U.S. patent application number 12/077397 was filed with the patent office on 2008-09-25 for apparatus and methods for making, storing, and administering freeze-dried materials such as freeze-dried plasma.
This patent application is currently assigned to HemCon Medical Technologies, Inc.. Invention is credited to William D. Block, Lisa A. Buckley, Lance D. Hopman, Simon J. McCarthy, John W. Morgan, Clinton B. Pepper.
Application Number | 20080234654 12/077397 |
Document ID | / |
Family ID | 39766679 |
Filed Date | 2008-09-25 |
United States Patent
Application |
20080234654 |
Kind Code |
A1 |
McCarthy; Simon J. ; et
al. |
September 25, 2008 |
Apparatus and methods for making, storing, and administering
freeze-dried materials such as freeze-dried plasma
Abstract
A vessel receives a liquid material, which is freeze-dried in
situ within the vessel. A gas permeable material carried by the
vessel provides gas transport for sublimation during drying. After
freeze drying, an oxygen-free inert gas is introduced into the
vessel through the gas permeable material, to occupy the interior
of the vessel with the freeze-dried material. The gas permeable
material is covered, to trap the oxygen-free inert gas within the
vessel with the freeze-dried material. The freeze-dried material is
stored in the entrapped oxygen-free inert gas within the vessel for
a storage period. The vessel receives a reconstituting liquid for
mixing with the freeze-dried material, and conveys the
reconstituted freeze-dried material from the vessel for
administration to an individual.
Inventors: |
McCarthy; Simon J.;
(Portland, OR) ; Block; William D.; (Lake Oswego,
OR) ; Morgan; John W.; (Portland, OR) ;
Buckley; Lisa A.; (Portland, OR) ; Hopman; Lance
D.; (Tigard, OR) ; Pepper; Clinton B.; (West
Linn, OR) |
Correspondence
Address: |
RYAN KROMHOLZ & MANION, S.C.
POST OFFICE BOX 26618
MILWAUKEE
WI
53226
US
|
Assignee: |
HemCon Medical Technologies,
Inc.
|
Family ID: |
39766679 |
Appl. No.: |
12/077397 |
Filed: |
March 19, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11881493 |
Jul 27, 2007 |
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12077397 |
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11725352 |
Mar 19, 2007 |
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11881493 |
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Current U.S.
Class: |
604/416 ;
604/518 |
Current CPC
Class: |
A61J 1/2037 20150501;
A61J 1/2013 20150501; A61B 50/13 20160201; A61J 1/2093 20130101;
A61M 2039/1061 20130101; A61P 7/08 20180101; A61J 1/2027 20150501;
A61B 90/96 20160201; A61J 2205/10 20130101; A61J 1/10 20130101;
A61B 50/30 20160201; A61J 1/1475 20130101; A61J 1/201 20150501;
A61B 50/10 20160201 |
Class at
Publication: |
604/416 ;
604/518 |
International
Class: |
A61B 19/00 20060101
A61B019/00 |
Claims
1. Apparatus comprising: a dry freeze-dried material, a
reconstituting liquid for the freeze-dried material, and a flexible
container including first chamber sized and configured to hold the
freeze-dried material in a dry state, a second chamber sized and
configured to hold the reconstituting liquid in a wet state, a
sealing wall within the flexible container sized and configured to
form a barrier between the first chamber and the second chamber
preventing contact between the freeze-dried material and the
reconstituting liquid, and at least one valve assembly in the
sealing wall operative to open a region of the sealing wall to
establish fluid flow communication between the first and second
chambers.
2. Apparatus according to claim 1 wherein the valve assembly
includes a pressure sensitive valve operative between a normally
closed condition normally resisting fluid flow communication
between the first and second chambers and an opened condition
establishing fluid flow condition communication between the first
and second chambers in response to a pressure differential applied
across the valve.
3. Apparatus according to claim 2 wherein the pressure sensitive
valve comprises a flap valve.
4. Apparatus according to claim 1 wherein the valve assembly
includes a normally closed septum operative in a normally closed
condition maintaining closure between the first and second chambers
and an opened condition establishing fluid flow communication
between the first and second chambers in response to at least a
partially tearing of the septum.
5. Apparatus according to claim 4 wherein the septum includes a
tear member coupled to a pulling member to at least partially tear
the septum.
6. Apparatus according to claim 1 wherein the valve assembly
includes a pressure sensitive valve operative between a normally
closed condition normally resisting fluid flow communication
between the first and second chambers and an opened condition
establishing fluid flow condition communication between the first
and second chambers in response to a pressure differential applied
across the valve, and a normally closed septum associated with the
valve operative in a normally closed condition maintaining closure
between the first and second chambers independent of the valve and
an opened condition establishing fluid flow communication between
the first and second chambers in response to at least a partially
tearing of the septum and a pressure differential applied across
the valve.
7. Apparatus according to claim 6 wherein the pressure sensitive
valve comprises a flap valve.
8. Apparatus according to claim 6 wherein the septum includes a
tear member coupled to a pulling member to at least partially tear
the septum.
9. Apparatus according to claim 1 further including an outer skirt
overlaying an exterior wall of the container in a region of the
sealing wall.
10. Apparatus according to claim 9 wherein the outer skirt includes
a tear member coupled to a pulling member to tear the outer skirt
for removal.
11. Apparatus according to claim 9 wherein at least a portion of
the exterior wall of the container overlaid by the outer skirt
includes placations.
12. Apparatus according to claim 9 wherein the flexible container
includes an integral administration port for administering material
from the container.
13. Apparatus according to claim 1 wherein the freeze-dried
material includes freeze-dried human plasma.
14. A method comprising providing a flexible container including
first chamber holding a freeze-dried material in a dry state, a
second chamber holds a reconstituting liquid for the freeze-dried
material, the flexible container including an interior sealing wall
sized and configured to form a barrier between the first chamber
and the second chamber preventing contact between the freeze-dried
material and the reconstituting liquid, and at least one valve
assembly in the sealing wall operative by manipulation to open a
region of the sealing wall to establish fluid flow communication
between the first and second chambers, manipulating the valve
assembly to open the region, and expressing the reconstituting
liquid from the second chamber through the valve assembly into the
first chamber into contact with the freeze-dried material.
15. A method according to claim 14 further including reconstituting
the freeze-dried material by successively expressing a mixture of
the reconstituting liquid and freeze-drive material between the
first and second chambers, thereby preparing a reconstituted
product.
16. A method according to claim 15 further including administering
the reconstituted product directly from one of the chambers to a
recipient.
17. A method according to claim 14 wherein the freeze-dried
material includes freeze-dried human plasma.
18. A method comprising providing a flexible container including
first chamber holding a freeze-dried material in a dry state, a
second chamber holding a reconstituting liquid for the freeze-dried
material, the flexible container including an interior sealing wall
sized and configured to form a barrier between the first chamber
and the second chamber preventing contact between the freeze-dried
material and the reconstituting liquid, at least one valve assembly
in the sealing wall operative by manipulation to open a region of
the sealing wall to establish fluid flow communication between the
first and second chambers, and an outer skirt overlaying an
exterior wall of the container in a region of the sealing wall and
blocking manipulation of the valve assembly, removing the outer
skirt to expose the valve assembly to manipulation, manipulating
the valve assembly to open the region, and expressing the
reconstituting liquid from the second chamber through the valve
assembly into the first chamber into contact with the freeze-dried
material.
19. A method according to claim 18 further including reconstituting
the freeze-dried material by successively expressing a mixture of
the reconstituting liquid and freeze-drive material between the
first and second chambers, thereby preparing a reconstituted
product.
20. A method according to claim 19 further including administering
the reconstituted product directly from one of the chambers to a
recipient.
21. A method according to claim 18 wherein the freeze-dried
material includes freeze-dried human plasma.
22. A method comprising providing a flexible container including
first chamber, a second chamber, and an interior sealing wall sized
and configured to form a barrier between the first chamber and the
second chamber, and at least one valve assembly in the sealing wall
operative by manipulation to open a region of the sealing wall to
establish fluid flow communication between the first and second
chambers, preparing a freeze-dried material comprising freeze-dried
human plasma, placing the freeze dried material in the first
chamber of the container, and placing a reconstitution liquid for
the freeze dried material in the second chamber of the
container.
23. A method according to claim 22 further including manipulating
the valve assembly to open the region, and expressing the
reconstituting liquid from the second chamber through the valve
assembly into the first chamber into contact with the freeze-dried
material.
24. A method according to claim 23 further including reconstituting
the freeze-dried material by successively expressing a mixture of
the reconstituting liquid and freeze-drive material between the
first and second chambers, thereby preparing a reconstituted
product.
25. A method according to claim 24 further including administering
the reconstituted product directly from one of the chambers to a
recipient.
26. A system comprising a vessel comprising a first end component
comprising a rigid or semi-rigid material defining a first frame
providing structural strength, the first end component including a
gas impermeable material peripherally sealed to the first frame and
spanning the frame to provide viewing into the interior space, a
second end component comprising a rigid or semi-rigid material
defining a second frame providing structural strength, the second
end component including a gas permeable material peripherally
sealed to the second frame and spanning the frame to provide gas
transport to and from the interior space, a side wall component
peripherally sealed to side edges of the first and second frames,
the side wall component comprising a flexible, gas impermeable
material, the first end component, the second end component, and
the side wall component peripherally defining an interior space,
and at least one port component on the side wall providing fluid
communication with the interior space, and a material introduced as
a liquid through the at least one port and freeze-dried in situ
within the interior space.
27. A system according to claim 26 wherein the vessel further
includes a closure cover hinged to the second frame for movement
between an opened condition exposing the gas permeable material of
the second end component to gas transport and a closed condition
covering the gas permeable material of the second end component to
substantially block the gas transport.
28. A system according to claim 26 further including a
gas-impermeable overwrap covering at least the hydrophic material
of the second end component to substantially block gas transport to
and from the interior space.
29. A system according to claim 26 further including a second port
component on the side wall component providing fluid transport with
the interior space, and a reconstituting liquid introduced through
the second port to reconstitute the freeze-dried material within
the interior space.
30. A system according to claim 26 further including a rigid outer
container for the vessel.
31. A system according to claim 26 further including an oxygen-free
inert gas introduced into the interior space through the gas
permeable material of the second end component.
32. A system according to claim 31 further including a closure
cover covering the gas permeable material of the second end
component to substantially block transport of the oxygen-free inert
gas from the interior space.
33. A system according to claim 31 further including a
gas-impermeable overwrap covering the gas permeable material of the
second end component to substantially block transport of the
oxygen-free insert gas from the interior space.
34. A system according to claim 26 wherein the freeze-dried
material includes freeze-dried human plasma.
35. A method comprising providing a vessel comprising a first end
component comprising a rigid or semi-rigid material defining a
first frame providing structural strength, the first end component
including a gas impermeable material peripherally sealed to the
first frame and spanning the frame to provide viewing into the
interior space, a second end component comprising a rigid or
semi-rigid material defining a second frame providing structural
strength, the second end component including a gas permeable
material peripherally sealed to the second frame and spanning the
frame to provide gas transport to and from the interior space, a
side wall component peripherally sealed to side edges of the first
and second frames, the side wall component comprising a flexible,
gas impermeable material, the first end component, the second end
component, and the side wall component peripherally defining an
interior space, and at least one port component on the side wall
providing fluid communication with the interior space, introducing
a liquid material through the first port, freeze-drying the liquid
material in situ within the interior space, the gas permeable
material of the second end component providing gas transport for
sublimation during drying, introducing a reconstituting liquid for
mixing with the freeze-dried material within the interior space
through the second port, to reconstitute the freeze-dried material,
and conveying the reconstituted freeze-dried material from the
interior space through the third port.
36. A method according to claim 30 further including, after freeze
drying, introducing an oxygen-free inert gas into the interior
space through the gas permeable material of the second end
component, to occupy the interior space with the freeze-dried
material, covering the gas permeable material of the second end
component to trap the oxygen-free inert gas within the interior
space with the freeze-dried material, and storing the freeze-dried
material in the entrapped oxygen-free inert gas within the vessel
for a storage period prior to introduction of the reconstituting
liquid.
37. A method according to claim 31 further including placing the
covered vessel within an outer container during storage.
38. A method according to claim 30 further including, after freeze
drying, introducing an oxygen-free inert gas into the interior
space through the gas permeable material of the second end
component, to occupy the interior space with the freeze-dried
material, sealing an overwrap of a gas-impermeable material over
the vessel to trap the oxygen-free inert gas within the interior
space with the freeze-dried material, and storing the freeze-dried
material in the entrapped oxygen-free inert gas within the vessel
and overwrap for a storage period prior to introduction of the
reconstituting liquid.
39. A method according to claim 33 further including placing the
vessel within an outer container during storage.
40. A method according to claim 30 wherein the liquid material
introduced through the first port comprises fresh human plasma.
Description
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending
U.S. patent application Ser. No. 11/881,493, filed 27 Jul. 2008,
and entitled "Apparatus and Methods for Making, Storing, and
Administering Freeze-Dried Materials Such as Freeze-Dried Plasma,"
which is a continuation-in-part of co-pending U.S. patent
application Ser. No. 11/725,352, filed 19 Mar. 2007, and entitled
"Apparatus and Methods for Making, Storing, and Administering
Freeze-Dried Materials Such as Freeze-Dried Plasma," both of which
are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to methods, systems, and
apparatuses for manufacturing, storing and administering
freeze-dried materials, such as single donor units of freeze-dried
human plasma.
BACKGROUND OF THE INVENTION
[0003] First aid is critical for the survival of a person that has
suffered a serious injury, such as a trauma victim. For instance,
initial treatment of a severely wounded person in combat situations
can often mean the difference between life and death. While it is
necessary to treat the wounds and stop the bleeding of the person,
it is also important to ensure that the person's body is capable of
properly functioning. Thus, it is necessary to take steps to ensure
that the person's body is properly hydrated after losing fluids due
to the injury. The present invention addresses these issues.
[0004] Previously, fluids were replenished within the patient by
delivering saline intravenously. While effective, research has
indicated that delivery of plasma to the patient is even more
effective in replenishing fluid to the patient than the use of
saline. However, delivery and storage of the plasma is critical to
prevent contamination of the plasma. An ideal way of delivering the
plasma is to deliver the plasma in a freeze dried form and
reconstituting the plasma when it is administered to a person.
SUMMARY OF THE INVENTION
[0005] The invention provides methods, systems, and apparatuses for
manufacturing, storing and administering freeze-dried materials,
such as single donor units of freeze-dried human plasma.
[0006] According to one aspect of the invention, a freeze-dried
material, e.g., freeze-dried human plasma, is stored in a first
chamber of a container along with a reconstituting liquid for the
freeze-dried material, e.g., de-gassed water. The reconstituting
liquid is stored in a second chamber of the container. A sealing
wall within the container forms a barrier between the first chamber
and the second chamber preventing contact between the freeze-dried
material and the reconstituting liquid. At least one valve assembly
in the sealing wall can be manipulated to selectively open at least
one region of the sealing wall to establish fluid flow
communication between the first and second chambers. This allows
the freeze dried material to be reconstituted within the container.
The reconstituted freeze-dried material can also be administered
directly from the same container to a recipient.
[0007] In one arrangement, the valve assembly includes a pressure
sensitive valve, e.g., a flap valve. The valve is operative between
a normally closed condition, normally resisting fluid flow
communication between the first and second chambers, and an opened
condition, establishing fluid flow condition communication between
the first and second chambers. The pressure sensitive valve can be
placed in its open condition in response to establishing a pressure
differential across the valve, e.g., by preferentially squeezing a
chamber of the container.
[0008] In one arrangement, the valve assembly includes a normally
closed septum. The septum is operative in a normally closed
condition, maintaining closure between the first and second
chambers, and an opened condition establishing fluid flow
communication between the first and second chambers in response to
at least a partially tearing of the septum. The septum can, e.g.,
include a tear member coupled to a pulling member to at least
partially tear open the septum.
[0009] The pressure sensitive valve and the septum can be arranged
serially to provide a redundant valve assembly. In this
arrangement, the normally closed septum is operative in a normally
closed condition, maintaining closure between the first and second
chambers, independent of the valve and an opened condition
establishing fluid flow communication between the first and second
chambers in response to at least a partially tearing of the septum
and a pressure differential applied across the valve.
[0010] In one arrangement, an outer skirt is provided that overlays
an exterior wall of the container in a region of the sealing wall.
The outer skirt can include a tear member coupled to a pulling
member to tear open the outer skirt for removal.
[0011] Another embodiment of the invention provides a method that
provides a flexible container as above generally described, with
first and second chambers. The first chamber holds a freeze-dried
material, such as freeze-dried human plasma, in a dry state. The
second chamber holds a reconstituting liquid for the freeze-dried
material. An interior sealing wall within the container is sized
and configured to form a barrier between the first chamber and the
second chamber preventing contact between the freeze-dried material
and the reconstituting liquid. At least one valve assembly in the
sealing wall is operative by manipulation to open at least one
region of the sealing wall to establish fluid flow communication
between the first and second chambers. According to this aspect of
the invention, the valve assembly is manipulated to open the
region, and the reconstituting liquid is expressed from the second
chamber through the valve assembly into the first chamber into
contact with the freeze-dried material.
[0012] In one arrangement, an outer skirt overlays an exterior wall
of the container in a region of the sealing wall and blocking
manipulation of the valve assembly. In this arrangement, the outer
skirt is removed to expose the valve assembly to manipulation prior
to manipulating the valve assembly to open the region in the
sealing wall.
[0013] In another arrangement, the reconstituted freeze-dried
plasma is administered directly from the container to a
recipient.
[0014] According to another aspect of the invention, a freeze-dried
material comprising freeze-dried human plasma is prepared and
stored, transported, reconstituted, and administered using a
container as just generally described in any of the foregoing
paragraphs. In one arrangement, liquid human plasma is loaded in
molds. The molds are cooled until they reach approximately
-45.degree. C. The plasma is dried so the moisture content is below
5% w/w, thereby forming the freeze-dried human material that can be
stored, transported, reconstituted, and administered using a
container. In another arrangement, liquid human plasma is
freeze-dried in situ within the container.
[0015] According to another aspect of the invention, a freeze-dried
material, e.g., freeze-dried human plasma, is stored in a first
container, and a reconstituting liquid for the freeze-dried
material, e.g., de-gassed water is stored in a separate second
container. A transfer set can be manipulated to couple the two
containers together, to establish fluid flow communication between
the first and second containers. This allows the freeze dried
material to be reconstituted within one of the containers. The
reconstituted freeze-dried material can also be administered
directly from the same container to a recipient.
[0016] According to another aspect of the invention, a system is
provided that comprises a vessel including first and second end
components each comprising a rigid or semi-rigid material defining,
respectively, first and second frames providing structural
strength. A transparent gas impermeable material peripherally is
sealed to the first frame, and a gas permeable material is
peripherally sealed to the second frame. A flexible side wall
component is peripherally sealed to side edges of the first and
second frames. The first end component, the second end component,
and the side wall component peripherally define an interior space.
At least one port component on the side wall provides fluid
communication with the interior space.
[0017] The system makes it possible for a material such a fresh
human plasma to be freeze-dried, transported, stored,
reconstituted, and administered in a single, multifunctional
vessel.
[0018] Another aspect of the invention provides a method that makes
use of the technical features of the multifunctional vessel just
described. The method includes introducing a liquid material, such
as fresh human plasma, through a first port component on the
vessel. The method includes freeze-drying the liquid material in
situ within the interior space of the vessel, during which time the
gas permeable material of the second end component provides gas
transport to accommodate sublimation of water vapor. The method
also includes introducing a reconstituting liquid for mixing with
the freeze-dried material within the interior space through a
second port component of the vessel, to reconstitute the
freeze-dried material. The method further includes conveying the
reconstituted freeze-dried material from the interior space through
a third port component of the vessel.
[0019] As defined, the single, multifunctional vessel accommodates
freeze-drying a material within the vessel; the transport and
storage of the freeze-dried material within the vessel; and the
reconstitution and administration of the material from the
vessel.
[0020] In one embodiment, the method further includes, after freeze
drying, introducing an oxygen-free inert gas into the interior
space through the gas permeable material of the second end
component. The oxygen-free inert gas occupies the interior space
with the freeze-dried material to prevent deterioration of the
material. The method also includes covering the gas permeable
material of the second end component, to trap the oxygen-free inert
gas within the interior space with the freeze-dried material. The
method includes storing the freeze-dried material in the entrapped
oxygen-free inert gas within the vessel for a storage period prior
to introduction of the reconstituting liquid.
[0021] In one embodiment, the method further includes placing the
covered vessel within an outer container during storage.
[0022] These and other areas of importance and significance will
become apparent from following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a front elevation view of a device for storing
freeze-dried material, e.g., freeze-dried human plasma, and a
reconstituting liquid for the freeze-dried material, making
possible a reconstitution of the freeze-dried material within the
device and an administration of the reconstituted freeze-dried
material directly from the device to a recipient, the device being
shown prior to the removal of an outer protective skirt.
[0024] FIG. 2 is side elevation view of the device shown in FIG.
1.
[0025] FIG. 3 is a front elevation view of the device shown in FIG.
1, showing the tearing of the outer protective skirt for its
removal prior to manipulating the device to reconstitute the
freeze-dried materials.
[0026] FIG. 4A is a front elevation view of the device shown in
FIG. 3, after the removal of the outer protective skirt and prior
to manipulating the device to reconstitute the freeze-dried
materials.
[0027] FIG. 4B is side elevation view of the device shown in FIG.
4A.
[0028] FIG. 5A is a side elevation section view of the interior
sealing wall and associated valve assembly formed within the device
taken generally along line 5A-5A in FIG. 1, prior to the removal of
the outer protective skirt.
[0029] FIG. 5B is a side elevation section view like that shown in
FIG. 5A, showing an alternative arrangement of the interior sealing
wall and multiple valve assemblies.
[0030] FIG. 6 is a side elevation section view of the interior
sealing wall and associated valve assembly formed within the device
taken generally along line 6-6 in FIG. 4A, after the removal of the
outer protective skirt and prior to manipulating the device to
reconstitute the freeze-dried materials.
[0031] FIG. 7 is a side elevation section view of the interior
sealing wall and associated valve assembly like that shown in FIG.
6, after opening at least one region of interior sealing wall and
prior to manipulating the device to reconstitute the freeze-dried
materials.
[0032] FIG. 8 is a front elevation view of the device shown in FIG.
1, showing the removal of the outer protective skirt prior to
manipulating the device to reconstitute the freeze-dried
materials.
[0033] FIG. 9 is a front elevation view of the device shown in FIG.
8, showing the manipulation of the valve assembly to open at least
one region of the interior sealing wall, in the manner also shown
in FIG. 7.
[0034] FIGS. 10 to 15 are front elevation view of the device shown
in FIG. 9, showing the manipulating the device to reconstitute the
freeze-dried materials.
[0035] FIG. 16 is a front elevation view of the device shown in
FIG. 15, showing the administration of reconstituted material
directly from the device to a recipient.
[0036] FIGS. 17A to 17E are diagrammatic perspective views to an
illustrative process for the preparation of a freeze-dried plasma
cake from liquid human plasma, prior to insertion and storage
within the device shown in FIG. 1.
[0037] FIGS. 18 and 19 are front elevation views of placing a
freeze-dried material (like the plasma cake formed using the
process FIGS. 17A to 17E) in the first chamber of the device shown
in FIG. 1.
[0038] FIG. 20 is a front elevation view of placing a
reconstituting liquid for the freeze-dried material in the second
chamber of the device shown in FIG. 1.
[0039] FIG. 21 is a front elevation view of placing the outer
protective sleeve about the device, to create the device shown in
FIG. 1.
[0040] FIG. 22 is a front elevation view of an alternative device
for storing freeze-dried material, e.g., freeze-dried human plasma,
and a reconstituting liquid for the freeze-dried material, making
possible a reconstitution of the freeze-dried material within the
device and an administration of the reconstituted freeze-dried
material directly from the device to a recipient, the device being
shown prior to the removal of an outer protective skirt.
[0041] FIG. 23 is a front elevation interior section view of the
valve assembly formed in the device taken generally along line
23-23 in FIG. 22, prior to the removal of the outer protective
skirt.
[0042] FIG. 24 is a front elevation view of the device shown in
FIG. 22, after the removal of the outer protective skirt and prior
to manipulating the device to reconstitute the freeze-dried
materials.
[0043] FIG. 25 is a front elevation interior section view of valve
assembly like that shown in FIG. 23, taken generally along line
25-25 in FIG. 23 after removal of the outer protective skirt.
[0044] FIGS. 26 and 27 are front elevation interior section views
showing the passage of materials through the valve assembly shown
in FIG. 25 by manipulating the device to reconstitute the
freeze-dried materials.
[0045] FIGS. 28A and 28B are a largely schematic views of an
alternative way of packaging the reconstituting liquid for the
freeze-dried material in the second chamber of the device of the
type shown in FIG. 1 or 22.
[0046] FIGS. 29A and 29B are largely schematic views of another
alternative way of packaging the reconstituting liquid for the
freeze-dried material in the second chamber of the device of the
type shown in FIG. 1 or 22.
[0047] FIG. 30 is a front elevation view of a system for storing
freeze-dried material, e.g., freeze-dried human plasma, and a
reconstituting liquid for the freeze-dried material, comprising
individual first and second containers and a transfer set that
makes possible a reconstitution of the freeze-dried material within
the system for administration to a recipient.
[0048] FIG. 31 is a front elevation view of the system shown in
FIG. 30, with the first and second containers joined in fluid
communication by the transfer set to reconstitute the freeze-dried
material.
[0049] FIG. 32 is a front elevation view of one of the containers
of the system shown in FIGS. 30 and 31, after the freeze-dried
material has been reconstituted, showing the administration of
reconstituted material directly from the container to a
recipient.
[0050] FIG. 33 is a front elevation view of a device for storing
freeze-dried material, e.g., freeze-dried human plasma, and a
reconstituting liquid for the freeze-dried material, the device
being sized and configured for freeze-drying material in situ
within the device.
[0051] FIG. 34 is a front elevation view of the device shown in
FIG. 33, showing the conveyance of liquid plasma into the device
for freeze-drying in situ within the device.
[0052] FIG. 35 is a perspective view of several devices shown in
FIG. 34 after placement in a freeze-dryer for the purpose of
freeze-drying liquid plasma in situ within each of the devices.
[0053] FIG. 36 is a front elevation view of a device shown in FIG.
35 after removal from the freeze-dryer, showing the freeze-dried
plasma cake that has been formed in situ within the device, and
prior to the conveyance of a reconstituting material into the
device.
[0054] FIG. 37 is a front elevation view of a device shown in FIG.
36 after the conveyance of a reconstituting material into the
device.
[0055] FIG. 38 is a front elevation view of placing an outer
protective sleeve about the device shown in FIG. 37, after
conveyance of the reconstituting material into the device, to
create the device of a type shown in FIG. 1.
[0056] FIG. 39A is an exploded perspective view of a
multifunctional device for freeze-drying, storing, reconstituting,
and administering a material, such as plasma, comprises a vessel
made of several components having different physical properties to
thereby serve different functions.
[0057] FIG. 39B is an assembled perspective view of the device
shown in FIG. 39A, showing the flexible side wall component and
transparent, gas impermeable end component.
[0058] FIG. 39C is an assembled perspective view of the device
shown in FIG. 39A, showing the flexible side wall component and the
gas permeable end component.
[0059] FIG. 39D is an assembled side elevation view of the device
shown in FIG. 39A, taken along line 39D-39D of FIG. 39C.
[0060] FIGS. 40 and 41A are perspective views of a freeze-dried
material storage assembly comprising the vessel shown in FIGS. 39A
to 39D sealed within a gas-impermeable overwrap, and also showing
in perspective view a rigid outer container with a lid for
enclosing the freeze-dried material storage assembly during
transport and storage until the instance of use, as FIG. 41
shows.
[0061] FIG. 41B shows a perspective view of a freeze-dried material
storage assembly sealed within a gas-impermeable overwrap, and
placed in a rigid outer container with a lid, as FIG. 41 shows,
with the outer container also including storage space for a vessel
of reconstitution liquid and associated reconstitution and
administration sets.
[0062] FIGS. 42 and 43 are perspective views of a unitary
freeze-died material storage assembly comprising a vessel as shown
in FIGS. 39A to 39D and an integral closure cover, FIG. 42 showing
the closure cover in an opened condition, and FIG. 43 showing the
closure cover in a closed condition.
[0063] FIGS. 44 and 45 are perspective views of the unitary
freeze-dried material storage assembly shown in FIG. 43 (with the
closure cover in the closed condition) placed within a rigid outer
container with a lid for enclosing the unitary freeze-dried
material storage assembly during transport and storage until the
instance of use.
[0064] FIGS. 46 and 47 are perspective views of another
representative embodiment of a unitary freeze-died material storage
assembly comprising a vessel as shown in FIGS. 39A to 39D and an
integral closure cover, FIG. 46 showing the closure cover in an
opened condition, and FIG. 47 showing the closure cover in a closed
condition.
[0065] FIGS. 48 and 49 are perspective views of the unitary
freeze-dried material storage assembly shown in FIG. 47 (with the
closure cover in the closed condition) placed within a rigid outer
container with a lid for enclosing the unitary freeze-dried
material storage assembly during transport and storage until the
instance of use.
[0066] FIGS. 50 and 51 are perspective views showing the transfer
of a unit of liquid plasma into a unitary freeze-dried material
storage assembly of the type shown in FIG. 42, with the closure
cover in the opened condition, which begins the process using the
unitary freeze dried material storage assembly.
[0067] FIG. 52 is a perspective view of the placement of several
unitary freeze-dried material storage assemblies shown in FIGS. 50
and 51 into a freeze dryer, the closure covers being in the opened
condition, the freeze dryer exposing the unitary freeze-dried
material storage assemblies to a range of temperature and vacuum
conditions to lyophilize the liquid plasma into freeze-dried
plasma, the open closure cover accommodating sublimation of water
vapor during drying.
[0068] FIG. 53 is a perspective view of the several unitary
freeze-dried material storage assemblies within the freeze dryer
shown in FIG. 52, with the closure covers still in the opened
condition, the freeze dryer exposing the unitary freeze-dried
material storage assemblies to a blanket of oxygen-free inert gas,
the open closure covers accommodating infiltration of the
oxygen-free inert gas into the freeze-dried plasma material
contained within the assemblies.
[0069] FIG. 54 is a perspective view of the several unitary
freeze-dried material storage assemblies within the freeze dryer
shown in FIG. 53, with the closure covers being placed into the
closed condition to trap the oxygen-free inert gas within the
unitary freeze-dried material storage assemblies, to protect the
freeze-dried plasma material from degradation during subsequent
transport and storage.
[0070] FIGS. 55 and 56 are perspective views of the unitary
freeze-dried material storage assembly shown in FIG. 54 (with the
closure cover in the closed condition) placed within a rigid outer
container with a lid for enclosing the unitary freeze-dried
material storage assembly during transport and storage until the
instance of use.
[0071] FIG. 57 shows the reconstitution of the freeze-dried plasma
material within a unitary freeze-dried material storage assembly
after under the freeze-drying and packaging process shown in FIGS.
50 to 56, by transferring a reconstituting liquid from a source
container into the unitary freeze-dried material storage assembly
for mixing with the freeze-dried plasma material.
[0072] FIG. 58 shows the administration of reconstituted
freeze-died plasma material from a unitary freeze-dried material
storage assembly into an individual.
[0073] FIG. 59 shows the mixing of freeze-dried plasma material
with a reconstituting liquid, after transferring a reconstituting
liquid into the unitary freeze-dried material storage assembly as
shown in FIG. 57, by transferring the mixture of reconstituting
liquid and freeze-dried plasma material back to the source
container, the mixture being transferred back and forth in the
manner shown in FIGS. 57 and 59 until ready for administration.
[0074] FIG. 60 shows the administration to an individual of
freeze-died plasma material reconstituted using a unitary
freeze-dried material storage assembly as shown in FIG. 57, the
reconstituted material being ultimately transferred after mixing as
shown in FIGS. 57 and 59 out of the unitary freeze-dried material
storage assembly into the original reconstituting liquid container
for administration.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0075] Although the disclosure hereof is detailed and exact to
enable those skilled in the art to practice the invention, the
physical embodiments herein disclosed merely exemplify the
invention which may be embodied in other specific structures. While
the preferred embodiment has been described, the details may be
changed without departing from the invention, which is defined by
the claims.
I. DEVICE FOR STORING AND RECONSTITUTING FREEZE-DRIED PLASMA
[0076] FIGS. 1 and 2 show a device 10 for storing and administering
a freeze-dried material. The device 10 comprises a flexible bag
having a first collapsible chamber 12 and a second collapsible
chamber 14.
[0077] The first chamber 12, also referred to as the dry chamber,
contains an aliquot of a freeze-dried material 16. The nature and
type of freeze-dried material 16 can vary. In the illustrated
embodiment, the freeze-dried material comprises human plasma, and
the aliquot is a single donor unit of human plasma.
[0078] The second chamber 14, also referred to as the wet chamber,
contains a reconstituting liquid 18 for the freeze-dried material
16. The nature and type of the reconstituting material 18 can vary.
In the illustrated embodiment, the reconstituting material 18
comprises sterile water, which may be degassed, if desired. In use,
the sterile water in the wet chamber 14 is mixed with the
freeze-dried plasma in the dry chamber 12 to provide plasma for
transfusion. The plasma is reconstituted and administered on site
using the device 10.
[0079] The first chamber 12 is sized and configured to maintain the
freeze-dried material 16, prior to its reconstitution, in a vacuum
packed, aseptic, moisture-free and low concentration oxygen
environment, preferably accommodating long term storage, e.g., at
least 2 years at room temperature. Stored in this environment, the
freeze-dried material 16 retains its desired qualities for
transfusion.
[0080] The second chamber 12 is sized and configured to maintain
the reconstituting liquid 18, prior to its mixing with the
freeze-dried material 16, in an aseptic environment and at a low
gas concentration, preferably accommodating long term storage,
e.g., at least 2 years at room temperature.
[0081] The volume of each of the chambers 12 and 14 is preferably
approximately 50% larger than the volume of the freeze-dried
material 16 in the first chamber 12. This provides ample volume
within the device 10 for mixing the freeze-dried material 16 and
reconstituting liquid 18, either in the first chamber 12 or the
second chamber 14, as will be described in greater detail
later.
[0082] The device 10 may be made, e.g., of an inert medical grade
plastic material, such as polyvinyl chloride, polyethylene,
polypropylene, or high density polyethylene. The device 10 can
comprise a multi-laminate of polymer layers for greater durability,
e.g., to resist tearing and puncturing that could be encountered in
normal handling.
[0083] The material of the device 10 can be selected to be
transparent, if desired, to allow visual inspection of the contents
of the chamber 12 and 14. The material in the first chamber 12 can
be selected to provide a gas-impermeable barrier, such as a
metallized, reduced gas-permeability coating, or a metal laminate.
In this case, the wall of the first chamber may be opaque.
[0084] Furthermore, the device 10 may be enveloped prior to use by
a vacuum sealed over-wrap 20 (shown in phantom lines in FIG. 1),
made, e.g., a metallized, gas impermeable material. The over-wrap
20 enhances shelf-stability.
[0085] An interior sealing wall 22 (see FIG. 1) compartmentalizes
the device 10 into the first and second chambers 12 and 14 (see
also FIG. 5A). The sealing wall 22 provides a barrier between the
first chamber 12 and the second chamber 14, which normally prevents
contact between the freeze-dried material 16 and the reconstituting
liquid 18 during storage, up to the instant of use.
[0086] As FIGS. 5A/B and 7 show, one or more regions 24 of the
sealing wall 22 may be selectively opened by a caregiver, as will
be described in greater detail later. The region(s) 24, when
opened, make possible fluid communication between the two chambers
12 and 14. The fluid communication makes it possible to mix the
reconstituting liquid 18 with the freeze-dried material 16, as will
further be described in greater detail later.
[0087] The region(s) 24 of the sealing wall 22 may be opened in
various ways. In a representative embodiment (see FIG. 5), the
sealing wall 22 includes a normally closed valve assembly 26
associated with each region 24 where the sealing wall 22 is to be
opened. In FIG. 5A, a single region 24 is shown, so a single valve
assembly 26 is shown. As shown in FIG. 5B, where multiple regions
24a and 24b are provided, each region 24a and 24b would include its
own dedicated valve assembly 26a and 26b, respectively.
[0088] In the representative embodiment (see FIGS. 5A and 5B), each
valve assembly 26 includes a primary, pressure sensitive valve 28.
The valve 28 can take the form, e.g., of a short duck bill or two
way flap valve. The primary valve 28 is sized and configured to
normally resist flow communication between the two chambers 12 and
14.
[0089] In the representative embodiment, each valve assembly 26
also includes a normally closed septum 30 between the valve 28 and
the wet chamber 14. The septum 30 maintains closure between the two
chambers 12 and 14, independent of the valve 28. Independent of the
valve 28, the septum 30 prevents unintended passage of material
between the two chambers 12 and 14, thereby maintaining the
separate integrity of the freeze-dried material 16 and the
reconstituting liquid 18 within the device 10 prior to use.
[0090] The septum 30 includes an integrated tear member 32 that is
incorporated within the septum 30. The integrated tear member 32 is
coupled to a pull string 34 that extends through a fluid sealed
pass-through or septum 36 in the wall of the second chamber 14. As
FIG. 1 shows, the pull string terminates outside the device 10 at a
pull tab 38.
[0091] As FIGS. 6 and 7 show, the tear member 32 is sized and
configured to open the septum 30 when a caregiver pulls on the tab
38. The pass-through or septum 26 seals around the pull string 34,
and also seals close after passage of the pull string 34 from the
interior of the chamber 14, maintaining in integrity of the second
chamber 14. Opening the septum 30 in this manner forms the open
region 24 (see FIG. 7). The open region 24 places the first and
second chambers 12 and 14 into communication through the valve
28.
[0092] With the region 24 opened (see FIG. 7), the primary valve 28
still serves to normally resist flow communication between the two
chambers 12 and 14. However, when the region 24 is opened, the
valve 28 is sized and configured to resiliently yield in response
to a difference in fluid pressure between opposite sides of the
valve 38 (see FIGS. 11 and 14). In response to the pressure
differential, the valve 28 opens in the direction of the fluid
pressure differential, from the region of higher pressure toward
the region of lower pressure.
[0093] As will be described in greater detail later (as shown,
respectively, in FIGS. 10 and 13), the caregiver creates the fluid
pressure differential across the valve 28 by selectively squeezing
one chamber and not the other chamber. Fluid is expelled in
response to the fluid pressure differential through the valve 28
from the chamber that is squeezed into the chamber that is not
squeezed.
[0094] The multi-component valve assembly 26 provides a redundant
sealing capability, to assure that the chambers 12 and 14 remain
separated until it is desired to reconstitute the freeze-dried
material 16.
[0095] In a representative embodiment (see FIGS. 1 and 2), the
device 10 further includes an outer tear-away skirt 40, which
provide further redundancy. As FIGS. 1 and 2 show, the skirt 40
overlays the device 10 in the region of the sealing wall 22. The
skirt 40 serves to overlay and protect the components of the valve
assembly 26 associated with the sealing wall 22.
[0096] At least one region of the skirt 40 is circumferentially
attached about an exterior wall of the device, e.g., by adhesive,
either in the region of the first chamber, the second chamber, or
both. Furthermore, as the skirt 40 is installed about the device
10, the exterior wall of the device is desirably plicated or
pleated or otherwise bunched together (as FIGS. 1 and 2 show).
Alternatively, the placations can be performed in the wall of the
container.
[0097] The placations relieve wall stress in the region of the
sealing wall 22. The skirt 40, once attached, maintains these
placations or pleats, and thereby serves to relieve or distribute
wall stresses in the region of sealing wall 22 and the components
of the valve assembly 26 associated with the sealing wall 22. Such
wall stresses can arise, e.g., due to the weight of the
reconstituting liquid 18 contained in the second chamber 14, and/or
by virtue of handling during transport and manipulation prior to
use. The presence of the overlaying skirt 40 also serves to isolate
the components of the valve assembly 26 associated with the sealing
wall 22 from unintended contact during transport and prior to
use.
[0098] As FIG. 1 shows, the skirt 40 includes an integrated tear
member 42. The integrated tear member 42 includes a pull string 44
that terminates with a pull tab 46, that depends outside the skirt
40. The tear member 42 is sized and configured to tear open the
skirt 40 when a caregiver pulls on the tab 46 (as FIG. 3 shows).
Upon removal of the skirt 40, the placations of the walls of the
bags 12 and 14 are relieved (as FIGS. 4A and 4B show), placing the
components of the valve assembly 26 associated with the sealing
wall 22 into condition for manipulation.
[0099] It should be understood that reference to the first chamber
12 and the second chamber 14 is done to distinguish one chamber
from the other, and not to limit either chamber to a specific
spatial relationship. For example, the chambers 12 and 14 may be
arranged face to face, having vertical edges in contact.
[0100] The technical features of the device 10 includes separate
chambers or compartments that are separated by sealing means that
will allow for eventual interconnection and intercommunication,
between the chambers, which can be accomplished in various ways.
Furthermore, reference to a bag or chambers should not be limited
to any specific structure or shape but should be understood to
refer any container capable of carrying and mixing the contents 16
and 18.
II. PREPARING AND PACKAGING THE FREEZE DRIED MATERIAL AND
RECONSTITUTING LIQUID
[0101] Preparing and packaging the freeze-dried material 16 and
reconstituting liquid 18 comprises two main processing steps: (i)
freeze-drying the material 16, and (ii) packaging the material 16
and the reconstituting liquid 18 within the chambers 12 and 14.
[0102] A. Preparation of Freeze-Dried Plasma
[0103] In a representative embodiment, the freeze-dried material 16
comprises plasma. A description of an illustrative way of preparing
freeze-dried plasma for packaging in the device 10 therefore
follows.
[0104] Preparation and manufacturing of the plasma will take place
in an aseptic setting. Preferably, manufacturing and preparation
procedures can be done, for example, in an ISO Class 5 clean room
(or better) with ISO Class 3 bio-containment hoods for aseptic
handling of human plasma. Freeze drying can be done aseptically in
a CIP/SIP freeze dryer.
[0105] Human plasma is collected from a single donor in a
conventional way, e.g., by collecting a unit of whole blood from
the donor in a closed system collection bag, followed by
centrifugal separation of the plasma and its collection in an
integrally connected transfer bag (containing one plasma unit of
about 250 ml). Each unit (contained in the transfer bag) will be
handled individually in the bio-containment hood. Between handling
one single donor unit and another unit single donor unit from a
different donor, there may be a line clearance protocol for
change-over in the bio-containment hood, or a validation process
for flow design and change-over can be otherwise provided. This
protocol may address removal of all tools and materials associated
with the previous handling. It may also address the thorough wash
down of the containment work area and work area instruments (mass
balances) to ensure no residues of the previous handling were left
in place. The identification of single donor samples will be
maintained by bar coding and other tagging of the single donor
human plasma containers.
[0106] As shown in FIG. 17A, prior to freeze drying, the 250 ml
human plasma unit is dispensed from the transfer bag 48 into a
sterile, pyrogen free, rectangular mold 50 (e.g., 4 cm.times.10
cm.times.12.5 cm--d.times.w.times.l). The mold 50 can be
stainless-steel; however it can also be composed of metal with good
thermal transfer properties such as aluminum, aluminum alloy,
titanium or gold. The mold 50 may be coated on its inside surfaces
with a tough, inert barrier film with good release properties such
as PTFE or diamond.
[0107] As shown in FIG. 17B, the mold 50 containing the human
plasma is then placed inside a water-impermeable, vapor-permeable,
sterile, heat sealable bag 52 with bar coding and tagging 54
indicative of the human plasma identification (source, blood type,
date of collection, etc.). This vapor permeable bag 52 would
typically be manufactured using microporous PTFE membrane material
(e.g. Gore-Tex.TM.) or microporous HDPE membranes (e.g.
Tyvek.TM.).
[0108] The bag 52 is heat sealed to contain the mold 50 and human
plasma. The bag 52 is designed to neatly contain the mold 50 and
its contents without any bunching or sagging of the bag material
below the surface of the interior mold wall edge or at the base of
the mold.
[0109] As shown in FIG. 17C, the mold 50 inside the containment bag
52 is then placed inside a freeze dryer 56 on an aseptic freeze
dryer shelf surface 58. The freeze dryer 56 used for the
lyophilization will be a validated clean in place, steam in place
freeze dryer with shelf area of near 200 square feet or more. Such
a freeze dryer 56 can accommodate at least 500 molds when it is
fully loaded.
[0110] Once loaded, the freeze dryer cycle is started. This cycle
generally cools the human plasma to near -45.degree. C. and
freezing for a prescribed period, e.g., 2 to 8 hours, followed by
cooling of the freeze dryer condenser and application of vacuum to
start the freeze drying cycle. A freeze-dried human plasma cake 60
is formed.
[0111] In a representative primary freeze drying cycle, the
temperature of the human plasma cake 60 needs to remain below its
collapse temperature (e.g., -33.degree. C.) to maintain its
integrity. When the moisture content of the cake 60 is below 5%
weight per weight (w/w), a secondary drying cycle (the elevated
temperature) may be used to further lower the moisture content, if
desired. The combined primary and secondary freeze drying cycles
may take 72 hours or more, but such times will vary with the
processing conditions. At the conclusion of the freeze drying
cycle, the freeze dryer vacuum may be opened to an atmosphere of an
oxygen-free, high purity inert gas such as nitrogen or argon.
[0112] As shown in FIG. 17D, the freeze dried cakes 60 in their
molds 50 and containment bags 52 are removed to an aseptic
containment cart 62 whose environment may be maintained under a
nitrogen or argon blanket to exclude moisture and oxygen. The
containment cart 62 may couple to the front of the freeze dryer to
allow for transfer of the freeze dryer contents under a controlled
inert gas blanket.
[0113] The containment carts 62 may be used to store human freeze
dried plasma cakes (each cake within a mold 50 and enclosed within
a bag 52) as well as allow cakes to be transferred to a device
loading area, which allows loading of the freeze dried plasma cake
60 into the device 10, as will be described in greater detail
later.
[0114] B. Packaging Freeze-Dried Plasma and Water into the
Device
[0115] As shown in FIG. 1, the device 10 comprises a first aseptic
vacuum port 64, which communicates with the first chamber 12, and a
second aseptic vacuum port 66, which communicates with the second
chamber 14. The vacuum ports 64 and 66 are sized and configured for
connection to various tubing T during final assembly (see FIGS. 18
to 21) to facilitate packaging of the freeze-dried plasma material
16 and reconstituting liquid 18 (e.g., water) within the device
10.
[0116] An administration port 68 is also heat sealed in
communication with the second chamber 14. The administration port
68 is used during the packaging process to convey the
reconstituting liquid 18 into the second chamber 14, as will be
described in greater detail later. After the reconstituting liquid
18 is packaged within the chamber 14, the administration port 68 is
sealed with a conventional septum or frangible membrane assembly or
a convention screw-lock luer fitting 70, to accommodate its
coupling to an administration set 72 to the port 28 at time of
transfusion, as shown in FIG. 16.
[0117] The device 10 also comprises a heat sealable aseptic flange
74 (see FIG. 1), which allows a freeze-dried plasma cake 60 to be
inserted into the first chamber 12, as shown in FIG. 18, and then
sealed in an aseptic fashion, as shown in FIG. 19.
[0118] A slot 76 may be pre-formed on the flange 74. The slot 76
makes it possible to hang the device 10 at a desired gravity head
height for administering reconstituted plasma to an individual, as
FIG. 16 shows.
[0119] Individual single donor human plasma freeze dried cakes 60
are aseptically loaded into the device 10 (see FIG. 18) through the
flange 74. The device loading area may be, e.g., a bio-containment
hood that excludes significant oxygen and moisture contamination by
inert gas blanketing. Also the device loading area may be an
aseptic glove-box system with an inert gas environment.
[0120] FIGS. 18 and 19 depict a representative loading process. The
bag 52 is opened, and the plasma cake 60 removed from the mold 50.
The plasma cake 60 is loaded through the open flange 74 into the
first chamber 12. As shown in FIG. 17E, it is anticipated that the
plasma cake 60 can be transferred into the chamber 12 directly from
the mold 50 (after removal of the bag 52) using a single-use,
aseptic, clear-plastic applicator tool 78, similar to a large
open-ended spatula. Once the chamber 12 is loaded, the flange 74
can be sealed closed using various conventional aseptic techniques,
e.g., dielectric welding or heat sealing.
[0121] The loading of the plasma chamber 12 can be through an
"oyster style" opening that comprises approximately 50% of the
flange 74 of the chamber 12, which can be readily sealed close
after loading. An oyster opening would allow loading of the plasma
cake 60 without concerns of damaging the first chamber 12 or the
freeze-dried plasma during the process. In the case of the oyster
opening, there would be sufficient excess overlay of the edge seam
to allow for straightforward edge-seam alignment and contact during
the sealing process.
[0122] Preferably, after loading and sealing of the chamber 12, an
aseptic vacuum is applied through tubing T connected to the vacuum
port 64 on the first chamber 12 (see FIG. 19). Upon achieving near
100 mTorr of pressure, the vacuum port 64 is heat sealed and the
tubing T removed. This evacuation process provides for the eventual
ability to mix and reconstitute the human freeze dried plasma
without introduction of bubbles and without foaming. The vacuum
would also cause the plasma cake 60 to be compacted to a fine
powder, forming the freeze-dried material 16 within the chamber
12.
[0123] To maintain a direct traceable link between the source
plasma and the material 16 packaged into the chamber 12, the device
10 preferably includes a bar coding and tagging 54' (see FIG. 1),
which is indicative of the human plasma identification (source,
blood type, date of collection, etc.), and which replicates or is
otherwise linked to the bar coding and tagging 54 placed on the bag
52 enveloping the mold 50 at the time of freeze-drying. In this
way, the device 10 maintains a traceable link back to the human
donor source.
[0124] To assist in the reconstitution of the freeze dried plasma
material 16, an aseptic dense sphere of an inert material such as,
but not limited to, glass, polyvinyl chloride or high density
polyethylene may be added to the inside of the chamber 12 prior to
its closure.
[0125] The reconstituting liquid 18 (in the representative
embodiment, gas-free water) is introduced into the second chamber
14. The vacuum port 66 and administration port 68 are connected to
feed lines 80 and 82, respectively, as FIG. 20 shows. Gas in the
chamber 14 is removed by application of aseptic vacuum.
[0126] The vacuum port 66 is sealed and the tubing 80 is removed.
The required aliquot (e.g., approximately 250 ml) of reconstitution
fluid is added to the chamber 14 through the administration port
68. The tubing 82 is removed and the administration port 68 is then
sealed with the conventional septum or frangible membrane assembly
or a convention screw-lock luer fitting 70, which accommodate
coupling of the administration set 68 to the port 68 at time of
transfusion.
[0127] To assist in the reconstitution of the freeze dried plasma,
an aseptic dense sphere of an inert material such as, but not
limited to, glass, polyvinyl chloride or high density polyethylene
may be present inside the second chamber 14.
[0128] As FIG. 21 shows, after packaging the freeze-dried material
16 and the reconstituting liquid 18 in the manner just described,
the wall of the device 10 is plicated in the region of the sealing
wall 22, as previously described, and the outer skirt 40 attached.
The overwrap 418 20 can be applied, as shown in FIG. 1, if
desired.
[0129] The device 10 is ready for storage, transport, and use
III. RECONSTITUTION AND ADMINISTRATION OF THE FREEZE-DRIED
MATERIAL
[0130] The device 10 makes possible a purposeful two step
manipulation in anticipation of reconstituting the freeze-dried
material 16.
[0131] In the first step (shown in FIG. 8), the tear member 42 is
pulled to open and remove the skirt 40, which places the sealing
wall 22 of the device 10 in the ready for use configuration shown
in FIG. 6. In the second step (shown in FIG. 9), the tear member 32
is pulled to open the septum 20 (which FIG. 7 shows in greater
detail). The region 24 of the sealing wall 22 is thereby
opened.
[0132] When the region 24 is opened, the caregiver can apply
pressure to the second chamber 14 to express the reconstituting
liquid 18 from the second chamber 14 into the first chamber 12 (see
FIGS. 10 and 11), thereby beginning the reconstitution of the
freeze-dried material 16. More particularly, with the region 24
opened, the caregiver can apply pressure to the second chamber 14
(as FIG. 10 shows) and not the first chamber 12. As FIGS. 10 and 11
show, the pressure differential between the second chamber 14 and
the first chamber 12 expels the liquid 18 from the second chamber
14, through the valve 28 (which yields in response to the pressure
differential to open in the direction of the first chamber 12, as
FIG. 11 shows), and into the first chamber 12. The expelled liquid
18 mixes with the freeze-dried material 16 in the first chamber 12,
beginning the reconstitution.
[0133] As FIG. 12 show, shaking the device 10 accelerates the
mixing of liquid 18 and freeze-dried material 18 in the first
chamber 12.
[0134] When the region 24 is opened, the caregiver can subsequently
apply pressure to the first chamber 12 to express the material 16,
now at least partially reconstituted in the liquid 18, from the
first chamber 12 into the second chamber 14 (see FIGS. 13 and 14).
Reconstitution of the freeze-dried material 16 is advanced. More
particularly, as FIG. 13 shows, the caregiver can now apply
pressure to the first chamber 12 (as FIG. 13 shows) and not the
second chamber 14. As FIGS. 13 and 14 show, the pressure
differential between the first chamber 12 and the second chamber 14
expels the mixture of the liquid 18 and the freeze-dried material
16 from the first chamber 12, through the valve 28 (which yields in
response to the pressure differential to open in the direction of
the second chamber 14, as FIG. 14 shows), and back into the second
chamber 14. The expelled liquid 18 continues to mix with the
freeze-dried plasma material 18, furthering the reconstitution of
the material 18.
[0135] As FIG. 15 shows, shaking the device 10 further accelerates
the mixing of water and freeze-dried plasma in the second chamber
14.
[0136] The material 16 reconstituted in the liquid 18 can be passed
back and forth between the two chambers 12 and 14 by alternating
pressure on the chambers 12 and 14, with intermediate shaking,
until the desired degree of mixing occurs, at which time the
mixture is ready for transfusion. More particularly, the caregiver
can proceed to squeeze one chamber and not the other, to expel the
mixture of the liquid 18 and freeze-dried material 18 back and
forth between the chambers 12 and 14, with periodic shaking, until
the desired degree of mixing and reconstitution of the plasma is
accomplished.
[0137] At this point (as FIG. 16 shows), the caregiver can couple
the administration fitting 70 of the device 10 to the fluid
administration set 72. The reconstituted plasma is transfused by
gravity flow through a phlebotomy needle 84 into the circulatory
system of an individual.
[0138] The administration fitting 70 can further include a static
mixing tube 86 (as shown in FIG. 16), to assist in continued
reconstitution of plasma aliquot 5 with water 7 during
transfusion.
[0139] The device 10 as described provides:
[0140] i) long term stable containment of a freeze-dried material
such as freeze-dried human plasma;
[0141] ii) eventual rapid reconstitution of the freeze-dried
material with a reconstituting liquid for injection; and
[0142] iii) eventual delivery of the reconstituted freeze dried
material to a trauma victim in a safe, aseptic manner.
IV. OTHER REPRESENTATIVE EMBODIMENTS
[0143] A. Dual Containers with Intermediate Valve Passage
[0144] FIG. 22 shows another representative embodiment of a device
100 for storing an administering a freeze-dried material. The
device 100 comprises a first collapsible container 102 and a second
collapsible container 104, joined by an intermediate normally
closed valve assembly 106.
[0145] The device 100 shares many of the technical features of the
device shown in FIG. 1, albeit the particular structure differs.
The first container 102 comprises the dry chamber 12 as previously
described, and is sized and configured to contains an aliquot of a
freeze-dried material 16, such as a freeze-dried single donor unit
of human plasma.
[0146] The second container 104 comprises the wet chamber 14, as
previously described, and is sized and configured to contain a
reconstituting liquid 18 for the freeze-dried material 16. As
before described, the reconstituting material 18 can comprise,
e.g., sterile water, which may be degassed, if desired.
[0147] In use, the sterile water in the wet chamber 14 is mixed
with the freeze-dried plasma in the dry chamber 12 to provide
plasma for transfusion. The plasma is reconstituted and
administered on site using the device 10.
[0148] As before described, the first container 102 is sized and
configured to maintain the freeze-dried material 16, prior to its
reconstitution, in a vacuum packed, aseptic, moisture-free and low
concentration oxygen environment, preferably accommodating long
term storage, e.g., at least 2 years at room temperature. Stored in
this environment, the freeze-dried material 16 retains its desired
qualities for transfusion.
[0149] As also before described, the second container 104 is sized
and configured to maintain the reconstituting liquid 18, prior to
its mixing with the freeze-dried material 16, in an aseptic
environment and at a low gas concentration, preferably
accommodating long term storage, e.g., at least 2 years at room
temperature.
[0150] The volume of each of the containers 102 and 104 is
preferably approximately 50% larger than the volume of the
freeze-dried material 16 in the first chamber 12. This provides
ample volume within the device 10 for mixing the freeze-dried
material 16 and reconstituting liquid 18, either in the first
container 102, or the second container 104, as will be described in
greater detail later.
[0151] The containers 102 and 104 may be made, e.g., of an inert
medical grade plastic material, such as polyvinyl chloride,
polyethylene, polypropylene, or high density polyethylene. One or
both of the container 102 and 104 can comprise a multi-laminate of
polymer layers for greater durability, e.g., to resist tearing and
puncturing that could be encountered in normal handling.
[0152] The material of the containers 102 and 104 can be selected
to be transparent, if desired, to allow visual inspection of the
contents of the chamber 12 and 14. The material in the first
container 102 can be selected to provide a gas-impermeable barrier,
such as a metallized, reduced gas-permeability coating, or a metal
laminate. In this case, the wall of the first chamber may be
opaque.
[0153] As before described, the device 100 may be enveloped prior
to use by a vacuum sealed over-wrap 20 (shown in phantom lines in
FIG. 22), made, e.g., a metallized, gas impermeable material. The
over-wrap 20 enhances shelf-stability.
[0154] In the alternative representative embodiment shown in FIG.
22, the valve assembly 106 includes a pressure sensitive valve 108
enclosed within a flexible tubular valve passage 110, which extends
between the two containers 102 and 104. The valve 108 can take the
form, e.g., of a short duck bill or two way flap valve. The valve
108 is sized and configured to normally resist flow communication
between the two containers 102 and 104. However, the valve 108 is
sized and configured to resiliently yield in response to a
difference in fluid pressure between opposite sides of the valve
108 (in the same manner as the valve 28 shown in FIGS. 11 and 14).
In response to the pressure differential, the valve 108, like the
valve 28, opens in the direction of the fluid pressure
differential, from the region of higher pressure toward the region
of lower pressure.
[0155] The regions of the wall of the containers to which the valve
passage 110 is joined normally close communication between the
containers 102 and 104 through the valve passage 110.
[0156] An outer tear-away skirt 112 is wrapped around the
mid-regions of the containers 102 and 104 and the intermediate
valve passage 110. The skirt 112 serves to overlay and protect the
components of the valve assembly 106 prior to use. At least one
region of the skirt 112 is circumferentially attached about an
exterior wall of each container 102 and 104, e.g., by adhesive,
either in the region of the first chamber, the second chamber, or
both.
[0157] As FIG. 23 shows, within the outer skirt 112, the
mid-regions of the containers 102 and 104, and the valve passage
110 itself, are desirably plicated or pleated or otherwise bunched
together, shortening the length of each container 102 and 104 and
the valve passage 110. Alternatively, the placations can be
performed in the walls of the containers 102 and 104 and/or valve
passage 110. The presence of the overlaying skirt 112 serves to
isolate the valve passage 100 from unintended contact during
transport and prior to use.
[0158] As FIG. 23 shows, the walls of each container 102 and 104
that overlay opposite ends of the valve passage 110 each includes
an integrated tear member 112. As FIG. 23 shows, each integrated
tear member 112 is coupled by an internal pull string 114 to an
adjacent side wall of the respective container 102 and 104. The
internal pull string 114 is normally held in slight tension when
the device 100 is in the plicated condition shown in FIG. 22 (i.e.,
when the mid-regions of the containers 102 and 104, and the valve
passage 110 itself, are plicated and held in this condition by the
outer shirt 112). When the device 100 is in the plicated condition,
the tension on the internal pull string 114 is not sufficient to
affect the tear member 112. The walls of each container 102 and 104
that overlay opposite ends of the valve passage 110 remain closed.
When the device 100 is in the plicated condition, the chambers 12
and 14 and their contents remain isolated and separated prior to
use.
[0159] As FIG. 24 shows, the skirt 112 can be torn and removed by
operation of an integrated tear member 116 (in the manner shown in
FIG. 3), to place the device 100 in the condition shown in FIG. 24.
As FIG. 24 shows, upon removal of the skirt 112, the placations of
the walls of the containers 102 and 104 and valve passage 110 are
relieved, and the device 100 lengthens.
[0160] As FIG. 25 shows, when the device 100 lengthens, tension on
the internal pull string 114 is increased. The increased tension is
sufficient to activate the tear member 112, tearing open regions
116 of the walls on opposite ends of the valve passage 110 (as FIG.
25 shows). The open regions 116 place the first and second chambers
12 and 14 into communication through the valve passage 110.
[0161] With the regions 116 opened, the caregiver can proceed to
manipulate the device 100 in the same manner previously described
with respect to device 10 (as shown in FIGS. 10 to 16). The
caregiver creates the fluid pressure differential across the valve
108 by selectively squeezing one container and not the other
container. Fluid is expelled in response to the fluid pressure
differential through the valve 108 from the container that is
squeezed into the container that is not squeezed to mix and
reconstitute the freeze-drive material for administration. Transfer
of materials in opposite directions between the chambers 12 and 14
through the valve passage 110 as a result of the manipulation of
the containers 102 and 104 is shown in FIGS. 26 and 27.
[0162] B. Dual Containers With Transfer Set
[0163] FIG. 30 shows a representative embodiment of a system 200
for storing an administering a freeze-dried material. The system
200 comprises a first collapsible container 202 and a second,
separate collapsible container 204. The system 200 further
comprises a transfer set 206 for establishing fluid communication
between the first and second containers 202 and 204.
[0164] The system 200 shares many of the technical features of the
devices shown in FIGS. 1 and 22, albeit the particular structure
differs.
[0165] The first container 202 comprises the dry chamber 12 as
previously described, and is sized and configured to contains an
aliquot of a freeze-dried material 16, such as a freeze-dried
single donor unit of human plasma. To maintain a direct traceable
link between the source plasma and the material 16 in the chamber
12, the container 202 preferably includes a bar coding and tagging
54 (see FIG. 30), which is indicative of the human plasma
identification (source, blood type, date of collection, etc.). In
this way, the container 202 maintains a traceable link back to the
human donor source.
[0166] The second container 204 comprises the wet chamber 14, as
previously described, and is sized and configured to contain a
reconstituting liquid 18 for the freeze-dried material 16. As
before described, the reconstituting material 18 can comprise,
e.g., sterile water, which may be degassed, if desired.
[0167] In use (see FIG. 31), using the transfer set 206, the
sterile water in the wet chamber 14 is mixed with the freeze-dried
plasma in the dry chamber 12 to provide plasma for transfusion. The
plasma is reconstituted and administered on site using the system
200.
[0168] As before described, the first container 202 is sized and
configured to maintain the freeze-dried material 16, prior to its
reconstitution, in a vacuum packed, aseptic, moisture-free and low
concentration oxygen environment, preferably accommodating long
term storage, e.g., at least 2 years at room temperature. Stored in
this environment, the freeze-dried material 16 retains its desired
qualities for transfusion.
[0169] As also before described, the second container 204 is sized
and configured to maintain the reconstituting liquid 18, prior to
its mixing with the freeze-dried material 16, in an aseptic
environment and at a low gas concentration, preferably
accommodating long term storage, e.g., at least 2 years at room
temperature.
[0170] The volume of each of the containers 202 and 204 is
preferably approximately 50% larger than the volume of the
freeze-dried material 16 in the first chamber 12. This provides
ample volume within the containers 202 and 204 for mixing the
freeze-dried material 16 and reconstituting liquid 18, either in
the first container 202, or the second container 204, or both, as
will be described in greater detail later.
[0171] The containers 202 and 204 may be made, e.g., of an inert
medical grade plastic material, such as polyvinyl chloride,
polyethylene, polypropylene, or high density polyethylene. One or
both of the container 202 and 204 can comprise a multi-laminate of
polymer layers for greater durability, e.g., to resist tearing and
puncturing that could be encountered in normal handling.
[0172] The material of the containers 202 and 204 can be selected
to be transparent, if desired, to allow visual inspection of the
contents of the chamber 12 and 14. The material in the first
container 202 can be selected to provide a gas-impermeable barrier,
such as a metallized, reduced gas-permeability coating, or a metal
laminate. In this case, the wall of the first chamber 12 may be
opaque.
[0173] Each container 202 and 204 may be enveloped prior to use by
a vacuum sealed over-wrap 208 (shown in phantom lines in FIG. 30),
made, e.g., a metallized, gas impermeable material. The over-wrap
208 enhances shelf-stability. The transfer set 206 also is
desirably packaged in a sterile over-wrap 208 prior to use (as
shown in phantom lines in FIG. 31).
[0174] The transfer set 206 includes plastic needles or spikes 210
at each end. An outer tear-away skirt or cap 216 can placed or
wrapped around each needle or spike 210 to preserve sterility until
the instant of use.
[0175] In use, the needles or spikes 210 are sized and configure to
puncture conventional pierceable membranes 212 located within port
tubes 214 coupled in fluid communication with each container 202
and 204. Each membrane 212 normally seals the respective container
202 and 204 until pierced by the respective needle or spike 210 of
the transfer set 206. Once pierced by the needle or spike 210,
fluid communication is opened through the port tube 214.
[0176] With the port tubes opened 214 opened, the caregiver can
proceed to manipulate the system 200 to transfer the reconstituting
liquid 18 from the second container 204 into contact with the
freeze-dried material 16, as FIG. 31 shows, The caregiver can
create a fluid pressure differential across the transfer set 206 by
selectively squeezing one container and not the other container.
Fluid is expelled in response to the fluid pressure differential
through the transfer set 206 from the container that is squeezed
into the container that is not squeezed to mix and reconstitute the
freeze-drive material for administration. Transfer of materials in
opposite directions back and forth between the chambers 12 and 14
can proceed as necessary to reconstitute the freeze-dried material,
at which time administration can occur.
[0177] At this time, the caregiver can couple the administration
fitting 70 (shown coupled to the first container 202) to an
appropriate administration set, for transfer of the reconstituted
material to the circulatory system of an individual, as shown in
FIG. 31, in the same manner as before described with reference to
FIG. 16. The administration fitting 70 can also be coupled to the
second container 204, or both the first and second containers 202
and 204.
[0178] C. Alternative Ways to Package the Reconstituting Liquid
[0179] FIGS. 28A/B and 29A/B shows alternative ways to package the
reconstituting liquid 18 in a device 10 or device 100 as previously
described. In these alternative ways, it is not necessary to use
the administration port 68 to convey the reconstituting liquid 18,
but can be closed and sealed in a pre-packaging operation.
[0180] In one alternative representative embodiment (see FIG.
28A/B), the wet chamber 14 includes two packaging ports 120 and
128. In use (see FIG. 28A), the first port 120 is coupled to a
source 124 of the reconstituting liquid 18 via a first inline valve
122. The second port 128 is coupled to a vacuum source 125 via a
second inline valve 126.
[0181] As shown FIG. 28A, the first valve 122 is closed and the
second valve 126 is opened. A vacuum is applied to the interior of
the chamber 14. As shown in FIG. 26B, the first valve 122 is opened
and the second valve 126 is closed. The reconstituting liquid 18 is
conveyed by gravity flow into the chamber 14. Both packaging ports
120 and 128 are sealed.
[0182] In another alternative representative embodiment (see FIGS.
29A/B), the wet chamber 14 includes a single packaging port 130. In
use (see FIG. 29A), the port 130 is coupled to a source 132 of the
reconstituting liquid 18 and a vacuum source 134 through a two way
valve 136.
[0183] As shown FIG. 29A, the two way valve 136 is operated to
close communication with the liquid source 132 and to open
communication with the vacuum source 134. A vacuum is applied to
the interior of the chamber 14. As shown in FIG. 29B, the two way
valve 136 is operated to open communication with the liquid source
132 and to close communication with the vacuum source 134. The
reconstituting liquid 18 is conveyed by gravity flow into the
chamber 14. The packaging port 130 is sealed.
[0184] In both arrangements, the administration port 68 can be
inserted and sealed close in a pre-packing operation. The
administration port 68 is not used until it is time to administer
the reconstituted freeze-dried material, as shown in FIG. 16.
[0185] D. Alternative Ways to Package the Freeze-Dried Material
[0186] In an alternative embodiment, the material 16 can be
freeze-dried in situ within the chamber 12. In this arrangement, as
FIG. 33 shows, a device 300 is compartmentalized by a sealing wall
22 into a chamber 12 and a chamber 14, in the manner previously
described. The sealing wall 22 includes a septum 26 with pull
string 34 and tab 38, as previously described.
[0187] To accommodate freeze-drying of the plasma within the
chamber 12, the device 300 is made of a material that resists
cracking at the low temperatures (e.g., below -33.degree. C.)
encountered during freeze-drying. Candidate materials include
polyolefin materials, polyurethane materials, polyurethane,
elastomer materials, and polysilicone materials. Polyvinyl chloride
materials treated to withstand low temperatures can also be
used.
[0188] The device 300 also includes first and second aseptic ports
302 and 304, which communicate with the first chamber 12. The first
aseptic port 302, in use, conveys liquid plasma into the chamber 12
for freeze-drying. The first port 302 is desirably normally closed
by a pierceable membrane or septum 314. The second aseptic port 304
is normally closed by a gas permeable membrane such as a gas
permeable membrane 316. In use, the gas permeable membrane 316
accommodates the transport of vapors and gases into and out of the
chamber 12 during and after the freeze-drying process, but
otherwise prevents liquid from leaving the chamber 12. The gas
permeable membrane 316 can comprise, e.g., a nylon material, a
polytetrafluoroethylene (PTFE) material, or a polypropylene
material.
[0189] The device 300 also includes an aseptic port 306, which
communicates with the second chamber 14. The port 306, in use,
conveys a reconstituting fluid into the second chamber 14, as
previously described (e.g., see FIGS. 29A and 29B). The first port
302 can also be normally closed by a pierceable membrane or septum
314.
[0190] An administration port 310 is also heat sealed in
communication with the second chamber 14. The administration port
310, in use, conveys reconstituted material from the second chamber
14 for administration to an individual, as previously
described.
[0191] As FIG. 34 shows, the first port 302 is sized and configured
to be attached to tubing T coupled to a source of liquid plasma
312. In the illustrated embodiment, the tubing T includes a spike
or needle 318 that pierces the membrane 314 in the port 302, to
open fluid communication through the port 302 into the chamber
12.
[0192] Through the tubing T, a desired volume of liquid plasma is
conveyed from the source 312 into the first chamber 12. Following
the conveyance of liquid plasma into the first chamber 12, the
tubing T is removed, and the port 302 is sealed closed. At this
stage of processing, the second chamber 14 remains empty, as FIG.
34 shows.
[0193] To maintain a direct traceable link between the source
plasma and the material 16 that will be freeze-dried in the chamber
12, the device 300 preferably includes a bar coding and tagging 54'
(see FIG. 31), which is indicative of the human plasma
identification (source, blood type, date of collection, etc.), and
which replicates or is otherwise linked to the bar coding and
tagging 54 placed on the source plasma bag 312. In this way, the
device 300 maintains a traceable link back to the human donor
source.
[0194] As shown in FIG. 35, one or more devices 300, with each
chamber 12 filled with liquid plasma, is placed inside a freeze
dryer 320 on an aseptic freeze dryer shelf surfaces 322. Once
loaded, the freeze dryer cycle is started. This cycle generally
cools the human plasma to near -45.degree. C. and freezing for 2 to
8 hours, followed by cooling of the freeze dryer condenser and
application of vacuum to start the freeze drying cycle. As a
result, a freeze-dried human plasma cake 324 is formed in situ
within the chamber 12 of each device 300 (see FIG. 36).
[0195] The representative parameters for the freeze-drying process
have been previously described and are incorporated herein by
reference.
[0196] Throughout the freeze drying process, the gas permeable
membrane 316 within the port 304 accommodates passage of gases,
e.g., water vapor as it sublimates from the liquid plasma during
freeze-drying, but otherwise prevents passage of liquid plasma from
the chamber 12.
[0197] As shown in FIG. 36, after freeze-drying, the devices 300
with the freeze dried cakes 324 in their chambers 12 are removed
from the freeze dryer 320.
[0198] Preferably, an aseptic vacuum is applied through the port
304. Upon achieving near 100 mTorr of pressure, the port 304 is
heat sealed closed. This evacuation process provides for the
eventual ability to mix and reconstitute the human freeze dried
plasma without introduction of bubbles and without foaming. The
vacuum would also cause the plasma cake 324 to be compacted to a
fine powder, forming the freeze-dried material 16 within the
chamber 12. The devices 300 can be maintained under a nitrogen or
argon blanket to exclude moisture and oxygen until subsequent
processing.
[0199] Next (see FIG. 37), the reconstituting liquid 18 is
introduced into the second chamber 14 through the port 306, for
example, in manner shown in FIGS. 29A and 29B. The port 306 is then
sealed.
[0200] As FIG. 38 shows, after packaging the freeze-dried material
16 and the reconstituting liquid 18 in the manner just described,
the wall of the device 300 is plicated in the region of the sealing
wall 22, as previously described, and an outer skirt 40 (with pull
string 44 and tab 46) attached, as also previously described. An
overwrap 20 can be applied, as shown in FIG. 1, if desired.
[0201] The device 300 is ready for storage, transport, and use.
[0202] It should be appreciated that liquid plasma could be
freeze-dried in situ within the container 202 shown in FIG. 30 in
the same manner as just described.
V. DEVICES, SYSTEMS AND METHODS FOR FREEZE-DRYING AND STORING
MATERIALS FOR RECONSTITUTION
[0203] A. Multifunctional Freeze-Drying and Storage Vessel
[0204] FIGS. 39A to 39D show a representative embodiment of a
multifunctional device 400 for freeze-drying, storing,
reconstituting, and administering a material, such as plasma. The
device 400 is sized and configured to receive the material while it
undergoes freeze-drying within the device 400. The device 400 is
also sized and configured to serve as a vessel for the freeze-dried
material while it undergoes transport, handling, and storage prior
to reconstitution at an intended site. The device 400 is also sized
and configured to further serve as a vessel in which the
freeze-dried material can be reconstituted. The device 400 is also
sized and configured to also serve as a vessel from which the
freeze-dried material, after being reconstituted, can be delivered
to an individual in a safe and aseptic manner. Using the
multifunctional device 400, a given material can be freeze-dried,
transported, stored, reconstituted, and administered in a single
vessel.
[0205] As shown in the exploded view of FIG. 39A, the device 400
comprises a vessel 402 made of several components having different
physical properties to thereby serve different functions. As shown,
the vessel 402 includes a side wall component 404 that peripherally
encircles an open interior space 406. The vessel 402 also includes
first and second end components 408 and 410 that overlay the side
wall component 404, enclosing the interior space 406. The vessel
402 also includes first, second, and third port components 412,
414, and 416 that pass through regions of the side wall component
404 to provide fluid communication into the interior space 406
bounded by the side wall component 404 and the first and second
overlaying end components 408 and 410.
[0206] Assembled together (as FIGS. 39B to 39C show), the various
components form a unitary, multifunctional vessel 402 in which a
given material can be freeze-dried, then transported and stored,
and then reconstituted, and then administered.
[0207] As shown in FIGS. 39A to 39D, the first and second end
components 408 and 410 comprise frames made of a rigid or
semi-rigid material selected to form a lightweight, yet durable
structural skeletons for the ends of the vessel 402. The material
for the first and second end components 408 and 410 can comprise,
e.g., non-plasticized polyvinyl chloride, or polyethylene, or
polypropylene, or high density polyethylene. The material is
desirably inert and of a medical grade sufficient for contact with
animal tissue and fluids. The frames defined by the first and
second end component 408 and 410 can, e.g., be molded in the
desired shape and size.
[0208] The frames defined by the first and second end components
408 and 410 define and maintain a shape for the vessel 402, as well
as provide overall structural support and attachment sites for
other components of the vessel 402. The frames defined by the first
and second end components 408 and 410 provide for the vessel 402
uniting structural elements that withstand pressure conditions and
other forces imposed upon the vessel 402 during freeze-drying and
subsequent handling.
[0209] The frames defined by the first and second end components
408 and 410 each supports a panel of material, respectively 408'
and 410'. In the illustrated embodiment, the panels of material
408' and 410' span horizontally across the respective end component
408 and 410. The panels of material 408' and 410' are peripherally
sealed to the frames defined by the end components 408 and 410,
e.g., by adhesives or heat sealing techniques.
[0210] The materials 408' and 410' selected for the panels differ,
because they serve different functions. This technical feature will
be described in greater detail later.
[0211] The side wall component 404 is appended to the frames
defined by the first and second end components 408 and 410. The
side wall component 404 spans in a vertical direction between the
side edges of the end components 408 and 410. The side wall
component 404 is peripherally sealed to the side edges of the end
components 408 and 410, e.g., by adhesives or heat sealing
techniques.
[0212] The sidewall component 404 and the first and second end
components 408 and 410 provide a closed, sealed integrity to the
interior space 406.
[0213] The side wall component 404 comprises a flexible, gas
impermeable material. The material is also desirably inert and of a
medical grade sufficient for contact with animal tissue and fluids.
The material for the side wall component 404 can comprise, e.g.,
plasticized polyvinyl chloride, or polyethylene film, or
polypropylene film, or high density polyethylene film. The side
wall component 404 can comprise a continuous film of flexible
material, as shown in FIG. 39A, or comprise shorter lengths of
flexible film material sealed together.
[0214] The flexibility of the side wall component 404 accommodates
expansion and contraction and flexure of the vessel 402 in response
to pressure conditions encountered during freeze-drying and
subsequent handling. Desirably, the material of the side wall
component 404 also provides resistant to tearing or puncturing
during freeze-drying and subsequent handling of the vessel 402. The
material for the side wall component 404 is desirably transparent,
thereby allowing a user to visually see and inspect the contents of
the vessel 402, without allowing gas transmission between the
interior space 406 and the ambient environment.
[0215] The material 408' of the first end component 408, like the
side wall component, is also selected to be gas impermeable, to
complement the side wall component 404 in this function. Desirably,
the material 408' is also selected to be transparent, to thereby
contribute to the visible view into the interior space 406. The
material 408' of the first end component 408 can be flexible or
rigid, as desired.
[0216] It should be appreciated that not all of the material 408'
of the first end component 408 need be transparent. The material
408' can include a region of transparency sufficient to permit
viewing the interior space 406, with the remainder of the material
408' being gas impermeable and non-transparent.
[0217] Like the material for the side wall component 404, the
material 408' for the first end component 408 is desirably inert
and of a medical grade sufficient for contact with animal tissue
and fluids. The material 408' for the first end component 408 can
comprise, e.g., plasticized polyvinyl chloride film, or
polyethylene film, or polypropylene film, or high density
polyethylene film.
[0218] The material 410' of the second end component 410 desirably
possesses, at least in part, physical characteristics that are
different than the physical characteristics of the side wall
component 404 and the first end component 408, because the
component 410 serves a different function. More particularly, the
material 410' of the second end component 410 is selected to be gas
permeable; for example, hydrophobic. The gas permeable material
410' accommodates the transport of vapors and gases into and out of
the interior space 406 during and after the freeze-drying process,
but, if hydrophoblic, otherwise prevents liquid from entering or
leaving the interior space 406. The gas permeable material 410' can
comprise, e.g., a nylon film material, a polytetrafluoroethylene
(PTFE) film material or other fluoropolymer film materials, a
polypropylene film material, or a polyurethane film material.
[0219] The presence of the gas permeable material 410' of the
second end component 410 allows water vapor to sublimate from
material within the interior space 406 during the freeze-drying
process. The presence of the gas permeable material 410' of the
second end component 410 also allows inert gases to be introduced
into the interior space 406 after the freeze-drying process, if
desired, to provide a protective atmosphere within the vessel 402
conducive to long term storage of the material. This technical
feature will be described in greater detail later.
[0220] The surface area of the gas permeable material 410' of the
second end component 410 may affect the rate of sublimation during
the freeze-drying process, i.e., the greater the surface area the
greater the rate of sublimation. In FIGS. 39A to 39D, the gas
permeable material 410' of the second end component 410 overlays
the entirely of the end component 410. Alternatively, and as will
be described later with respect to the embodiment shown in FIGS. 46
and 47, the gas permeable material 410' of the second end component
410 can comprise a smaller region of the end component 410, with
the remainder of the second end component 410 being gas impermeable
and, desirably, transparent.
[0221] The first, second, and third port components 412, 414, and
416 are sealed within regions of the side wall component 404. The
ports 412, 414, and 416 comprise, e.g., extruded or molded medical
grade plastic tubes that are sealed, e.g., by heat or adhesive, to
the adjacent material of the side wall component 404. The ports
412, 414, and 416 provide fluid communication into the interior
space 406 formed by the side wall component 404 and the first and
second overlaying end components, as described.
[0222] Each port component 412, 414, and 416 is desirably initially
sealed with a conventional septum or frangible membrane assembly or
by a convention screw-lock luer fitting. Each port component 412,
414, and 416 is sized and configured to be coupled to transfer
tubing to enable transfer of materials into and out of the interior
space 406, as will be described in greater detail later.
[0223] For example, in a representative arrangement, the first port
component 412 can be sized and configured, in use, to accommodate
introduction of a material in liquid form into the interior space
406 for freeze-drying in situ within the vessel 402. The second
port component 414 can be sized and configured, in use, to
accommodate introduction of a reconstituting liquid into the
interior space 406 for mixing with and reconstituting the
freeze-dried material. The third port component 416 can be sized
and configured, in use, to accommodate transfer of reconstituted
material from the interior space 406. The use of the port
components for these purposes will be described in greater detail
later.
[0224] In the illustrated embodiment, the first port component 412
occupies a different side wall region than the second and third
port components 414 and 416. This separation segregates the port
component 412 dedicated to the freeze-drying function from the port
components 414 and 416 dedicated to the reconstitution and
administration functions.
[0225] As best shown in FIG. 39D, at least the first port component
412 is desirably oriented at a non-perpendicular angle relative to
the side wall component 404. More particularly, the port component
412 angles away from the first end component 408, presenting a
high-gravity position above the plane of the gas permeable material
410' of the second end component 410. This orientation minimizes
wetting of the gas permeable material 410' of the second end
component 410 during introduction of the liquid material into the
interior space 406 through the port component 412. Although the
freeze-drying process will ultimately dry a wetted material 410' of
the second end component 410, prevention of wetting in the first
instance may nevertheless be desirable, to maximize the rate of
sublimation throughout the freeze-drying process.
[0226] During the freeze-drying process, the vessel 402 sits on a
shelf within a freeze-dryer in the orientation shown in FIG. 39D
(as also shown in FIG. 52. In this orientation, the gas-impermeable
material 408' of the first end component 408 rests on the shelf.
The frame defined by the first end component 408 provides a stable
platform of support for the liquid material as it undergoes
freeze-drying, keeping the vessel 402 upright in this desired
orientation.
[0227] In this desired upright orientation, the gas permeable gas
permeable material 410' of the second end component 410 faces
upward into the freeze-drying environment. In this orientation,
during drying, sublimating water vapor will escape upward from the
material through the gas permeable material 410' of the second end
component 410.
[0228] Specific details of the use of the vessel 402 before,
during, and after the freeze-drying process will be described in
greater detail later.
[0229] B. Freeze-Dried Material Storage Assembly
[0230] As will also be described in greater detail later, after
completion of the freeze-drying process, the vacuum condition
existing during the drying process may, if desired, be opened to an
atmosphere of an oxygen-free, high purity inert gas, such as
nitrogen or argon. The oxygen-free inert gas enters the interior
space 406 through the gas permeable material 410' of the second end
component 410, to exclude moisture and oxygen.
[0231] In this arrangement, while the vessel 402 (now containing
the freeze-dried material) is maintained under the blanket of the
oxygen-free inert gas, the vessel 402 is placed in a vacuum sealed,
transparent vapor barrier or overwrap 418, as shown in FIG. 40. The
overwrap 418 is made from a gas-impermeable material and is
desirable flexible, e.g., plasticized polyvinyl chloride film, or
polyethylene film, or polypropylene film, or high density
polyethylene film, as previously described in connection with the
first end component 408. Such materials may be used in combination
with metallized, reduced gas-permeability coatings, or metal
laminates. The vapor barrier or overwrap 418 traps the oxygen-free
gas environment within the vessel 402 during transportation and
storage.
[0232] The vessel 402 and overwrap 418 comprise a freeze-dried
material storage assembly 420. The exclusion of moisture and oxygen
in the presence of the oxygen-free inert gas trapped by the
overwrap 418 prevents degradation of the freeze-dried material
carried within the vessel 402 during subsequent transport and
storage.
[0233] The freeze-dried material storage assembly 420 can be
further protected during transportation and storage by placement
within a rigid outer container or can 422 as shown in FIGS. 40 and
41A. The outer container 422 may comprise, e.g., of metal or high
impact plastic material. The outer container 422 provides further
protection against tearing, puncturing, or collapse of the overwrap
418 and vessel 402 during subsequent handling and storage. As FIG.
41B shows, the outer container 422 can, if desired, include
additional compartments to hold, along with the freeze-dried
material vessel 402, a vessel filled with a reconstitution liquid,
as well as associated reconstitution and administration sets.
[0234] In the illustrated embodiment (as shown in FIG. 41A), the
outer container 422 includes a lid 424 that closes and, desirably,
seals the container 422. The lid 424 can be removed to provide
access to the vessel 402 and overwrap 418 at the instance of
use.
[0235] If desired (as shown in FIGS. 42 and 43), one or more
integrity marker elements 426 can be placed within or on the
interior of the overwrap 418. The integrity marker elements 426
carry a material sensitive to the presence of oxygen and/or
moisture, or combinations thereof, and/or other pre-selected
conditions adverse to or possibly adverse to the integrity or
efficacy of the freeze-dried material. For example, the sensitive
material can change color to visibly indicate through the overwrap
418 when a predetermined threshold level of oxygen and/or moisture,
or combination thereof, exists within the overwrap 418. The markers
426 provide further visual indications of the integrity and
efficacy of the freeze-dried material within the freeze-dried
material storage assembly 420 prior to reconstitution.
[0236] D. Unitary Freeze-Dried Material Storage Assemblies
[0237] FIGS. 42 and 43 show a representative embodiment of a
unitary freeze-dried material storage assembly 428. In this
representative embodiment, the vessel 402 as above described and
shown in FIGS. 39A to 39D further includes a pivotally mounted
closure cover 430. The closure cover 430 is made from a
gas-impermeable material, e.g. polyvinyl chloride, or polyethylene,
or polypropylene, or high density polyethylene. Such materials may
be used in combination with metallized, reduced gas-permeability
coatings, or metal laminates.
[0238] In the illustrated embodiment, the closure cover 430 is made
from a generally rigid material. In this arrangement, a hinge
assembly 432 on the frame defined by the second end component 410
couples the closure cover 430 on the vessel 402 for movement
between an opened condition, as shown in FIG. 42, and a closed
condition, as shown in FIG. 43.
[0239] In the opened condition (shown in FIG. 42), the closure
cover 430 is spaced away from the gas permeable material 410' of
the second end component 410, permitting unrestricted gas
transmission through the gas permeable material 410' of the second
end component 410 for the purposes previously described.
[0240] In the closed condition (shown in FIG. 43), the closure
cover 430 covers the entirety of the gas permeable material 410' of
the second end component 410, substantially blocking gas
transmission through it.
[0241] Desirably, the edges of the closure cover 430 and frame
defined by side end component 410 are sized and configured, e.g.,
by interference fit and/or by use of gasket assembly, to form a
gas-impermeable seal assembly about the entirety of the gas
permeable material 410' of the second end component 410 when the
closure cover 430 is in the closed condition. If a vapor barrier
overwrap is to be used, the seal assembly need not be "air tight"
or aseptic, but instead provide sufficient gas holding capacity to
accommodate handling in the time period between removal from the
freeze dryer and the application of the vapor barrier overwrap.
[0242] Desirably, a latch assembly 434 on the closure cover 430 and
the second end component 410 forms a lock when the closure cover
430 is in the closed condition, resisting inadvertent opening the
closure cover 430.
[0243] Alternatively, the closure cover 430 can comprise a more
flexible material attached to the frame defined by the second end
component 410, which is normally rolled or folded away from the gas
permeable material 410' of the second end component 410 (i.e., the
opened condition). In this arrangement, the more flexible closure
cover 430 is unrolled or unfolded and drawn over the gas permeable
material 410' of the second end component 410 (i.e., the closed
condition). The more flexible closure cover 430 is then
peripherally sealed about the gas permeable material 410' of the
second end component 410, e.g., by heat sealing.
[0244] In the arrangement shown in FIGS. 43 and 43, the unitary
freeze-dried material storage assembly 428 undergoes the
freeze-drying process in the orientation shown in FIG. 42, with the
gas permeable material 410' of the second end component 410 facing
upward, and the closure cover 430 being in the opened condition
(this is also shown in FIG. 52). In this orientation, during
drying, water vapor will sublimate and escape upward from the
material within the vessel 402 through the gas permeable gas
permeable material 410' of the second end component 410.
[0245] As previously described, after drying, a blanket of
oxygen-free inert gas may, if desired, be introduced over the
unitary freeze-dried material storage assembly 428 in the
orientation shown in FIG. 42. The oxygen-free inert gas enters the
interior space 406 through the gas permeable gas permeable material
410' of the second end component 410, to infiltrate and exclude
moisture and oxygen in the interior space 406, as previously
described.
[0246] In this arrangement, while the unitary freeze-dried material
storage assembly 428 (now containing the freeze-dried material) is
maintained under the blanket of the oxygen-free inert gas, the
closure cover 430 is placed into its closed condition (see FIG.
54), and the latch assembly 434 is engaged, as shown in FIG. 43.
The closure cover 430 traps the oxygen-free gas environment within
the unitary freeze-dried material storage assembly 428 during
subsequent transportation and storage. As before described, the
exclusion of moisture and oxygen in the presence of the oxygen-free
inert gas trapped within the unitary freeze-dried material storage
assembly 428 prevents degradation of the freeze-dried material
carried within the vessel 402 during subsequent transport and
storage.
[0247] As shown in FIGS. 44 and 45, the unitary freeze-dried
material storage assembly 428 can be placed within a rigid outer
container or can 422 with a lid 424, as previously described, made
e.g., of metal or high impact plastic material. The outer container
422 provides further protection against tearing, puncturing, or
collapse of the unitary freeze-dried material storage assembly 428
during subsequent handling and storage. As earlier described, if
desired, the outer container 422 can include one or more separate
compartments to hold a vessel containing a reconstitution liquid,
as well as associated reconstitution and administration sets.
[0248] If desired, the unitary freeze-dried material storage
assembly 428 shown in FIG. 43 can also be placed a vacuum sealed,
transparent gas-impermeable vapor barrier or overwrap 418, of the
type shown in FIG. 40, prior to placement in the rigid outer
container. The optional overwrap 418 is shown in phantom lines in
FIG. 43.
[0249] FIGS. 46 and 47 show an alternative representative
embodiment of a unitary freeze-dried material storage assembly 428.
In this representative embodiment, the vessel 402 as above
described and shown in FIGS. 39A to 39D includes a region of gas
permeable material 436 that does not extend over the entire area of
the second end component 410. In this arrangement, the remaining
region 438 of the second end component 410 comprises a
gas-impermeable material, examples of which have already been
described.
[0250] As shown in FIG. 46, the region of gas permeable material
436 is supported by and sealed to a frame 440, which is itself
joined to the second end component 410. The sealing can be
accomplished, e.g., by adhesives or heat.
[0251] As FIG. 46 shows, the frame 440 rises slightly above the
plane of the remainder 438 of the second end component 410.
Stand-offs 442 extend from the frame 440 into the vessel 402, to
moderate inward flexure of the frame 440 relative on the second end
component 410, e.g., when closing the closure cover 430, as will be
described. Upon an initial amount of inward flexure of the frame
440 under such conditions, the stand-offs 442 will move into
contact with the first end component 408 and will thereby resist
further inward flexure.
[0252] In this arrangement, the frame 440 carries a pivotally
mounted closure cover 430. The closure cover 430 is made from a
gas-impermeable material, e.g. polyvinyl chloride, or polyethylene,
or polypropylene, or high density polyethylene. Such materials may
be used in combination with metallized, reduced gas-permeability
coatings, or metal laminates.
[0253] In the illustrated embodiment, the closure cover 430 is made
from a generally rigid material. In this arrangement, A hinge
assembly 432 on the frame 440 couples the closure cover 430 for
movement between an opened condition, as shown in FIG. 46, and a
closed condition, as shown in FIG. 47.
[0254] In the opened condition (shown in FIG. 46), the closure
cover 430 is spaced away from the region of gas permeable material
436 carried by the frame 440, permitting unrestricted gas
transmission through the region of gas permeable material 436
during and after the freeze-drying process for the purposes
previously described.
[0255] In the closed condition (shown in FIG. 47), the closure
cover 430 covers the entirety of the region of gas permeable
material 436 carried by the frame 440, substantially blocking gas
transmission through it.
[0256] Desirably, the edges of the closure cover 430 and the frame
440 are sized and configured, e.g., by interference fit and/or by
use of gasket assembly, to form a gas-impermeable seal about the
entirety of the frame 440 when the closure cover 430 is in the
closed condition. If a vapor barrier overwrap is to be used, the
seal need not be "air tight" or aseptic, but instead provide
sufficient gas holding capacity to accommodate handling in the time
period between removal from the freeze dryer and the application of
the vapor barrier overwrap.
[0257] Desirably, a latch assembly 434 on the closure cover 430 and
the frame 440 forms a lock when the closure cover 430 is in the
closed condition, resisting inadvertent opening the closure cover
430.
[0258] Alternatively, the closure cover 430 can comprise a more
flexible material attached to the frame 440, which is normally
rolled or folded away from the gas permeable second end component
410 on the frame 440 (i.e., the opened condition). In this
arrangement, the more flexible closure cover 430 is unrolled or
unfolded and drawn over the gas permeable second end component 410
on the frame 440 (i.e., the closed condition). The more flexible
closure cover 430 is then peripherally sealed about the frame, to
cover the gas permeable second end component 410, e.g., by heat
sealing.
[0259] In the arrangement shown in FIGS. 46 and 47, the unitary
freeze-dried material storage assembly 428 undergoes the
freeze-drying process in the orientation shown in FIG. 46, with the
region of gas permeable material 436 carried by the frame 440
facing upward and the closure cover 430 in the opened condition. In
this orientation, during drying, water vapor will sublimate and
escape upward from the material through the region of gas permeable
material 436 carried by the frame 440. As previously described,
after drying, a blanket of oxygen-free inert gas is introduced over
the unitary freeze-dried material storage assembly 428 while
maintained the orientation shown in FIG. 46. The oxygen-free inert
gas enters the interior space 406 through the region of gas
permeable material carried by the frame 440, to infiltrate and
exclude moisture and oxygen in the interior space 406, as
previously described.
[0260] In this arrangement, while the unitary freeze-dried material
storage assembly 428 (now containing the freeze-dried material) is
maintained under the blanket of the oxygen-free inert gas, the
closure cover 430 is placed into its closed condition and the latch
assembly 434 engaged, as shown in FIG. 47. The closure cover 430
traps the oxygen-free gas environment within the unitary
freeze-dried material storage assembly 428 during subsequent
transportation and storage. As before described, the exclusion of
moisture and oxygen in the presence of the oxygen-free inert gas
trapped within the unitary freeze-dried material storage assembly
428 prevents degradation of the freeze-dried material carried
within the vessel 402 during subsequent transport and storage.
[0261] As shown in FIGS. 48 and 49, the unitary freeze-dried
material storage assembly 428 can be placed within a rigid outer
container or can 422 with a lid 424, as previously described, made
e.g., of metal or high impact plastic material. The outer container
422 provides further protection against tearing, puncturing, or
collapse of the unitary freeze-dried material storage assembly 428
during subsequent handling and storage.
[0262] If desired, the unitary freeze-dried material storage
assembly 428 shown in FIG. 43 can also be placed a vacuum sealed,
transparent gas-impermeable overwrap 418, of the type shown in FIG.
40, prior to placement in the rigid outer container. The optional
overwrap 418 is shown in phantom lines in FIG. 47.
[0263] E. Using the Unitary Freeze-Dried Material Storage
Assemblies
[0264] 1. Freeze-Drying a Material within a Freeze-Dried Material
Storage Assembly
[0265] In a representative embodiment, the freeze-dried material
comprises plasma. A description of an illustrative way of preparing
freeze-dried plasma for packaging in a representative freeze-dried
material storage assembly as disclosed in FIGS. 42 and 43 therefore
follows.
[0266] Preparation and manufacturing of the plasma will take place
in an aseptic, clean room setting. The manufacturing and
preparation procedures can be done, for example, in an ISO Class 5
clean room (or better) with ISO Class 3 bio-containment hoods for
aseptic handling of human plasma. Freeze drying can be done
aseptically in a CIP/SIP freeze dryer.
[0267] Human plasma is collected from a single donor in a
conventional way, e.g., by collecting a unit of whole blood from
the donor in a closed system collection bag, followed by
centrifugal separation of the plasma and its collection in an
integrally connected transfer bag 444 (containing one plasma unit
of about 250 ml). Each unit (contained in the transfer bag 444)
will be handled individually in the bio-containment hood. Between
handling one single donor unit and another unit single donor unit
from a different donor, there will be a line clearance protocol for
change-over in the bio-containment hood, or a validation process
for flow design and change-over can be otherwise provided. This
protocol may address removal of all tools and materials associated
with the previous handling. It may also address the thorough wash
down of the containment work area and work area instruments (mass
balances) to ensure no residues of the previous handling were left
in place. The identification of single donor samples will be
maintained by bar coding and other tagging of the single donor
human plasma containers.
[0268] The freeze-dried material storage assembly 428 is subjected
to a pre-processing protocol to provide a sterile, pyrogen free
assembly. A representative size for the assembly 420 for
freeze-drying about 250 ml of plasma is about 10 cm.times.12
cm.times.2 cm (l.times.w.times.d).
[0269] As shown in FIG. 50, the 250 ml human plasma unit is
dispensed from the transfer bag 444 into the freeze-dried material
storage assembly 428. Flexible medical grade tubing 446 coupled
integrally to the transfer bag 444 is coupled to the first port
component 412 in an aseptic manner, e.g., using known aseptic
coupling techniques well know in blood component processing or a
spike or a leur fitting coupling under aseptic conditions. The
plasma can be transferred from the transfer bag 444 into the
freeze-dried material storage assembly 428 through the tubing 446
and the first port component 412 by gravity flow.
[0270] As shown in FIG. 51, the transfer tubing 446 is then
disconnected in an aseptic fashion either under the conditions
described above or using, e.g., a Hematron.RTM. Dielectric Sealer
to provide snap-apart aseptic seals well known in blood component
processing.
[0271] Bar coding and tagging 448 is applied to freeze-dried
material storage assembly 428. The bar coding and tagging 448
reflects the human plasma identification 450 carried by the
transfer bag 444 (source, blood type, date of collection,
etc.).
[0272] As shown in FIG. 52, the freeze-dried material storage
assembly 428 (now containing the liquid plasma) is then placed
inside a freeze dryer 452 on an aseptic freeze dryer shelf surface
454. The freeze dryer 452 used for the lyophilization is desirably
a validated clean in place, steam in place freeze dryer.
[0273] As shown in FIG. 52, the freeze-dried material storage
assembly 428 is oriented with the gas permeable material 410' of
the second end component 410 facing upward, and the closure cover
430 placed in the opened condition.
[0274] Once loaded, the freeze dryer cycle (controlled by a
processor 456) is started. This cycle generally cools the human
plasma to near -45.degree. C. and freezing for 2 to 8 hours,
followed by cooling of the freeze dryer condenser and application
of vacuum to start the freeze drying cycle. A freeze-dried human
plasma cake is formed within the freeze-dried material storage
assembly 428.
[0275] In the primary freeze drying cycle, the temperature of the
human plasma cake needs to remain below -33.degree. C. (the
collapse temperature) to maintain its integrity. When the moisture
content of the cake is below 5% weight per weight (w/w), a
secondary drying cycle (the elevated temperature) is used to
further lower the moisture content. Generally the combined primary
and secondary freeze drying cycles will take at least 72 hours. As
before described, in the orientation shown in FIG. 52, during the
drying cycle, sublimating water vapor will escape upward from the
frozen plasma material through the gas permeable material 410' of
the second end component 410, unrestricted by the opened closure
cover 430.
[0276] The flexible side wall component 404 accommodates flexure of
the vessel due to pressure conditions encountered during the freeze
drying cycle.
[0277] At the conclusion of the freeze drying cycle (see FIG. 53),
the freeze dryer vacuum is opened (by operation of the controller
456) to an atmosphere 458 of an oxygen-free, high purity inert gas
such as nitrogen or argon. As before described, the blanket of
oxygen-free inert gas enters the interior space of the freeze-dried
material storage assembly 428 through the gas permeable material
410' of the second end component 410, unrestricted by the opened
closure cover 430, to infiltrate and exclude moisture and oxygen in
the interior space, as previously described.
[0278] As shown in FIG. 54, while the unitary freeze-dried material
storage assembly 428 (now containing the freeze-dried material) is
maintained under the blanket of the oxygen-free inert gas, the
closure cover 430 is placed into its closed condition and the latch
assembly 434 engaged.
[0279] In a representative embodiment shown in FIGS. 52 and 53, the
freeze-dryer 452 includes means 460 for providing aseptic access
into the freeze-dryer 452, so that the closure cover 430 can be
manually closed, as FIG. 54 shows. Alternatively, the means 460 can
comprise remotely actuated mechanical or robotic means within the
freeze dryer, to close the closure covers 430 of the unitary
freeze-dried material storage assemblies 428.
[0280] Still alternatively, the freeze-dried material storage
assemblies 428 can removed to an aseptic containment area or cart
(e.g., as generally shown FIG. 17D) having a contained environment
maintained under an oxygen-free inert gas blanket to exclude
moisture and oxygen. The containment area or cart may couple to the
front of the freeze dryer to allow for transfer of the freeze dryer
contents under a controlled inert gas blanket. The closure covers
430 of the freeze-dried material storage assemblies 428 can be
closed within the environment provided by the aseptic container
area or cart.
[0281] It should be appreciated that, instead of providing a
unitary closure cover 430, or in combination with a unitary closure
cover 430, a vacuum sealed, transparent overwrap 418, as shown in
FIG. 40, made from a gas-impermeable material can be placed over
the vessel 402 in the presence of an oxygen-free inert gas
environment.
[0282] Regardless, the closure cover 430 and/or overwrap 418 traps
the oxygen-free inert gas environment within the unitary
freeze-dried material storage assembly 428 (or a vessel 402 with an
overwrap 418) during subsequent transportation and storage. As
before described, the exclusion of moisture and oxygen in the
presence of the oxygen-free inert gas trapped within the unitary
freeze-dried material storage assembly 428 prevents degradation of
the freeze-dried material carried within the vessel 402 during
subsequent transport and storage.
[0283] As shown in FIGS. 55 and 56, the closed unitary freeze-dried
material storage assembly 428 (with or without an overwrap 418) can
be placed within a rigid outer container or can 422 with a lid 424,
as previously described, made e.g., of metal or high impact plastic
material. The outer container 422 provides further protection
against tearing, puncturing, or collapse of the unitary
freeze-dried material storage assembly 428 during subsequent
handling and storage.
[0284] 2. Reconstituting and Administering Freeze-Dried Plasma from
a Unitary Freeze-Dried Material Storage Assembly
[0285] In use at a remote site (see FIG. 57), the freeze dried
material storage assembly 428 (or vessel 402 with overwrap 418, as
shown in FIGS. 40 and 41) is removed from the outer container 422.
After removal of the overwrap 418 (if provided), a transfer set 462
is coupled to a container 464 of sterile reconstituting liquid
(e.g., water) and the second port component 414 of the respective
unitary freeze-dried material storage assembly 428 (or vessel 402).
The transfer set 462 can include plastic needles or spikes at each
end to make the coupling, e.g., as shown in FIG. 30. The transfer
set 462 may be long and flexible (as shown in FIG. 57).
Alternatively, the transfer set 462 can be short and rigid, to
reduce storage space and simplify handling.
[0286] The caregiver can now proceed to manipulate the freeze dried
material storage assembly 428 (or vessel 402), together with the
container 464 of reconstituting liquid to transfer the
reconstituting liquid from the container 464 into contact with the
freeze-dried material within the freeze dried material storage
assembly 428, as FIGS. 57 and 59 shows. The caregiver can create a
fluid pressure differential across the transfer set 462 by
selectively establishing head height differentials. Fluid can be
expelled in response to the fluid pressure differential through the
transfer set 462 back and forth the between the freeze dried
material storage assembly 428 (or vessel 402) and the container 464
of reconstituting liquid 206, as necessary to reconstitute the
freeze-dried material, in preparation for administration to an
individual.
[0287] In the embodiment shown in FIG. 58, the reconstituted
material is administered from the freeze dried material storage
assembly 428 (or vessel 402). In this arrangement, the
administration set 462 used for mixing is uncoupled from the second
port component 414, and the second port component 414 is closed (as
before described, the second port component 414 can include a
septum that automatically closes upon the removal of the transfer
spike or needle). At this time, as shown in FIG. 58, the caregiver
couples the third port component 416 to an administration set 466,
for transfer of the reconstituted material into the circulatory
system of an individual, as shown in FIG. 58. The administration
set 466 includes a phlebotomy needle 468 for insertion into a vein,
in the same manner as before described with reference to FIG. 16 or
32. The flexible side wall component 404 accommodates the collapse
of the vessel 402 as the reconstituted material is administered
into the circulatory system of an individual.
[0288] In the embodiment shown in FIG. 60, the reconstituted
material is administered from the container 464 that initial
contained the reconstituting liquid. In this arrangement, after
mixing, the reconstituted material is finally transferred from
freeze dried material storage assembly 428 (or vessel 402) to the
reconstituting liquid container 464. In this arrangement, the
administration set 462 used for mixing is uncoupled from the
reconstituting liquid container 464, and the associated port 470
closed. At this time, as shown in FIG. 60, the caregiver couples
another port 472 on the reconstituting liquid container 464 to an
administration set 466, for transfer of the reconstituted material
to the circulatory system of an individual, as shown in FIG. 60.
The administration set 466 includes a phlebotomy needle 468 for
insertion into a vein, in the same manner as before described with
reference to FIG. 16 or 32.
VII. CONCLUSION
[0289] The foregoing is considered as illustrative only of the
principles of the invention. Furthermore, since numerous
modifications and changes will readily occur to those skilled in
the art, it is not desired to limit the invention to the exact
construction and operation shown and described. While the preferred
embodiment has been described, the details may be changed without
departing from the invention, which is defined by the claims.
* * * * *