of the flask body 12e.
• the first terminal end 54 of the edge 52 may be generally centered between side edges 78 of respective facet 72, as shown in FIG.18.
• the edge 52 of each baffle 24 is angled relative to the central axis (i.e., a vertical axis) of the cell culture flask 10 to define a baffle angle 02.
• the baffle angle 02 may be within a range of between 45° to 70° (or 20° to 45° from a horizontal base plane), for example. In a preferred embodiment, the baffle angle 02 is 60° (or 30° from a horizontal base plane).
• each baffle 24 is generally V-shaped in transverse cross-section as a result of the angled relationship between the pair of sidewalls 50. More particularly, as shown in FIG. 19, the pair of sidewalls 50 are angled relative to each other to form a baffle sidewall angle 03 therebetween.
• the baffle sidewall angle 03 may be within a range of between 90° to 110°, for example. In a preferred embodiment, the baffle angle 03 is 100°.
• the circumferential faceted portion of the sidewall, and in particular each facet 72 includes a length Li measured as a distance between base edge 74 and the rounded edge 76 of each facet 72.
• Each first leg edge 58 may extend a distance from the base edge 74 (or outer edge 36e of the base surface 32e) to locate the first terminal end 54 of the edge 52 within an area on a facet 72 that is between 40% to 60%, and preferably 45% to 50%, of the length Li of the facet 72 measured from base edge 74 of the facet 72.
• the base surface 32e includes a width Wi measured as a distance between the inner circumferential edge 38 and the outer edge 36e of the base surface 32e of the flask body 12e.
• each second leg edge 60 may extend a distance from the outer edge 36e of the base surface 32e (or the base edge 74 of the face 72) to locate the second terminal end 56 of the edge 52 within an area on the base surface 32e that is between 50% to 70%, and preferably 60% to 65%, of the width Wi of the base surface 32e measured from the outer edge 36e of the base surface 32e of the flask body 12e.
• the cell culture flask 10e includes four baffles 24 with a first pair 64e, or grouping of baffles 24 and a second pair 66e, or grouping of baffles 24 diametrically opposed from the first pair 64e of baffles 24 about the central axis A1 of the cell culture flask 10e.
• the first pair 64e of baffles 24 are spaced 60° apart from each other about the central axis A1 of the cell culture flask 10e and the second pair 66e of baffles 24 are spaced 60° apart from each other about the central axis A1 of the cell culture flask 10e.
• FIG. 21 B illustrates a cell culture flask 10f having six baffles 24 in accordance with another embodiment of the present invention.
• the baffles 24 are spaced apart in a symmetrical arrangement about the central axis A1 of the cell culture flask 10f with the baffles 24 being spaced equidistantly apart in 60° increments about the central axis A1 of the cell culture flask 10f.
• the cell culture flask 10f may include fewer or more baffles 24 spaced apart in different increments about the central axis A1 of the cell culture flask 10f, such as four baffles 24 spaced 90° apart about the central axis A1 of the cell culture flask 10f, for example.
• FIGS. 22A-22C wherein like numerals represent like features compared to the embodiment of the cell culture flask 10e described above with respect to FIGS. 15-21 A, cell culture flasks 10g, 10h in accordance with additional embodiments of the present invention are shown and will now be described.
• the primary difference between the cell culture flask 10g, 10h of these embodiments and the cell culture flask 10e of the embodiment described above is the use of large baffles 24b, like the embodiment of the cell culture flask 10b described above with respect to FIGS. 8A-8C.
• each first leg edge 58b extends a distance from the base edge 74 of the facet 72 (or the outer edge 36g of the base surface 32g) to locate the first terminal end 54b of the edge 52b within an area on each facet 72 that is between 85% to 99%, and preferably 95% to 99%, of the length Li of the facet 72 measured from the base edge 74 of the facet 72.
• each second leg edge 60b extends a distance from the base edge 74 of the facet 72 (or the outer edge 36g of the base surface 32g) to locate the second terminal end 56b of the edge 52b within an area on the base surface 32g that is between 85% to 99%, and preferably 95% to 99%, of the width of the base surface 32g measured from the base edge 74 of the facet 72.
• the baffle angle 02b is 52° (or 38° from a horizontal base plane), as shown in FIG. 22C.
• the baffles 24b are spaced apart in a symmetrical arrangement about the central axis A1 of the cell culture flask 10g.
• the cell culture flask 10g includes a first pair 64g, or grouping of large baffles 24b and a second pair 66g, or grouping of large baffles 24b diametrically opposed from the first pair 64g of baffles 24b about the central axis A1 of the cell culture flask 10g.
• each baffle 24b is formed on surfaces of a different one of the plurality of facets 72 and the base 32g.
• FIG. 22B illustrates a cell culture flask 10h having six large baffles 24b according to another embodiment of the present invention, with the baffles 24b being spaced apart in a symmetrical arrangement about the central axis A1 of the cell culture flask 10h.
• the baffles 24b are spaced equidistantly apart in 60° increments about the central axis A1 of the cell culture flask 10h.
• each baffle 24b is formed on surfaces of a different one of the plurality of facets 72 and the base 32h.
• the above-described cell culture flasks 10-1 Oi may be molded using a blow molding manufacturing process, and may be formed from polyethylene terephthalate glycol (PETG). However, the cell culture flasks 10-1 Oi may be formed using other manufacturing techniques, such as using a three-dimensional (3D) printing machine to print the cell culture flask 10-1 Oi from a digital model, for example.
• PETG polyethylene terephthalate glycol
• 3D three-dimensional
• the cell culture flasks 10-1 Oi may be molded from a variety of clear plastics which can be sterilized by radiation such as polycarbonate (PC), polystyrene (PS), polyethylene terephthalate (PET), assorted acrylic-based polymers (ACR), polymethylpentene (PMP), or any other suitable plastic that is optically clear to permit quick visual observations of the cell growth medium and cells such as for fill volume, foaming, media deterioration and contamination, pH shift, etc.
• the sidewall 22-22i of each cell culture flask 10-1 Oi may be formed with volume graduations that are legible in specific units (e.g., metric units) from the outside of the cell culture flask 10a-10h when empty. For a 5L cell culture flask, the volume graduations may be 0.5L to 5L in 0.5L increments, for example.
• FIG. 23 depicts an exemplary laboratory shaker 80 located within an incubator 82 for agitating and culturing cells located within an exemplary cell culture flask 10.
• the cell culture flask 10 may be any one of the embodiments 10-1 Oi described above.
• the incubator 82 may be a Thermo Fisher Reach-In CO2 incubator model 3950 and the laboratory shaker may be a Thermo Fisher MAX Q16HP, a Thermo Scientific MaxQ 416HP, or a Thermo Scientific MaxQ 2000, each of which is commercially available from the Assignee of the present invention.
• the cell culture flask 10 contains an amount of fluid 84 (i.e.
• the laboratory shaker 80 is configured to orbitally agitate the cell culture flask 10 at different agitation frequencies up to 150 rpm, for example, to express a protein of interest into the cavity 14 of the cell culture flaks 10.
• the orbital agitation of the cell culture flask 10 causes the liquid 84 held in the cell culture flask 10 (i.e., cell culture medium and cells) to swirl and flow up the sidewall 22 of the cell culture flask 10.
• the present invention also contemplates a method of culturing cells using the above-described cell culture flasks 10-1 Oi.
• the specific cell lines targeted and tested for culturing in certain embodiments of the cell culture flasks 10-1 Oi described above are the following: Expi293 suspension-adapted human embryonic kidney (HEK) for growth in Gibco Expi293 Expression Medium; ExpiSfTM non-engineered derivative of Sf9 insect cells adapted for growth in ExpiSfTM CD Medium; and ExpiCHO derived from a nonengineered sub clone that has been screened and isolated from CHO-S Chinese hamster ovary (CHO) cells.
• the cell culture flask can be used to culture prokaryotic cells, mammalian cells such as a CHO cell, yeast cells, or insect cells, for example.
• the method includes providing a cell culture flask 10-1 Oi and introducing a volume of cell culture medium (e.g., Gibco Expi293 Expression Medium) and an amount of cells (e.g., Expi293) into the cavity 14 of the cell culture flask 10. Culturing the cells under conditions to support growth and/or expansion of the one or more cells, including agitating the cell culture flask with the laboratory shaker 80 at an agitation frequency of between 50 rpm to 150 rpm, for example, to express a protein of interest into the cavity 14. The method also includes isolating the protein of interest from the cell culture medium and/or the one or more cells.
• a volume of cell culture medium e.g., Gibco Expi293 Expression Medium
• cells e.g., Expi293
• the protein of interest may include a recombinant protein.
• the protein of interest includes a viral protein, such as without limitation a lentiviral protein or an adeno-associated viral protein.
• the method further includes isolating the protein of interest from the cell culture medium and/or the one or more cells.
• Exemplary protein expression systems for use with the cell culture flasks provided herein include, without limitation, ExpiCHOTM Expression System, FreestyleTM MAX CHO Expression System, Expi293TM Expression System, FreestyleTM 293 Expression System, FreestyleTM MAX 293 Expression System, and ExpiSfTM Expression System (all from Thermo Fisher Scientific).
• kits for producing viral particles by culturing cells in a flask described herein under conditions to support virus particle production from the cells are transfected with a recombinant viral vector, including without limitation a lentivirus vector or an adeno- associate virus vector, prior to culturing in the flask.
• the cells are infected with a recombinant virus particle, including without limitation a lentivirus particle or an adeno-associate virus particle, prior to culturing in the flask.
• the method further includes isolating the virus particles from the cell culture medium and/or cells following the culture period.
• Exemplary virus production systems for use with the cell culture flasks provided herein include, without limitation, AAV-MAX Helper-Free AAV Production System (Thermo Fisher Scientific) and LV- MAXTM Lentiviral Production System (Thermo Fisher Scientific).
• Expi293 TM cells suspension-adapted human embryonic kidney cell line, were seeded at a density of 0.5 million cells per mL in Expi293 TM Expression Medium (Thermo Fisher Scientific) and grown in standard culture conditions. Starting from this very low cell density and doubling every 24 hours, the culture typically will reach a peak density after about 6 days in culture.
• Expi293 cell growth and viability was evaluated in culture volumes ranging from 2 liters up to 3.5 liters in the 5-1 iter flasks.
• An example of Expi293 cell growth performance in the faceted bottom flasks is shown in Fig. 30 with viable cells exceeding 1.0 x 107 cells/ml by day 6 post-seeding.
• the Expi293 cell growth performance in the 2 to 3.5 liter cultures was similar to that of the cells in a 30 ml culture volume.
• ExpiSf9TM cells insect cells adapted for high-density suspension growth, were seeded at a density of 0.5 million cells per mL in ExpiSf9 TM CD Medium (Thermo Fisher Scientific) and grown in standard culture conditions per manufacture’s recommendations. Starting from this very low cell density and doubling every 24 hours, the culture typically will reach a peak density after about 6 days in culture. ExpiSf9 cell growth and viability was evaluated in culture volumes ranging from 2 liters up to 3.5 liters in the 5-liter flasks. An example of ExpiSf9 cell growth performance in 2-liter cultures in the beveled bottom flask and the faceted bottom flask is shown in Fig. 31 with viable cells reaching peak density of about 1 .8 x 107 cells/ml by about day 6 postseeding.
• ExpiCHOTM cells Chinese hamster ovary cells doe high density suspension culture, were seeded at a density of 0.3 million cells per mL in ExpiCHOTM Expression medium (Thermo Fisher Scientific) and grown in standard culture conditions. Starting from this very low cell density and doubling every 18-20 hours, the culture typically will reach a peak density after 5 days post-seeding. ExpiCHO cell growth and viability was evaluated in culture volumes ranging from 2 liters up to 3.5 liters in the 5-liter faceted bottom flasks. An example of ExpiCHO cell growth performance of a 2-liter culture in the beveled-bottom flask is shown in Fig. 32 with viable cells reaching peak density of about 1 .7 x 10 7 cells/ml by about day 6 post-seeding.
• Expi293TM cells were seeded at a density of 3 x 10 6 cells/mL of culture in Expi293 TM Expression medium and transfected with an antibody expression vector plasmid DNA per manufacture instructions. The following day Expi293 TM Transfection Enhancers were added to the transfected cell culture according to manufacture instructions. After 6 days of culture, the titer of antibody expressed and secreted into the culture medium was determined.
• Recombinant protein production was evaluated in Expi293 culture volumes ranging from 2 liters to 2.5 liters in the 5-liter beveled-bottom and faceted-bottom flasks. Protein production results from the large volume cultures were comparable to that of the small-scale control flasks.
• An example of recombinant antibody production in a 2.25- liter end volume Expi293 culture is shown in Fig. 33.
• ExpiSf9 TM cells To assess protein production using the ExpiSf9 TM cells, recombinant baculovirus containing GFP-encoding DNA was prepared using the Bac-to-BacTM Baculovirus Expression System (Thermo Fisher Scientific). Using the ExpiSfTM Expression System (Thermo Fisher Scientific), ExpiSf9 TM cells were seeded at a density of 5 x 10 6 cells/mL of culture in ExpiSfTM CD medium and ExpiSfTM Enhancer added to the culture per manufacturer instructions. The following day, the cells were infected with a baculovirus stock containing GFP-encoding DNA. After 3 days, the culture was harvested and GFP protein titer was quantified using a plate reader.
• ExpiCHOTM cells were seeded at a density of 6 x 10 6 cells/mL of culture in ExpiCHOTM Expression medium and transfected with an antibody expression vector plasmid DNA per manufacture instructions. The following day ExpiCHOTM Enhancer and ExpiCHOTM Feed were added to the transfected cell culture according to manufacture instructions. After 8-1 days of culture, the titer of antibody expressed and secreted into the culture medium was determined.

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