Apparatus for separating plasma and other wastes from blood

Abstract

An apparatus is provided for separating cellular components of blood (red blood cells, white blood cells, and platelet) from waste components (plasma, anticoagulant, toxins, and other relatively small molecules). The presently preferred embodiment is a two stage plasma separator apparatus. One feature of the present invention is the use of rotors, and further providing rotors with wedge shaped cavities to cause turbulence, and thereby increase the filtration rate of waste components.

Description

BACKGROUND OF THE INVENTION

1. Technical Field

The present invention relates to apparatus used in processing, cleansing and reconstituting blood for use by a patient, such as during surgical procedures, and more specifically to apparatus for filtering blood plasma and washing cellular components of blood to remove unwanted waste components.

2. Background Information

Most surgical procedures result in some loss of blood from associated surgical incisions. Injured patients can also often experience external and internal bleeding. If blood loss from injury or surgery is substantial, it becomes necessary to replenish lost blood through transfusion.

In many instances, it is possible to collect a patient's blood for use in replacing most or even all of the blood losses. It will be readily appreciated that blood collected from a wound or a surgical site will contain tissue fragments, lysed blood cells, and other unwanted substances. Such blood must be treated for removal of unwanted substances before it is safe for reinfusion into the patient.

The general procedure of collecting a patient's blood, cleansing it, and then returning it to the patient is sometimes referred to as autotransfusion. Where autotransfusion is possible, it is a strongly preferred way of replacing a patient's blood losses. One reason that autotransfusion is so preferred is that it avoids incompatibility problems which sometimes can occur when giving transfusions of blood obtained from someone other than the patient. Use of a patient's own blood to replace blood losses has also become increasingly important in view of issues relating to the safety of replacement blood, such as the prevalence of acquired immune deficiency syndrome (AIDS) or other diseases among blood donors in some locales. Because of these benefits, and others, autotransfusion is often the method of choice for minimizing loss of cellular blood components during diverse procedures ranging from surgery to plasma exchange therapy, and is likely to become increasingly important in the future.

The process of removing blood plasma and other unwanted substances without any cleansing of the blood is commonly referred to as plasmapheresis. Plasmapheresis has long been practiced through use of filters having a pore size large enough to pass plasma and other unwanted substances found in the blood, such as anticoagulant, toxins and components of lysed cells (which, for purposes of brevity and simplicity, shall sometimes hereinafter be referred to collectively as the "waste components" of blood), but small enough to retain intact cells, such as red blood cells, white blood cells and platelets (which shall sometimes hereinafter be referred to collectively as the "cellular components" of blood). Plasmapheresis has also been practiced through use of a centrifuge to separate plasma and other suspended waste components from the denser cellular components, and then removing the plasma and associated waste components.

Simple removal of plasma and associated waste components is not adequate to remove all waste materials associated with blood. It has been found that much more thorough cleansing of blood can occur if the cellular components are washed after the plasma is removed. U.S. Pat. No. 4,631,050 describes a process of autotransfusion utilizing a membrane for filtration to separate waste components from cellular components. That patent describes an initial filtration to remove gross debris, followed by addition of a washing solution to reconstitute the blood, and then subjecting the reconstituted mixture to another filtration step in order to remove remaining waste components. Although more effective at cleansing blood than simple plasmapheresis, there is a tendency for cellular components to clog the filter when utilizing this type of process. This is a serious problem because it seriously limits the flow rate of such a device, making it impractical for autotransfusion.

Numerous attempts were thereafter made to prevent buildup of cellular components on the filter membrane. One of the more effective solutions is set forth in U.S. Pat. No. 4,935,002, which was issued to the inventor of the present invention, and which is hereby incorporated by reference as though separately set forth herein. That patent describes a high speed filter for rapidly cleansing blood so that it can realistically be depended upon as a source of blood for autotransfusion. The plasma separator apparatus disclosed in U.S. Pat. No. 4,935,002 includes within a single housing a first filtration zone where waste components of blood are separated from the cellular components; a washing zone where a wash solution is mixed with the cellular components; and a second filtration zone where wash solution and residual waste components are separated from the cellular components. A rotating disk is used to create a shear force which prevents cellular components from building up and clogging the filter pores, and also serves to prevent clotting. Although a substantial improvement over previous apparatus for conducting plasmapheresis or for cleansing blood of unwanted waste materials, the apparatus disclosed in U.S. Pat. No. 4,935,002 could still be improved upon. For example, it was found that the apparatus of U.S. Pat. No. 4,935,002 was difficult to build within tolerances necessary to avoid unwanted mixing between the two filter zones at a reasonable cost. It was also discovered that the flow rate of blood through the device disclosed in that patent was slower than desirable and did not cleanse the cellular components of blood as effectively as desired.

SUMMARY OF THE INVENTION

It is a primary object of the present invention to provide improved apparatus for effecting the cleansing of blood to remove unwanted waste materials so that it is suitable for infusion into a patient.

Another object of the present invention is to provide apparatus for cleansing blood capable of more rapid flow rates than available in previous devices.

Yet another object of the present invention is to provide apparatus for cleansing blood which remove more of the waste components of blood than was removed by previous devices.

A still further object of the present invention is to provide an apparatus requiring less critical tolerances so that it can be produced more economically.

Additional objects and advantages of the invention are set forth hereinbelow in the detailed description, or will be appreciated by the practice of the invention.

To achieve the foregoing objects, and in accordance with the invention as embodied and broadly described herein, a plasma separator apparatus is provided which is capable of rapid, yet thorough cleansing of blood in order to remove unwanted substances.

More specifically, the present invention provides an apparatus for separating cellular components of blood (red blood cells, white blood cells and platelets) from waste components (plasma, anticoagulant, toxins, and other relatively small molecules).

The presently preferred embodiment is a two stage plasma separator apparatus. The first stage is comprised of a first chamber having inlet means for admitting blood requiring separation of cellular components from waste components, and outlet means for discharging blood processed in said first chamber. A first filter means and associated waste outlet means is associated with the first chamber for separating waste components from cellular components of blood. First rotating means are associated with the first filter means in order to produce movement of cellular components of blood as blood passes between the inlet means and the outlet means of the first chamber in order to substantially prevent obstruction of the first filter means by said cellular components of blood.

The second stage is similar to the first, but has in addition to second filter means and second rotating means, wash inlet means for introducing wash solution to the blood processed in the first stage, so as to accomplish more thorough cleansing thereof.

An important feature of the present invention is the use of rotors as rotating means, and providing the rotors with wedge shaped cavities to cause turbulence, which significantly increases the filtration rate of waste components through the first and second filter means.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, which represent the best mode presently contemplated for carrying out the present invention:

FIG. 1 is a schematic representation of an autotransfusion system, one component of which is the plasma separator of the present invention;

FIG. 2 is a perspective view of the top of the presently preferred embodiment of the plasma separator of the present invention;

FIG. 3 is a perspective view of the bottom of the plasma separator of FIG. 2;

FIG. 4 is a partially exploded view of the plasma separator of FIG. 2, which serves to illustrate the principal components thereof;

FIG. 5 is a cross-sectional view taken along lines 5--5 of FIG. 2;

FIG. 6 is a cross-sectional view taken along lines 6--6 of FIG. 3;

FIG. 7 is a cross-sectional view taken along lines 7--7 of FIG. 4; and

FIG. 8 is a schematic representation of another embodiment of a plasma separator in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is directed to a plasma separator apparatus for cleansing blood so that it can be safely reinfused into a patient. Such apparatus will have wide applications, including removal of waste components from blood collected during surgery, including anticoagulant; plasma exchange therapy; removal of glycerin and other storage agents from blood frozen for storage; and any other applications requiring separation of cellular components of blood from unwanted substances which are susceptible to separation through use of a filtration system. For purposes of brevity and simplicity, the discussion herein will be principally directed to the processing of blood during a surgical procedure for use in autotransfusion. It should be appreciated, however, that the teachings herein will be readily transferable to other applications involving separating cellular components of blood from plasma and other waste components.

Reference is first made to FIG. 1, which illustrates the use of a plasma separator apparatus in accordance with the present invention as a element of an autotransfusion system. Autotransfusion involves removal of blood from a patient, processing it for removal of unwanted components, and returning it to the patient. In order to be practical, the processing of a patient's blood must be accomplished quickly, yet thoroughly.

The autotransfusion system of FIG. 1, identified generally by reference numeral 10, satisfies these needs. Autotransfusion system 10 is configured for use in recovering blood from a surgical site so that it can be cleaned and returned to the patient. A sucker 12 is used to aspirate blood from a surgical site. A source of anticoagulant 14 is coupled to sucker 12 so that mixing of anticoagulant occurs quickly, thereby minimizing formation of blood clots. Aspirated blood and anticoagulant are drawn into a conventional blood collection reservoir 16, which includes a filter 18 having a pore size which will remove large particles such as blood clots, pieces of tissue, orthopedic cement, and the like, but which will pass cellular components of blood. Blood collection reservoir 16 also serves to effect defoaming of blood collected therein.

A roller pump 20 is advantageously used to pump blood from collection reservoir 16 into a plasma separator, a presently preferred embodiment of which is depicted generally by reference numeral 22. A wash solution, preferably saline, is also pumped into plasma separator 22 from a source 24. As described in detail below, the wash solution is mixed with partially cleansed blood in order to effect more thorough separation of waste components from the cellular components of the blood being processed by the plasma separator. Cleansed blood processed by plasma separator 22 is collected in a blood collection bag 26, and from there it is returned to the patient, typically by conventional gravity infusion. Plasma, anticoagulant, and other waste components of the blood are collected in a waste collection bag 28, which may be discarded.

STRUCTURE OF THE PREFERRED EMBODIMENT OF FIGS. 2-7

The presently preferred embodiment of the plasma separator of the present invention is illustrated in FIGS. 2 through 7. FIGS. 2 and 3 show top and bottom perspective views of plasma separator 22. Referring first to FIG. 3, it may be seen that the underside of plasma separator 22 has a blood inlet port 30 which functions as a means for admitting blood into the plasma separator which requires separation of cellular components from waste components of blood. It is advantageous to introduce blood at an underside location so that air can be most efficiently expelled from the plasma separator as it is brought into operation. As seen in FIG. 2, processed blood suitable for autotransfusion is discharged from plasma separator 22 through blood outlet port 32. Waste components are removed from the plasma separator to a waste collection bag through waste outlet port 34.

Referring now to FIG. 4, plasma separator 22 is comprised of several component parts which interact to effect thorough cleansing of blood introduced through blood inlet port 30. Beginning at the bottom of FIG. 4 and working upwardly, the first of these components is a generally circular bottom plate 36. The upper face of bottom plate 36 is preferably slightly concave and provided with a series of radial raised ridges 38. The ridges utilized in the presently preferred embodiment of FIGS. 2-7 are configured so as to decrease in height when moving from the more central portion of bottom plate 36 toward the outside thereof along the concave surface of the bottom plate. This structure provides a generally level upper surface.

A filter 44 rests upon the generally level upper surface of ridges 38, and is secured to annular inner and outer rings 40 and 42 in conventional fashion so that nothing can leak past the edges of the filter. The diameter of bottom plate 36 at the location of the outermost edge of outer ring 42 is preferably about 6 inches, and the width of ring 42 is preferably about 1/8 inch. Filter 44 is advantageously constructed from a biocompatible material having a pore size suitable for passing plasma and other waste components of blood but which will not pass the cellular components of blood. Filter 44 is also about 6 inches in diameter, so the outermost 1/8 inch will be affixed to the outer ring 42. The center of filter 44 is cut out to conform to inner ring 40. Ridges 38 support filter 44 while defining channels through which waste fluid can flow as it passes through filter 44.

A waste outlet port 46 (see FIGS. 3 and 5) is provided on the underside of bottom plate 36 to serve as means for discharging waste components of blood which have passed through filter 44. Ridges 38 are preferably provided with notches 48 and 50 in order to permit unrestricted flow of waste components to and through waste outlet port 46.

The second component of plasma separator 22 is a rotor 52. Rotor 52 is circular in shape, and is about 53/4 inches in diameter, thereby leaving a gap of approximately 1/8 inch between the circumferential surface of the rotor and the inner edge of rim 72 of bottom plate 36. As best seen in FIG. 5, the underside of rotor 52 is provided with a cylindrically shaped projection 54. Projection 54 is provided with a hollow bore 54a which is sized so as to receive and rest upon a pin 56 which is secured to and extends upwardly from chamber 58 of bottom plate 36. The lower end of projection 54 is designed to rest closely about a beveled ledge 56a at the base of pin 56, thereby stabilizing rotor 52 for rotation around pin 56. Projection 54 of rotor 52 serves as a bearing which permits rotor 52 to rotate freely about pin 56, yet also provides lateral support to insure that the rotor maintains its orientation with respect to filter 44. The lengths of projection 54 and pin 56 are selected to as to leave a small gap between the underside of rotor 52 and the top of filter 44. For reasons explained below, it is presently preferred that this gap be about 0.026 inches.

The underside of rotor 52 is also provided with an annular flange 60. An annular magnet 62 and associated collar 64 are affixed to flange 60. This arrangement permits use of an external motor (not shown) having a rotating magnetic coupler capable of magnetically coupling with magnet 62. In use, application of a rotating magnetic force on magnet 62 results in rotation of rotor 52 without requiring the use of rotating seals, or the like. The upper side of rotor 52 has a cylindrical recess 53 (see FIG. 5), and a pair of projecting keys 55 for mechanical coupling to a second rotor, as explained below. Rotor 52 is provided with a small hole 65 (see FIG. 5) to facilitate debubbling as the plasma separator is brought into operation.

The next component of plasma separator illustrated in FIG. 4 is a center plate 66. Center plate 66 is circular in shape and of the same diameter as bottom plate 36. Both sides of center plate 66 are bounded by a circumferential rim 68 and flange 70. The bottom rim 68 and flange 70 are adapted to interface with a corresponding rim 72 and lip 74 provided on the upper surface of bottom plate 36. This arrangement permits bottom plate 36 to be secured to the underside of center plate 66 in a fluid-tight manner, thereby forming a first chamber.

Both sides of center plate 66 are provided with a plurality of radial ridges 76. Ridges 76 are bounded at their inside end by a gap 78 and an inner annular ledge 80, and on the outside by another gap 82 and an annular ridged ledge 84. Filters 86 and 88 are secured to the lower and upper sets of ledges 80 and 84. Filters 86 and 88 are preferably made of the same material as filter 44, and are also about 6 inches in diameter The center portion of filters 86 and 88 are removed so that they cover the area between ledges 80 and 84. As with ridges 38 on the bottom plate, ridges 76 of the center plate provide support for filters 86 and 88 while providing a channel for flow of fluid passing through the filters.

The center of center plate 66 is provided with an annular collar 85 forming a cylindrical hole 87 through center plate 66. The radius of hole 87 is slightly larger than the cylindrical recess 53 of the bottom plate 36, preferably about 0.022 inches, for reasons set forth below. When the bottom plate, rotor 52 and center plate 66 are assembled, there is preferably a gap of about 0.026 inches between rotor 52 and filters 44 and 86.

Center plate 66 is provided with a waste outlet port 34, which serves as means for discharging waste components of blood which have passed through both filters 86 and 88 to a waste collection bag. Waste outlet port 34 is in fluid communication with a hole 90 passing through gap 82. This hole permits waste components passing through filters 86 and 88 to join together and pass out through waste outlet port 34.

Center plate 66 is also provided with a wash inlet port 92 which is adapted for attachment to a source of wash solution. As best seen in FIG. 6, wash inlet port 92 advantageously opens through an aperture 94 located on the upper side of rim 68. Bottom plate 36 is provided with two cutouts 75 and 77 in lip 74 to accommodate ports 34 and 92 (see FIG. 4).

The next component of plasma separator 22 shown in FIG. 4 is a second rotor 96. Rotor 96 is of the same general size and shape as rotor 52, except, as best seen by reference to FIG. 5, it has projecting from the bottom thereof a cylindrical extension 98 which is sized to pass through hole 87 and to be received by cylindrical recess 53 of lower rotor 52. A pair of keyways 100 mate with keys 55 of lower rotor 52 so that the two rotors are mechanically coupled together. Hence, rotation of the lower rotor 52 will cause upper rotor 96 to rotate as well. As noted above, there is an annular gap 89 of approximately 0.022 inches between the edge of center plate 66 in the region of hole 87 and cylindrical extension 98. This gap provides a flow path for cellular components of blood as they move through plasma filter 22, thereby serving as an outlet means from the first chamber and also as inlet means into a second chamber in which rotor 96 sits.

The center of the upper side of rotor 96 has a small projecting nub 102, which serves as a thrust bearing to keep rotor 96 from rising during use, and thus maintaining the appropriate gap between rotor 96 and filter 114, described below. A small hole 104 passes through rotor 96 to help in debubbling plasma separator 22 as it is initially primed and brought into operation, similar to hole 65 found in rotor 52.

The final component illustrated in FIG. 4 is top plate 106. Top plate 106 is similar in construction to bottom plate 36 It is provided with ridges 108 similar to ridges 38, including notches 110 and 112 which correspond to notches 48 and 50. A filter 114 is affixed to an inner annular ring 116 and an outer annular ring 118, the centermost portion of filter 114 being removed to expose blood outlet port 32. Once again, the various components are constructed so as to leave a gap of approximately 0.026 inches between the top of rotor 96 and filter 114. Like bottom plate 36, top plate 106 has a rim 120 and a lip 122 adapted to interface with rim 68 and flange 70 of the center plate 66, thereby forming a second chamber. It is also provided with cutouts 124 and 126 in lip 122 to accommodate ports 34 and 92. A waste outlet port 128 (FIG. 5) is provided on the upper side of top plate 106 to serve as means for discharging waste components of blood which have passed through filter 114. Advantageously so as to reduce the number of tubes which lead from plasma separator 22 to the waste collection bag, outlet port 34 is provided with a pair of extension ports 130 and 132. Waste outlet ports 46 and 128 are connected to port 34 using tubing 134 and 136. This arrangement results in all of the waste components being discharged from plasma separator 22 through a single outlet port.

It will be appreciated that filters 44 and 86 both pass plasma and other waste components from within the first chamber formed between bottom plate 36 and center plate 66. The combination of these two filters in the presently preferred embodiment of the plasma separator as illustrated in FIGS. 2-7 serve as a first filter means for separating cellular components from waste components of blood. Waste outlet ports 34 and 46 serve as first waste outlet means for discharging waste components of blood processed within the first chamber. Similarly, filters 88 and 114 serve as second filter means situated within the second chamber formed by center plate 66 and top plate 106 for separating cellular components of blood from waste components. Waste outlet ports 34 and 128 serve as second waste outlet means for discharging waste components of blood processed in the second chamber.

An important feature of the presently preferred embodiment of the present invention involves an enhancement to the design of rotors 52 and 96. As best seen by reference to FIG. 7, both sides of the rotor 96 (and also rotor 52) are provided with a plurality of wedge shaped cavities 140 to generate turbulence in blood being processed through the plasma separator, thereby substantially preventing the associated filter membranes from becoming clogged by cellular components of blood, as discussed more completely below in connection with a description of the operation of plasma separator 22.

OPERATION OF THE PREFERRED EMBODIMENT ILLUSTRATED IN FIGS. 2-7

The operation of plasma separator 22 will now be described, following the pathway that blood will follow as it passes through the presently preferred embodiment of plasma separator in accordance with the present invention.

As noted above with respect to the autotransfusion system 10 of FIG. 1, blood is admitted into plasma separator 22 through inlet port 30, and then flows around the outside of magnet 62 and fills chamber 58. A pocket of air advantageously remains trapped within the area of magnet 62, thereby preventing blood from entering bore 54a or otherwise interfering with smooth rotation of the rotors. At first, plasma separator 22 will be full of air which must be removed by "priming" the separator. During this priming stage, air flows upwardly around the periphery of rotors 52 and 96, through holes 65 and 104 in the rotors, and through gap 89 near the center of center plate 66, and then out of plasma filter 22 through blood outlet port 32. Air also passes through the filters 44, 86, 88 and 114, and out through waste outlet ports 46, 128 and 34.

As blood moves upwardly through plasma separator 22, it first enters gap 142 (see FIG. 5) located between lower rotor 52 and filter 44. Plasma and other waste components of blood pass through filter 44, and are discharged through waste outlet port 46. In the absence of a spinning rotor, cellular components of blood would tend to accumulate and clog the pores of filter 44, thereby significantly impairing its throughput volume of plasma and other waste components. Accordingly, plasma separator 22 is magnetically coupled to an external drive (not shown), which causes rotor 52 to rotate in a clockwise direction (looking upwardly from the bottom of bottom plate 36). The rotation of rotor 52 imparts a shear force upon the cellular components of blood contained within gap 142, thereby tending to keep them in movement rather than clogging the pores of filter 44. Hence, rotor 52 functions as a first rotating means associated with the first filter means for producing movement of cellular components of blood passing between the inlet means and the outlet means of the first chamber in order to substantially prevent obstruction of the first filter means by those cellular components. The spinning rotor also prevents formation of blood clots as anticoagulant is removed.

In addition, as the rotor turns, blood follows the contour of wedge shaped cavities 140 from the shallow end to the abrupt rear face, at which point the blood is ejected in a manner which generates significant turbulence. The use of a plurality of wedge shaped cavities ensures numerous paths of turbulence as the rotor turns. This turbulence adds to the motion of cellular components caused by the shear forces, and significantly increases movement of cellular components within gap 142, which in turn increases the throughput volume of waste components through filter 44 over a given period of time. Indeed, the configuration of wedge shaped cavities 140 illustrated in FIGS. 2-7 has been found to increase the filtration flow rate by approximately 15 percent over the flow rate of a rotor lacking such cavities.

It should be understood that although wedge shaped cavities are the presently preferred structure for imparting turbulence to blood flowing through plasma separator 22, other structures could also be used to perform that function. For example, cavities of other shapes and sizes would also be useful. Alternatively, it would be possible to provide a plurality of short posts projecting from the surface of the rotor. Even a plurality of simple spokes projecting from an annular hub in place of a rotor has been found capable of providing adequate swirling motion to give excellent results. One of ordinary skill in the art will appreciate that any structure which will generate some reasonable degree of turbulence could be used in place of the rotor illustrated in FIGS. 2-7 without departing from the teachings and concepts of the present invention; any rotating means for generating movement of the cellular components of blood will assist in keeping the pores of the filters clear and assist in moving the cellular components through the plasma separator.

The speed at which rotor 52 is turned has a direct effect upon the amount of clogging that will occur; turning the rotor at a faster rate increases the magnitude of shear forces applied to the cellular components and hence decreases the tendency for cellular components to clog the pores of the filters. The result is an increased filtration flow rate of waste components. Yet, there are practical limits to the speed of the rotor, because increasing the rate of rotation eventually leads to shear forces which damage the cellular components. The configuration of plasma separator 22, utilizing wedge shaped cavities on the rotors permits the use of a relatively moderate rotor speed of about 750 rpm while maintaining excellent throughput volumes of waste components.

The flow of blood next moves upwardly past the outside edge of rotor 52 and then inwardly within gap 144 located between the top of rotor 52 and filter 86. Additional waste components flow through filter 86, while the cellular components continue to be stirred by the shear forces and turbulence generated by rotor 52. Waste components passing through filter 86 are discharged from plasma separator 22 through waste outlet port 34.

By the time the blood has traveled through gaps 142 and 144, which shall sometimes hereinafter be referred to as the "first stage" of plasma separator 22, a substantial amount of plasma and other waste components of the blood will be removed through filters 44 and 86. A reduction of the hematocrit of the blood to about 50 as the blood completes its passage through the first stage has been found a desirable target which leaves the cellular components suspended in a sufficient volume of plasma to remain fluid, yet which removes much of the unwanted waste components contained in the blood entering blood inlet port 30.

The blood next enters a "second stage" through gap 89 defined by the edge of annular collar 85 of center plate 66 and the surface of cylindrical extension 98 of top rotor 96. In similar manner to the first stage, blood passes through gap 89 and then enters gap 146 located between filter 88 and the underside of rotor 96. In similar manner to that discussed above with respect to the first stage of plasma separator 22, rotor 96 functions as a second rotating means associated with second filter means (filters 88 and 114) to prevent significant clogging of the pores of the filter means by cellular components of blood. The blood then moves generally outwardly toward the periphery of the rotor. Simultaneously, a wash solution, generally saline, is introduced through wash solution inlet port 92, which functions as means for admitting wash solution into the second chamber for mixing with blood in the second chamber. The shear forces and turbulence caused by rotation of rotor 96 effect rapid mixing of the wash solution with the partially cleansed blood contained within gap 146. Concurrently with the introduction of wash solution, waste components, now including wash solution as well as remaining plasma and other unwanted substances, flow through filter 88 and are discharged through waste outlet port 34.

Again following the pattern of the first stage, the mixture of blood and wash solution flows upwardly around the edge of rotor 96 and into gap 148 formed between the top of rotor 96 and filter 114. Additional mixing occurs between this mixture and wash solution which is continuously introduced through wash inlet port 92. Waste components flow through filter 114, for discharge through waste outlet port 128. The high efficiency of mixing of wash solution with blood in the second stage results in very thorough cleansing of the cellular components of blood, even with relatively small volumes of wash solution. Indeed, the use of two stages and rotors having wedge shaped cavities 140 is so much more efficient than the device disclosed in U.S. Pat. No. 4,935,002, that it is possible to make plasma separator 22 smaller than the device disclosed in that patent. Cleansed blood, again at a hematocrit of about 50, finally exits plasma separator 22 through blood outlet port 32.

It is important to the operation of plasma separator 22 that mixing not occur between the two stages. If mixing occurs, plasma separator 22 will operate as a single stage filter, and a loss of wash efficiency has been found to result. The primary cause presently known which results in unwanted mixing is the formation of Taylor vortices in the area of gap 89.

A "Taylor Number" has been defined as the Reynolds Number for a system multiplied by the square root of the ratio of the annular gap 89, divided by the radius at the gap. This reduces to the following formula:

T=N (G).sup.1.5 (R).sup.0.5 /V Where: T=Taylor Number G=Width of Annular Gap 89 R=Radius at Gap 89 N=Rotor Speed V=Viscosity

At a Taylor number of approximately 41 or greater, Taylor vortices will exist. The application of this formula was verified empirically by use of dye studies. Saline wash solution colored by use of a dye was observed as exiting only through the second stage waste outlets at Taylor Numbers below 41, but was observed to exit from the waste outlets of both stages at Taylor numbers greater than 41. In other experiments, it was discovered that a gap between the rotor and the outside casing of the device of U.S. Pat. No. 4,935,002 had to be about 0.008 inches to avoid Taylor vortices between the two "zones" of that device, a tolerance which was very difficult and expensive to obtain. In the present device, gap 89 can be increased to 0.022 inches, a measurement which is readily attainable at reasonable cost in a production device.

Plasma separator 22 is capable of processing blood at an input flow rate of up to about 400 milliliters per minute (ml/min), although it is contemplated that the normal flow rate will be about 150 ml/min. At this flow rate, approximately 75 ml/min of waste components will be removed from the first chamber. About 70 ml/min of wash solution is introduced into the second chamber, while about 70 ml/min of additional waste components are removed from the second chamber. When operating under these parameters, about 75 ml of processed blood will be collected in blood collection bag 26 each minute.

Although the two stage construction of plasma separator 22 is presently preferred, it would be a relatively simple matter to add additional stages, should such be desirable for particular applications. It is to be understood that the use of additional stages is contemplated within the scope of the present invention.

STRUCTURE AND OPERATION OF THE ALTERNATIVE EMBODIMENT OF FIG. 8

FIG. 8 sets forth in schematic form an alternative embodiment or a plasma separator 160 constructed in accordance with the present invention. The device of FIG. 8 utilizes a pair of cylinders 162 and 164, mechanically joined by an annular collar 166 so that both will rotate together. Cylinders 162 and 164 are advantageously disposed for rotation about pivot pins 168 and 170. Suitable drive means (not shown), such as the use of a magnetic coupling system as shown above in connection with the presently preferred embodiment of FIGS. 2-7, are provided to cause rotation of cylinders 162 and 164.

Cylinders 162 and 164 are disposed within a cylindrical housing 172, so that gaps 175 and 174 exist between cylinders 162 and 164, respectively and the wall of housing 172. Gap 176 exists between collar 166 and housing 172.

First and second filters 178 and 180 are disposed over the surface of cylinders 162 and 164, respectively, and the cylinders are advantageously provided with a plurality of orifices (not shown) to carry fluid from the outside of the cylinders, to the inside thereof.

In use, cylinders 162 and 164 are brought to a suitable operating speed, and blood is introduced through blood inlet port 182. Blood flows upwardly within gap 175, forcing air out through blood outlet port 184. Plasma and other waste components pass through filter 178 within the first stage of plasma separator 160, and then are discharged through waste outlet port 186. The spinning of cylinder 162 generates shear forces at the surface of filter 178, thereby preventing clogging of the pores of the filter.

As blood continues to rise within plasma separator 160, it passes through gap 176 into the second stage of the plasma separator. Wash solution is introduced through wash inlet port 188 and is mixed with blood through operation of the rotating cylinder 164. As in the first stage, waste components pass through filter 180 and are discharged through waste outlet port 186. Cleansed blood is discharged from plasma separator 160 through blood outlet port 184.

Although not illustrated, it will be readily appreciated that structures (such as wedge shaped cavities or protrusions) could be provided on the interior of housing 172 to generate additional turbulence, should that be desired to prevent filters 178 and 180 from becoming clogged during use. Inasmuch as the filters are themselves in motion in the embodiment of FIG. 8, however, it is contemplated that adequate filtration rates will normally be obtained even without such additional structures.

The plasma separator apparatus and associated improvements to rotor design are significant improvements over previous apparatus for effecting the cleansing of blood to remove unwanted waste materials, thereby making it suitable for reinfusion into a patient. It is capable of more rapid flow rates than previous devices, which in turn permits it to be made smaller and less expensively without sacrificing effectiveness. Its construction is also such that manufacturing tolerances are less critical than previous designs, making it more economical to produce for commercial uses.

It will be appreciated that the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive, and the scope of the invention is indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Claims

1. An apparatus for separating cellular components of blood from plasma and other waste components of blood, comprising:

a first chamber, said first chamber having inlet means for admitting blood requiring separation of cellular components from waste components, and outlet means for discharging cellular components of blood processed in said first chamber;

first filter means situated within the first chamber for separating cellular components from waste components of blood, said first filter means including

at least one filter element having a pore size suitable for passing plasma and other waste components of blood but not cellular components of blood, and

first waste outlet means for discharging plasma and other waste components of blood passing through said at least one filter element;

first rotating means for producing movement of cellular components of blood passing between the inlet means and the outlet means of the first chamber in order to substantially prevent obstruction of the first filter means by said cellular components of blood;

a second chamber, said second chamber having inlet means in communication with the outlet means of the first chamber for admitting cellular components of blood processed in the first chamber, and outlet means for discharging cellular components of blood processed in said second chamber;

second filter means situated within the second chamber for separating cellular components from waste components of blood, said second filter means including

at least one filter element having a pore size suitable for passing plasma and other waste components of blood but not cellular components of blood, and

second waste outlet means for discharging plasma and other waste components of blood passing through said at least one filter element;

wash inlet means in direct communication with the second chamber for admitting wash solution for mixing with cellular components of blood in the second chamber;

second rotating means for producing movement of cellular components of blood passing between the inlet means and the outlet means of the second chamber in order mix wash solution introduced into the second chamber with cellular components of blood, and to substantially prevent obstruction of the second filter means by cellular components of blood.

2. An apparatus as defined in claim 1, further comprising means for generating turbulence within blood passing between the inlet means and outlet means of the first and second chambers.

3. An apparatus as defined in claim 2, wherein the means for generating turbulence comprises a plurality of cavities.

4. An apparatus as defined in claim 3, wherein said cavities are wedge shaped.

5. An apparatus as defined in claim 1, wherein the first and second rotating means comprise first and second rotors.

6. An apparatus as defined in claim 1, wherein the first and second rotating means comprise first and second disk-shaped rotors; and wherein the first filter means includes two filter elements, one situated on each side of said first rotor, and the second filter means includes two filter elements, one situated on each side of said second rotor.

7. An apparatus as defined in claim 6,

wherein the inlet means for admitting blood into the first chamber is near the center of one side of the first rotor, and the outlet means for discharging blood processed in the first chamber is near the center of the other side of said first rotor, and

wherein there is a circumferential gap between the circumferential surface of said first rotor and the first chamber, so that blood flows between the rotor and one of the filter elements of the first filter means, through the circumferential gap between the rotor and the first chamber, and then between the other side of the first rotor and the other of the filter elements of the first filter means; and

wherein the inlet means for admitting blood into the second chamber is near the center of one side of the second rotor, and the outlet means for discharging blood processed in the second chamber is near the center of the other side of said second rotor, and

wherein there is a circumferential gap between the circumferential surface of said second rotor and the second chamber, so that blood flows between the second rotor and one of the filter elements of the second filter means, through the circumferential gap between the rotor and the second chamber, and then between the other side of the second rotor and the other of the filter elements of the second filter means.

8. An apparatus as defined in claim 7, wherein the first and second rotors are mechanically coupled together by means of a cylindrical coupling; and wherein the second chamber inlet means in communication with the outlet means of the first chamber comprises an annular gap around said cylindrical coupling.

9. An apparatus as defined in claim 8, wherein the gap between each of the rotors and the filter elements disposed about each of said rotors is about 0.026 inches, and the annular gap around the cylindrical coupling is about 0.022 inches.

10. An apparatus as defined in claim 1 wherein

the first and second chambers comprise a single elongate cylindrical housing;

the first and second rotating means comprise first and second cylinders situated for rotation within said cylindrical housing,

there being a gap between each of said cylinders and said housing sufficiently small so as to insure that blood passing through each of the first and second chambers is cleansed of a substantial portion of waste components;

the first filter means includes a filter element secured around the first cylinder and means communicating through said first cylinder for passing waste components passing through said first filter element;

the second filter means comprises a filter element secured around the second cylinder and means communicating through said second cylinder for passing waste components through said second filter element;

an annular collar member affixed between the first and second cylinders;

said annular collar member being sized so as to form a circumferential gap between the annular collar member and the cylindrical housing sufficiently small that blood passes from the first chamber to the second chamber without mixing between the two chambers.

11. An apparatus for separating cellular components of blood from plasma and other waste components of blood, comprising

a first chamber, said first chamber having inlet means for admitting blood requiring separation of cellular components from waste components, and outlet means for discharging blood processed in said first chamber;

a first rotor for producing movement of cellular components of blood passing between the inlet means and the outlet means of the first chamber;

a pair of filter elements associated with said first rotor, one of each of said filter elements being situated on each side of said first rotor, said filter elements being capable of separating cellular components from waste components of blood;

waste outlet means for discharging waste components of blood processed in the first chamber;

a second chamber, said second chamber having inlet means in communication with the outlet means of the first chamber for admitting blood processed in the first chamber, and outlet means for discharging blood processed in said second chamber;

a second rotor for producing movement of cellular components of blood passing between the inlet means and the outlet means of the second chamber;

a pair of filter elements associated with said second rotor, one of each of said filter elements being situated on each side of said second rotor, said filter elements being capable of separating cellular components from waste components of blood;

wash inlet means communicating with the second chamber for admitting wash solution for mixing with blood processed in the first chamber; and

waste outlet means for discharging waste components of blood processed in the second chamber.

12. An apparatus as defined in claim 11, wherein the inlet means for admitting blood into the first chamber is near the center of the bottom of the first rotor, and the outlet means for discharging blood processed in the first chamber is near the center of the top of said first rotor, and wherein there is a gap between the circumferential edge of said first rotor and the first chamber, so that blood traveling between the inlet means of the first chamber will flow between the bottom face of the rotor and the associated filter element, through the gap between the edge of the rotor and the first chamber, and then between the top of the first rotor and the other associated filter element; and wherein the inlet means for admitting blood into the second chamber is situated near the center of the bottom of the second rotor, and the outlet means for discharging blood processed in the second chamber is near the center of the top of said second rotor, and wherein there is a gap between the circumferential edge of said second rotor and the second chamber, so that blood traveling between the inlet and outlet means of the second chamber will flow between the bottom face of the second rotor and the associated filter element, through the gap between the edge of the rotor and the second chamber, and then between the top of the second rotor and the other associated filter element.

13. An apparatus as defined in claim 12, wherein the first and second rotors are mechanically coupled together by means of a cylindrical coupling; and wherein the second chamber inlet means in communication with the outlet means of the first chamber comprises an annular gap around said cylindrical coupling.

14. An apparatus as defined in claim 13, wherein the gap between each of the rotors and the filter elements disposed about each of said rotors is about 0.026 inches, and the annular gap around the cylindrical coupling is about 0.022 inches.

15. An apparatus as defined in claim 11, wherein each of said rotors further comprises means for generating turbulence within blood travelling between the inlet and outlet ports of the first and second chambers.

16. An apparatus as defined in claim 15, wherein said means for generating turbulence comprises a plurality of cavities on the faces of said first and second rotors.

17. An apparatus as defined in claim 16, wherein said cavities are wedge shaped.

18. An apparatus for separating cellular components of blood from plasma and other waste components of blood, comprising:

a generally cylindrical center plate having a top and a bottom;

a bottom plate affixed to the bottom of said center plate so as to leave a first generally cylindrical chamber therebetween;

a top plate affixed to the top of said center plate so as to leave a second generally cylindrical chamber space therebetween;

inlet means associated with the first chamber for admitting blood requiring separation of cellular components from waste components;

outlet means for discharging blood processed in said first chamber into said second chamber;

a first pair of filter elements, one of said filter elements being affixed to the top of the bottom plate and the other affixed to the bottom of the center plate, each of said filter elements being capable of separating cellular components from waste components of blood;

waste outlet means for discharging waste components of blood passing through said first filter elements;

a first disk-shaped rotor situated within the first chamber for producing movement of cellular components of blood passing between the inlet means and the outlet means of the first chamber;

inlet means associated with the second chamber in communication with the outlet means of the first chamber for admitting blood from said first chamber;

outlet means for discharging blood processed in said chamber;

a second pair of filter elements, one of said filter elements being affixed to the top of the center plate and the other being affixed to the bottom of the top plate, each of said filter elements being capable of separating cellular components from waste components of blood;

waste outlet means for discharging waste components of blood passing through said second filter elements;

a second disk-shaped rotor situated within the second chamber for producing movement of cellular components of blood passing between the inlet means and the outlet means of the second chamber; and

wash inlet means communicating with the second chamber for admitting wash solution for mixing with blood processed in the first chamber.

19. An apparatus as defined in claim 18, wherein the inlet means for admitting blood into the first chamber is situated near the center of the bottom of the first rotor, and the outlet means for discharging blood processed in the first chamber into the second chamber is situated near the center of the top of said first rotor, and wherein there is a gap between the circumferential edge of said first rotor and the juncture between the bottom plate and the center plate, so that blood traveling between the inlet and outlet means of the first chamber will flow between the bottom face of the rotor and the associated bottom filter element, then through the gap between the edge of the rotor and the said juncture in the first chamber, and then between the top of the first rotor and the top filter element; and wherein the inlet means for admitting blood into the second chamber is situated near the center of the bottom of the second rotor, and the outlet means for discharging blood processed in the second chamber is near the center of the top of said second rotor, and wherein there is a gap between the circumferential edge of said second rotor and the juncture between the top plate and the center plate, so that blood traveling between the inlet and outlet means of the second chamber will flow between the bottom face of the second rotor and the bottom filter element of the second chamber, through the gap between the edge of the rotor and said juncture in the second chamber, and then between the top of the second rotor and the associated top filter element.