The present disclosure generally relates to devices and methods for automatically reconstituting a drug, or multiple drugs that require diluting and/or mixing.
As background, certain drugs may not be stable in a liquid solution for long-term storage, or must be diluted from a more stable concentrated liquid form prior to administration (collectively “reconstitution”). For example, in some instances drug solutions are lyophilized into a powdered form using a freeze-dry or other similar process. A lyophilized drug may then be suitable for long-term storage and may be converted back into a liquid form when it is ready to be used. Furthermore, some combinations of drugs are not stable long-term and must be combined a short time prior to administration.
Reconstitution of a drug or combination of drugs for administration such as reconstitution of a lyophilized drug from its powdered state to a liquid state may require a number of steps such as, for example, mixing the drug with a predetermined amount of a reconstitution liquid (e.g., water) and waiting a minimum time period to allow the reconstitution process to fully complete. It may be beneficial for a device to automate the reconstitution process for ease of use and to reduce the possibility of human error. Furthermore, automated preparation of a drug or drug combination can reduce the risk of exposure to highly toxic or mutagenic substances such as are utilized for chemotherapy. Also, during the reconstitution process, it may be beneficial to prevent the formation of air bubbles in the reconstituted drug. Thus, devices and methods are needed which automatically reconstitute a lyophilized drug while minimizing or eliminating the introduction of air bubbles into the reconstituted drug, as well enabling the process to take under laminar flow conditions without the presence of the operator.
In one embodiment, a device which automatically reconstitutes a drug is disclosed. The device comprises a cartridge which contains a liquid capable of reconstituting the drug; a vial containing the drug; a connector providing a fluid conduit and to which the vial containing the drug removably inserts, said fluid conduit fluidly couples the cartridge to the vial and defines an entry point where the fluid conduit enters the vial when inserted into the connector; a cartridge drive mechanically coupled to the cartridge and which changes a pressure of fluid in the cartridge to transfer fluid into or out of the cartridge through the fluid conduit; a vial drive which adjusts an orientation of the vial; and a controller electrically coupled to the cartridge drive and the vial drive such that the controller controls transfer of fluid into or out of the cartridge by activating the cartridge drive and controls the orientation of the vial by activating the vial drive.
In another embodiment, a method for automatically reconstituting a drug is disclosed. The method comprises fluidly coupling a vial containing the drug to a cartridge containing a liquid with a fluid conduit, wherein an entry point is defined where the fluid conduit enters the vial; automatically adjusting an orientation of the vial such that the entry point of the vial is gravitationally higher than the drug in the vial; automatically transferring the liquid out of the cartridge and into the vial to create a reconstituted drug; automatically adjusting the orientation of the vial such that the entry point of the vial is gravitationally lower than the reconstituted drug; and automatically transferring the reconstituted drug from the vial and into the cartridge.
In another embodiment, a method for automatically reconstituting and delivering a drug to a user which comprises utilizing the above mentioned device is also disclosed.
These and other advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the drawings.
The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the inventions defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference characters and in which:
The embodiments described herein generally relate to devices and methods for automatically reconstituting a drug, or multiple drugs that require diluting and/or mixing.
For purposes of this disclosure, reconstitution refers to any of and combinations of conversion of a drug in a solid or semi-solid form into a liquid form suitable for administration to an animal by infusion or injection, conversion of a concentrated liquid form of a drug into a diluted liquid form suitable for administration to an animal by infusion or injection, or to preparing a liquid mixture of two or more drugs (each of which can initially be provided in any of a solid, a semi-solid or a liquid form) suitable for administration to an animal by infusion or injection. Thus, a reconstituted drug is any liquid drug formulation formed from any combination of one or more drugs each provided in any of a solid, semi-solid or liquid form and possibly by addition of a reconstitution liquid to dilute or dissolve the drug(s). A reconstitution liquid that is added to one or more drugs to prepare a reconstituted drug can be any suitable liquid pharmaceutical diluent including but not limited to water, buffers, organic solvents such as ethanol and dimethylsulfoxide, and combination thereof. A reconstituted drug can also contain other substances that aid in delivery or increase the stability of the reconstituted drug. For example, a hyaluronidase enzyme that increases the rate of subcutaneous infusion could be part of a reconstituted drug.
For purposes of this disclosure, a lyophilized drug is a drug that has been converted into a powdered form or other suitable form by removing some or all of the moisture contained therein. The drug may be lyophilized by any suitable manner including, but not limited to, a freeze dry process. In order to use the lyophilized drug, it must be reconstituted with a reconstitution liquid such as, for example, water or a buffer. The reconstitution process converts the lyophilized drug into a liquid form so it can be injected or infused into an animal such as a human or a veterinary animal such as a cow, a horse, a sheep, a pig, a dog or a cat.
For purposes of this disclosure, stating that Component A is “gravitationally higher” than Component B means that a fluid would flow from Component A to Component B when the fluid is only under the influence of gravity. Likewise, stating that Component X is “gravitationally lower” than Component Y means that a fluid would flow from Component Y to Component X when the fluid is only under the influence of gravity. If the component is a fluid such as, for example, the reconstituted drug, the fluid is considered gravitationally higher than the other component if any portion of the fluid is gravitationally higher than the other component. Likewise, the fluid is considered gravitationally lower than the other component if the entire fluid is gravitationally lower than the other component.
For purposes of this disclosure, stating that the vial is fluidly coupled to the cartridge means that the content of the vial is fluidly coupled to the content of the cartridge. The content may include liquids, gases, powders, or combinations thereof. For example, the vial may initially contain the lyophilized (i.e., powdered) drug and a gas such as air. As another example, the cartridge may initially contain the reconstitution liquid which may be water. For purposes of this disclosure, fluid is defined as any material which is capable of flowing such as, for example, air, liquids, powders, and combinations thereof.
Referring to
In order to automatically reconstitute the drug, the user may insert a vial 30 containing the drug, such as a lyophilized drug, into the connector 14 and activate the user input 22 (e.g., a pushbutton) in order to start the automatic reconstitution process in one embodiment. Alternatively, in another embodiment the device 10 can automatically detect the vial 30, such as by a contact, optical or Hall Effect sensor. Furthermore, the time and sequence of reconstitution steps can either be set in the device 10 by default or can be set prior to use by virtue of another information source such as an identification label on a vial 30 containing a drug or a vial containing a reconstitution liquid (for example, a bar-code, an OCR code, an RFID-Tag, a mechanical code or a contact code). In addition, the device 10 can, based on the information contained in such codes or user input, guide a user through a complicated reconstitution procedure (such as where multiple drug/reconstitution liquid vials 30 are loaded into the device 10 in a particular order). To further ensure that a complicated series of vial connections and reconstitution steps is carried out properly, the device 10 can further check that the correct vial 30 is in place at a given point in a reconstitution procedure (such as by reading a barcode or any other information source/identifier on the vial) and time periods for reconstitution steps are followed. An alarm or alarms (audible, tactile and/or visual) can be employed to alert a user to change vials at the correct time, and/or to warn the user of incorrect vial insertions and/or attempts by a user to remove a vial prior to a reconstitution step being completed.
After receiving an indication that the (proper) vial 30 is inserted into the connector 14, the device 10 then automatically mixes the reconstitution liquid in the cartridge 12 and the drug in the vial 30 to create a reconstituted drug. After automatically reconstituting the drug, the device 10 may activate the annunciator 24 (e.g., a light) in order to indicate to the user that the reconstitution process has been completed and the reconstituted drug is disposed in the cartridge 12. The cover 26 may provide physical access to the cartridge 12 in order to replace or remove the cartridge 12.
In alternative embodiments, the device 10 can be provided with a cartridge 12 that is either empty initially or one that already contains a drug, and in which the drug can be any of a solid drug, semi-solid drug or a liquid drug. If the drug in the cartridge 12 is a solid or semi-solid drug, the first vial 30 connected to the device 10 contains either a reconstitution liquid or a liquid drug. Likewise, if the first vial 30 contains a solid or semi-solid drug, the cartridge 12 initially contains a reconstitution liquid or a liquid drug. Additional cartridges 12 and/or vials 30 may then be connected to device 10 as needed to form the reconstituted drug, or to dilute or mix multiple drugs.
Referring to
Referring to
The plunger 12p may also include one or more seals 12o, which may be o-rings or other similar devices. The seals 12o may comprise rubber, plastic or any other suitable material. For example, in the illustrated embodiment of
The movement or stroke of the plunger 12p in the in the first direction 12b and the second direction 12c may operate in one of two manners. First, the cartridge 12 may be designed such that the stroke of the plunger 12p in the first direction 12b and in the second direction 12c is sufficient to transfer all of the fluid in one stroke. For example, a single movement of the plunger 12p in the first direction 12b is sufficient to transfer all of the liquid (e.g., the reconstitution liquid initially stored in the cartridge 12) out of the cartridge 12 and into the vial. In another embodiment, the cartridge 12 may be designed such that the stroke of the plunger 12p in the first direction 12b and in the second direction 12c is less than a volume of fluid in the cartridge 12, and a plurality of strokes of the plunger 12p is required to transfer all of the fluid out of the cartridge 12 and to transfer all of the fluid back into the cartridge 12. Other designs of the plunger 12p and the cartridge 12 may be used as well.
As shown best in
In the embodiment shown in
Likewise, in this embodiment rotation of the motor 16m in the other direction causes the plunger 12p to move in the second direction 12c, which decreases pressure on fluid in the cartridge 12 and causes the fluid in the vial 30 to be transferred into the cartridge 12 when the vial 30 is inserted into the connector 14, and preferably when the vial 30 is gravitationally above the cartridge 12 such that air is not introduced into the liquid. In other embodiments, the motor 16m may rotate only in one direction wherein bidirectional rotation is facilitated and selected by a cam and/or gearbox which moves the plunger 12p backwards and forwards. As bidirectional gearing arrangements are known by those skilled in the art no further discussion is provided.
The cartridge drive 16 (e.g., through the motor 16m) may be electrically coupled to the controller 18 (
In the embodiment shown in
Although the cartridge 12 and the connector 14 are mechanically coupled to each other in the embodiments shown and described herein, it is contemplated that, in other embodiments, they are not mechanically coupled to each other. In these embodiments, the vial drive 20, when activated, may only adjust the position of the connector 14. That is, activating the vial drive 20 may have no effect on the cartridge 12, which may be mechanically coupled to the device 10, for example. It is contemplated that other mechanical arrangements may be used as well, as is known in the art. Furthermore, the relative positions of the cartridge 12 and the vial 30 may include a number of arrangements. For example, in one embodiment a longitudinal axis of the cartridge 12 is substantially perpendicular to a direction of gravity. In this embodiment, a longitudinal axis of the vial 30 may be substantially perpendicular to the longitudinal axis of the cartridge 12; the vial drive 20 may be operable to adjust the orientation of the vial 30 by axially rotating the vial about the longitudinal axis of the cartridge 12; and the vial drive 20 may be mechanically coupled to the cartridge 12, and the vial drive rotates a body of the cartridge about its longitudinal axis, which adjusts the orientation of the vial 30.
In another embodiment, the vial drive 20 may be operable to adjust the orientation of the vial 30 by axially rotating the vial about an axis substantially perpendicular to a direction of gravity. In still another embodiment, a longitudinal axis of the cartridge 12 is substantially parallel to a direction of gravity. In this embodiment, a longitudinal axis of the vial 30 may be substantially parallel to the longitudinal axis of the cartridge 12, or the orientation of the vial 30 may be adjusted by rotating the vial 30 and the cartridge 12 about an axis substantially perpendicular to the direction of gravity.
Referring to
The fluid conduit 14f of the connector 14 may include a needle 14n disposed at the connector such that, when the vial 30 is inserted into the connector 14, the needle 14n is inserted into the vial 30 at the entry point 30e. The needle 14n may comprise steel or other suitable material. In still other embodiments, the needle may be plastic and an integral part of the connector 14. The vial 30 may have a stopper 30s disposed in the neck of the vial 30 which seals the vial 30 and the drug 30d contained therein. The stopper 30s may comprise rubber, plastic, or other suitable material. The needle 14n may be hollow to allow fluid to pass through it and may also have a sharp tip which is capable of puncturing and passing through the stopper 30s when the vial 30 is inserted into the connector 14. The needle 14n may be of sufficient length to pass through and emerge from the stopper 30s so that the tip of the needle 14n enters the vial 30 and is fluidly coupled to the vial 30. The connector 14 may also permit the user to remove the vial 30 (e.g., after reconstitution of the drug) by overcoming the friction or mechanical coupling created by the ridge 14x and pulling the vial 30 out of the connector 14. The vial 30 may also include a septum (not shown) which seals the vial 30 before it is used. When the vial 30 is inserted in the connector 14, the needle 14n may pass through the septum of the vial 30 such that location where the needle 14n passes through the septum defines the entry point of the vial 30.
In another embodiment, the fluid conduit comprises a needle disposed at the connector 14 such that when the vial 30 is inserted into the connector, the needle is inserted through a septum (not shown) of the cartridge 12 to make a fluid connection with the cartridge 12. In still another embodiment, the cartridge 12 may be rotated about a longitudinal axis of the cartridge in order to break a seal, which creates a fluid connection between the connector 14 and the cartridge 12. Other similar manners of fluidly coupling the cartridge 12 to the vial 30 may be used, as is known in the art.
The vial 30 may have a body 30b, a neck 30n, and a rim 30i and may comprise glass, plastic, metal, or other suitable material. In still other embodiments, the vial 30 may be rigid, or have flexible membranes such as, e.g., in the form of a bag. The neck 30n and the rim 30i may be arranged so that the vial 30 can be removably inserted into the connector 14. The vial may also have a stopper 30s which is inserted into the neck 30n to seal the drug 30d inside the vial 30. The vial 30 may have a generally cylindrical shape although other geometric shapes are contemplated. The neck 30n may be narrower than both the body 30b and the rim 30i such that the rim 30i provides a surface which allows the vial 30 to be frictionally coupled to the connector 14, as discussed herein. The vial 30 may be based on a standard vial format which is used in other types of medical application. Using a standard vial format may allow the vial 30 to be cost-effective since the manufacturer may take advantage of economies of scale and existing manufacturing processes. Alternatively, the vial 30 may be specially designed and configured for the devices and methods described herein.
The vial drive 20 (e.g., through the motor 20m) may be electrically coupled to the controller 18 (
After some or all of the reconstitution liquid 12r has been transferred into the vial 30, the drug 30d becomes a reconstituted drug 30r through the natural mixing of the reconstitution liquid 12r and the drug 30d. The device 10 may wait a reconstitution time period to allow the mixing to complete and/or any chemical reactions to conclude. For example, the reconstitution time period can be implemented in the device 10 by the controller 18 waiting automatically for a desired period that has set either programmatically or discretely (binary registers, dip switches, timing circuits, etc). The reconstitution time period may range from about 1 second to 10 minutes or more. In one embodiment, the reconstitution time period is about 60 seconds.
In
Referring to
In one embodiment, the cartridge drive 16 comprises an electric motor, and the controller 18 automatically controls transfer of fluid into or out of the cartridge 12 by activating the electric motor. In this embodiment, the electric motor may comprise a DC electric motor which rotates in one direction when a positive electrical current is applied to it, and which rotates in the opposite direction when a negative electrical current is applied to it. In this manner, the controller 18 may control automatically the direction of rotation of the motor which correspondingly controls whether the cartridge drive 16 transfers fluid into or out of the cartridge 12. The controller 18 may further comprise a power circuit (not shown) for the motor in order to step up the voltage and/or current to a suitable level for driving the motor.
In other embodiments, e.g., when the motor 16m always drives in one direction with a cam to move the plunger 12p backwards and forwards, repeated strokes pump all the reconstitution liquid 12r from the cartridge 12 and into the vial 30 when the vial is gravitationally below the cartridge, or draws the drug 30d from the vial when the vial 30 is gravitationally higher than the cartridge 12.
The cartridge drive 16 may further comprise one or more sensors (not shown) in order to provide feedback to the controller 18 regarding the state of the cartridge drive 16. For example, a position sensor may be disposed on the plunger of the cartridge drive 16 in order to allow the controller 18 to ascertain the position of the plunger. This may allow the controller 18 to accurately control the amount of fluid transferred as well as the rate of the transfer. As an alternative, the cartridge drive 16 may have one or more proximity sensors to detect when the plunger is fully extended or fully retracted. In this embodiment, the controller 18 may activate the cartridge drive 16 to transfer fluid into or out of the cartridge 12 until the one or more sensors indicate that the plunger is fully extended (e.g., for transferring fluid out of the cartridge 12) or fully retracted (e.g., for transferring fluid into the cartridge 12), at which time the controller 18 deactivates the cartridge drive 16. In summary, there are numerous ways for the controller 18 to activate the cartridge drive 16 and control the transfer of fluid into or out of the cartridge 12.
Referring still to
In one embodiment, the vial drive 20 comprises an electric motor, and the controller 18 controls the orientation of the vial 30 by activating the electric motor. In this embodiment, the electric motor may comprise a DC electric motor which rotates in one direction when a positive electrical current is applied to it, and which rotates in the opposite direction when a negative electrical current is applied to it. In this manner, the controller 18 may control the direction of rotation of the motor which correspondingly controls the orientation of the vial 30. The controller 18 may further comprise a power circuit (not shown) for the motor in order to step up the voltage and/or current to a suitable level for driving the motor.
The vial drive 20 may further comprise one or more sensors (not shown) in order to provide feedback to the controller 18 regarding the state of the vial drive 20. For example, a position sensor may be disposed on the motor of the vial drive 20 in order to allow the controller 18 to ascertain and control the orientation of the vial 30. As an alternative, the vial drive 20 may have one or more proximity sensors to detect when the entry point in the vial is gravitationally higher or lower than fluid in the vial. In this embodiment, the controller 18 may activate the vial drive 20 to orient the vial 30 until the one or more sensors indicate that the vial 30 is oriented in the desired manner (e.g., in an orientation for transferring fluid out of the cartridge 12 or in an orientation for transferring fluid into the cartridge 12). In summary, there are numerous ways for the controller 18 to activate the vial drive 20 and control the orientation of the vial 30. A sensor 31 may also be provided such that the controller 18 can automatically detect when the drug has been fully dissolved by the reconstitution liquid. Examples of such suitable sensors include optical sensors which detect either a color change, or a transmissive (interrupter) sensors, or reflective sensors which detects either the presence or absence of particulates in the reconstituted drug, and the likes. In addition, a heater 33 may be provided such that the controller 18 can automatically heat (gently) the vial 30 in order, for example, to heat the contents of the vial to a predetermined desired temperature, and/or to accelerate the reconstitution process such as, for example, if after a pre-determined time particulates are still detected by the sensor 31 in the vial 30. In an alternative embodiment, the heater 33 may be replaced with an ultrasonic device/transducer or supplemented therewith, such that ultrasonic waves may be applied to help speed up the reconstitution process and/or to reduce fraction of undissolved settling.
Referring still to
Referring still to
At step 44, the microcontroller 18u of the device 10 may automatically adjust an orientation of the vial 30 such that the entry point of the vial is gravitationally higher than the drug 30d in the vial. At step 46, the microcontroller 18u of the device 10 may automatically transfer the reconstitution liquid 12r out of the cartridge 12 and into the vial 30 to create a reconstituted drug 30r. At step 48, the microcontroller 18u of the device 10 may automatically adjust the orientation of the vial 30 such that the entry point of the vial is gravitationally lower than the reconstituted drug 30r. And at step 50, the microcontroller 18u of the device 10 may automatically transfer the reconstituted drug 30r from the vial 30 and into the cartridge 12. At the end of the reconstitution process, the microcontroller 18u of the device 10 may automatically activate the annunciator 24 to indicate that the reconstituted drug 30r is disposed in the cartridge 12.
The method 40 may include other steps as well. For example, the microcontroller 18u of the device 10 may automatically agitate the reconstituted drug 30r in the vial 30 by activating the vial drive 20. Furthermore, the microcontroller 18u of the device 10 may automatically wait a reconstitution time period after the reconstitution liquid 12r is transferred out of the cartridge 12 and into the vial 30 with the drug 30d. This reconstitution time period may allow the mixing of the drug and the reconstitution liquid to complete and may, for example, be from 10 seconds or less to ten minutes or more. Finally, the microcontroller 18u of the device 10 may automatically adjust the orientation of the vial 30 such that the entry point of the vial is gravitationally higher than a body of the vial after the reconstituted drug 30r has been transferred from the vial 30 into the cartridge 12 to allow a user to fluidly uncouple the vial 30 from the connector 14 of the cartridge 12. These and other suitable steps may be included in the method and may be performed in any suitable order.
For example,
For example, when the reconstitution process begins when using the in-line system 200, the microcontroller 18u of the device 10 may automatically adjust the orientation of the vial 30 such that the entry point of the vial is gravitationally higher than the drug 30d in the vial. Next, as depicted by
The above described method may include other steps as well. For example, the microcontroller 18u of the device 10 may automatically agitate the reconstituted drug 30r in the vial 30 by activating the vial drive 20 such that the vial 30 is moved, e.g., in a side-to-side motion as depicted by the arrow in
It should now be understood that the devices and methods described herein may automatically reconstitute a drug. This may allow a user to manually insert a vial containing the drug into a connector of the device and start the automatic reconstitution process. The device may then automatically reconstitute the drug and, upon completion of the reconstitution process, may inform the user via an annunciator that the reconstitution process has completed and the reconstituted drug is disposed in the cartridge. Automation increases safety because it can reduce exposure of healthcare workers to potentially toxic substances in any case, and further permits reconstitution to be performed in a safe environment such as under a laminar flow hood. An advantage of certain embodiments is that due to the automated reconstitution process the liquid transfer between cartridge and vial takes place under flow conditions avoiding turbulences during the transfer processes. Drug specific reconstitution times can be predefined so that administering can start at earliest after the time obliged for reconstitution. Still another advantage of certain embodiments is that after completing the reconstitution process, the cartridge is filled entirely with the reconstituted drug (which is not the case for in line reconstitution syringes which include a certain amount of air after reconstitution and therefore need to be expelled by a nurse before administering). Because the vial during the reconstitution process can be located higher than the cartridge, the vial can work as bubble trap.
While particular embodiments and aspects of the present invention have been illustrated and described herein, various other changes and modifications may be made without departing from the spirit and scope of the invention. Moreover, although various inventive aspects have been described herein, such aspects need not be utilized in combination. It is therefore intended that the appended claims cover all such changes and modifications that are within the scope of this invention.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2010/061643 | 8/10/2010 | WO | 00 | 7/9/2013 |