STERILE SENSOR INSERTION

Abstract

The present invention provides a system for the insertion of a pre-sterilized sensor probe into a sterile vessel. The system of the invention provides a reliable and straightforward way to insert one or more sterile probes into a sterile vessel. The present invention also provides a sterile vessel that includes one or more of the systems of the invention. The sterile vessel can be a flexible or semi-rigid bag or tubing of the type typically used for carrying out biochemical and/or biological processes and/or manipulating liquids and other products of such processes. Furthermore, the present invention provides a method for aseptically inserting a probe into a sterile vessel where the method makes use of the system of the invention.

Claims

1. A system for insertion of a sterile probe into a sterile vessel wherein said system comprises: (i) a body formed of plastic and having a sterile bore formed through at least a portion of its interior, the body having a first and second end, the second end comprising a body sterile face connection; (ii) a plunger formed of plastic and contained within the sterile bore of the body, the plunger having a shape substantially corresponding to that of said sterile bore and being of a diameter less than said sterile bore, the plunger also having an inner channel opening onto a first aperture on a first end of said plunger and a second aperture on a second end of said plunger, wherein said first and second ends of said plunger correspond respectively to said first and second ends of said body, and wherein said plunger is moveable between a first position and a second position; (iii) a sterile probe secured within the inner channel of said plunger wherein said sterile probe comprises an electrical connection end substantially aligned with said first end of said plunger, a sensor end substantially aligned with said second end of said plunger, and a sensor body therebetween; (iv) one or more seals between the plunger and the sterile bore to form a liquid-tight seal between various portions of the plunger and the sterile bore; and, (v) a handle cooperating with said plunger to direct movement of said plunger within the sterile bore between said first position and said second position.

2. The system as defined in claim 1 wherein said sterile probe is selected from the group comprising metabolic, biologic, and physical sensors.

3. The system as defined in claim 2 wherein said sterile probe is a glucose sensor, a lactate sensor, a pH sensor, a temperature sensor, a conductivity sensor or a cell mass and cell viability sensor.

4. The system as defined in claim 3 wherein each of said body and said plunger is independently formed of a plastic selected from the group consisting of polyetherimides (PEI), polyetheretherketone (PEEK), polyetherketone (PEK), polysulphones, polyarylsulphones, polyalkoxysulphones, polyethersulphones, polyphenyleneoxide, polyphenylenesulphide, polycarbonate, and blends thereof.

5. The system as defined in claim 4 wherein said body further comprises a sterilization port.

6. The system as defined in claim 5 further comprising one or more seals between the sterile probe and the inner channel of said plunger.

7. The system as defined in claim 6 wherein said handle is rotated around the longitudinal axis of said system to direct movement of said plunger within the sterile bore between said first position and said second position.

8. The system as defined in claim 7 wherein, between said first end and said one or more seals, said plunger comprises a plunger thread on its outer surface, said handle comprises a central opening of dimensions suitable to accommodate the width of said plunger and wherein said central opening comprises a handle thread that cooperates with said plunger thread such that rotational movement of said handle directs the movement of said plunger within the sterile bore between said first position and said second position.

9. The system as defined in claim 8 wherein said central opening further comprises a recess and said body comprises a first notch protruding outwardly from its surface and located substantially at its first end, wherein said first notch is received in said recess.

10. The system as defined in claim 9 wherein said body further comprises a second notch protruding outwardly from the surface of said body wherein said second notch provides mechanical support to the interaction of said first notch and said recess.

11. The system as defined in claim 10 which further comprises a cam formed on an outer surface of the plunger and contained within a cam slot defined by the body, wherein said cam is moveable between a first position within said cam slot and a second position within said cam slot and wherein said first position of said plunger is concurrent with said first position of said cam in said cam slot, and said second position of said plunger is concurrent with said second position of said cam in said cam slot.

12. The system as defined in claim 11 wherein said plunger is locked into said second position.

13. The system as defined in claim 12 wherein said sensor end of said sterile probe comprises a sheath.

14. A sterile vessel comprising one or more of said system as defined in claim 13.

15. The sterile vessel as defined in claim 14 which is a biocontainer.

16. The sterile vessel as defined in claim 15 which is a bioreactor.

17. The sterile vessel as defined in claim 16 which is a flexible bag supported within a rigid holder.

18. The sterile vessel as defined in claim 17 which comprises a wall including a vessel sterile face connection and wherein said system is connected to said sterile vessel by mating said body sterile face connection of the body of said system with said vessel sterile face connection.

19. The sterile vessel as defined in claim 18 wherein said body sterile face connection and said vessel sterile face connection are each a single-use aseptic connection.

20. A method for the insertion of a sterile probe into a sterile vessel wherein said sterile probe is provided along with the system as defined in claim 13 and wherein said sterile vessel comprises a body sterile face connection, wherein said method comprises: (a) mating said body sterile face connection of the body of said system with said vessel sterile face connection; (b) actuating the handle of the plunger of said system so as to move said plunger from said first to said second position.

21. The method as defined in claim 20 wherein said actuating step comprises rotating said handle around the longitudinal axis of said system.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of illustrative embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Those skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. The features illustrated or described in connection with one exemplary embodiment can be combined with the features of other embodiments. Such modifications and variations are intended to be included within the scope of the present invention.

[0019] FIG. 1 is a cross-sectional view of an exemplary system of the present invention connected to a bioreactor and with the probe inserted.

[0020] FIG. 2 is a cross-sectional view of an exemplary the second end of the plunger, which is in the form of a spike, advancing towards the sterile face connection and then the septum leading into the sterile vessel.

[0021] FIG. 3 illustrates exemplary configurations of the plunger having a spike configuration at its second end (A-C) and examples of probe sheaths suitable for use in the system of the invention (D-E).

[0022] FIG. 4 is a cross-sectional view of an exemplary second end of the plunger having a flat configuration.

[0023] FIG. 5 shows a cross-sectional view of an exemplary second end of the plunger having a small septum spike as its second end.

[0024] FIG. 6 is the plunger of FIG. 5 following insertion through the septum and into the sterile vessel.

[0025] FIG. 7 shows a sensor probe and a modified ReadyMate™ connection system that can be used as exemplary body and plunger parts of the invention. A bioreactor with a sterile face connector is also shown, including a septum into which the probe can be inserted.

[0026] FIG. 8 shows an exemplary system of the invention with the probe secured within an insertion of the sensor probe and modified ReadyMate™ connection system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] To more clearly and concisely describe and point out the subject matter of the claimed invention, the following definitions are provided for specific terms used throughout the present specification and claims. Any exemplification of specific terms herein should be considered as non-limiting examples.

[0028] The term “sterile probe” refers to a device useful in the measurement of one or more physical, chemical or biological properties of a substance, in particular where that substance is a solution, where the device has been sterilized. The term “probe” may be used interchangeably with the word “sensor”. The present invention is suitable for insertion of any sterile probe into a sterile vessel, but is particularly suitable for the insertion of a pre-sterilized probe, i.e. one that requires a means of sterilization other than ionizing gamma radiation or heat, e.g. sterilization using ethylene oxide.

[0029] A “sterile vessel” can be any vessel having a sterile interior. More particularly the term sterile vessel is intended to cover any vessel used to contain a particular biological material without being contaminated by any other biological material. Such a vessel may also be known as a “biocontainer” and non-limiting examples include bioreactors, intermediate reactor vessels and bioprocessing devices. In a particular example, a sterile vessel can be a flexible bag contained within a rigid holder (e.g. made from stainless steel)

[0030] The “body” of the system of the invention is a substantially rigid and cylindrical component.

[0031] The term “substantially” as used herein encompassing the pure definition of the term with which it is used as well as embodiments that can for the most part be defined as that particular term.

[0032] The term “sterile face connection” as used herein refers to any means permitting the sterile connection, or “mating” of two opposing planar surfaces. Commonly-used sterile face connections are single-use aseptic connections, a non-limiting example of which is the Readymate™ connector.

[0033] The term “plunger” as used herein is taken to mean a component, substantially rigid and cylindrical like the above-described body, but configured to moveably fit within said body. The term “moveably” is intended to refer generally to the property of being able to be moved by hand with relative ease, applying a routine level of effort to permit movement of the plunger in a direction along the central axis of the body. The term “diameter less than” in this context can be understood more specifically to mean of a diameter only slightly less than, e.g. such that when seals are fitted to the outer surface of the plunger a liquid-tight seal is formed.

[0034] The term “channel” as used herein is taken to mean a substantially tubular passage within which a component or a substance can be contained.

[0035] The term “secured within” used herein to describe the relationship of the sterile probe with the inner channel of the plunger is intended to mean secured to the extent that with any routine movement of the plunger, the sterile probe is also moved. Means for securing the sterile probe within the plunger might include use of adhesive or connectors applied between the sterile probe and the inner surface of the plunger, or by using a variety of other securing means well-known to the skilled person, as long as said means does not interfere with the normal operation of the probe.

[0036] The term “electrical connection” refers to any well-known means connecting the sterile probe to a supply of electricity suitable to permit functioning of the probe.

[0037] The term “handle” refers to an attachment that allows movement to be applied by hand. While a variety of configurations are possible, the handle should be strong enough to transmit the force required to move the plunger within the body, long enough so that a hand can grip it reliably to exert that force, and sufficiently small so that a hand can surround it enough to grip it as solidly as required to exert that force.

[0038] The term “sterilization port” refers to an opening in said body that allows the penetration of sterilizing gas, e.g. ethylene oxide or peroxide, into the sterile bore (11). This is facilitated through a sterile porous barrier, a non-limiting example of which is Tyvek™.

[0039] The term “thread” as used in connection with the plunger and the handle in certain embodiments refers to co-operating screw threads, one on certain parts of the outer surface of the plunger and one on the internal surface of the handle. Such threads are well-known in the mechanical arts to convert rotational force into linear movement, as applied in certain embodiments of the present invention.

[0040] The term “notch” means an indentation or incision on an edge or surface. Specifically in the context of the present invention a notch is configured to be received into a recess, for example to permit two elements to be associated with or to co-operate with each other.

[0041] The term “cam” as used herein refers to a rotating piece used to transform rotary motion into linear motion.

[0042] The term “locked” as used herein refers to being rigidly fixed or immovable. Specifically the term is used to refer to wherein the plunger is locked into the second position, wherein the probe is positioned within the sterile vessel. Examples of locking mechanisms suitable for application to the present invention are described in U.S. Pat. No. 7,927,316.

[0043] The term “sheath” refers to a close-fitting protective cover for the sensor end of the probe that at the same time as protecting the sensor allows liquid to flow and contact the sensor allowing it to function. Non-limiting examples of sheaths suitable for use with the present invention are illustrated in FIGS. 3D and 3E.

[0044] In a first aspect the present invention provides a system (1) for insertion of a sterile probe (30) into a sterile vessel (2) wherein said system comprises: [0045] (i) a body (10) formed of plastic and having a sterile bore (11) formed through at least a portion of its interior, the body (10) having a first (12) and second (13) end, the second end (13) comprising a body sterile face connection (14); [0046] (ii) a plunger (20) formed of plastic and contained within the sterile bore (11) of the body (10), the plunger (20) having a shape substantially corresponding to that of said sterile bore (11) and being of a diameter less than said sterile bore (11), the plunger (20) also having an inner channel (21) opening onto a first aperture (22) on a first end (24) of said plunger (20) and a second aperture (23) on a second end (25) of said plunger (20), wherein said first (24) and second (25) ends of said plunger (20) correspond respectively to said first (12) and second (13) ends of said body (10), and wherein said plunger (20) is moveable between a first position and a second position; [0047] (iii) a sterile probe (30) secured within the inner channel (21) of said plunger (20) wherein said sterile probe (30) comprises an electrical connection end (31) substantially aligned with said first end (24) of said plunger (20), a sensor end (32) substantially aligned with said second end (25) of said plunger (20), and a sensor body (33) therebetween; [0048] (iv) one or more seals (40, 41, 42) between the plunger (20) and the sterile bore (11) to form a liquid-tight seal between various portions of the plunger (20) and the sterile bore (11); and, [0049] (v) a handle (50) cooperating with said plunger (20) to direct movement of said plunger (20) within the sterile bore (11) between said first position and said second position.

[0050] In one embodiment of the system (1) of the invention the sterile probe (30) is selected from the group comprising metabolic, biologic, and physical sensors. In another more particular embodiment, said sterile probe is a glucose sensor, a lactate sensor, a pH sensor, a temperature sensor, a conductivity sensor or a cell mass and cell viability sensor.

[0051] In one embodiment of the system (1) of the present invention, each of said body (10) and said plunger (20) is independently formed of a plastic selected from the group consisting of polyetherimides (PEI), polyetheretherketone (PEEK), polyetherketone (PEK), polysulphones, polyarylsulphones, polyalkoxysulphones, polyethersulphones, polyphenyleneoxide, polyphenylenesulphide, polycarbonate, and blends thereof.

[0052] In one embodiment of the system (1) of the present invention illustrated in FIG. 1, said body (10) further comprises a sterilization port (15).

[0053] In one embodiment, the system (1) of the present invention further comprises one or more seals (70, 71) between the sterile probe (30) and the inner channel (21) of said plunger (20).

[0054] In one embodiment of the system (1) of the present invention said handle (50) is rotated around the longitudinal axis of said system (1) to direct movement of said plunger (20) within the sterile bore (11) between said first position and said second position. In a particular embodiment the movement of the plunger is linear.

In one embodiment of the system (1) of the present invention, between said first end (24) and said one or more seals (40, 41, 42), said plunger (20) comprises a plunger thread (26) on its outer surface, said handle (50) comprises a central opening (52) of dimensions suitable to accommodate the width of said plunger (20) and wherein said central opening (52) comprises a handle thread (51) that cooperates with said plunger thread (26) such that rotational movement of said handle (50) directs the movement of said plunger (20) within the sterile bore (11) between said first position and said second position. An example of this embodiment is illustrated in FIG. 1.

[0055] In one embodiment of the system (1) of the present invention said central opening (52) further comprises a recess (53) and said body (10) comprises a first notch (16) protruding outwardly from its surface and located substantially at its first end (12), wherein said first notch (16) is received in said recess (53).

[0056] In one embodiment of the system (1) of the present invention said body (10) further comprises a second notch (16a) protruding outwardly from the surface of said body (10) wherein said second notch (16a) provides mechanical support to the interaction of said first notch (16) and said recess (53).

[0057] In one embodiment and as illustrated in FIGS. 7 and 8, the system (1) of the present invention further comprises a cam (60) formed on an outer surface of the plunger (20) and contained within a cam slot (61) defined by the body (10), wherein said cam (60) is moveable between a first position within said cam slot (61) and a second position within said cam slot (61) and wherein said first position of said plunger (20) is concurrent with said first position of said cam (60) in said cam slot (61), and said second position of said plunger (20) is concurrent with said second position of said cam (60) in said cam slot (61).

[0058] In one embodiment of the system (1) of the present invention said plunger (20) is locked into said second position.

[0059] In one embodiment of the system (1) of the present invention the sensor end (32) of said sterile probe (30) comprises a sheath (32a, 32b).

[0060] In a second aspect, the present invention provides a sterile vessel (2) comprising one or more of the system (1) of the invention as defined hereinabove. FIGS. 2 and 4-7 illustrate examples of how a system (1) of the first aspect of the invention is connected to a sterile vessel (2).

[0061] FIG. 2 shows an exemplary arrangement of the second end (13) of the body (10) and the corresponding second end (25) of the plunger (20) of the system (1) of the present invention. In FIG. 2 the body sterile face connection (14) and the vessel sterile face connection (14a) have been connected to create a sterile path (8) through which the plunger (20) can pass before piercing the septum (7) to enter the sterile vessel (2).

[0062] FIG. 4 also shows an example of how the second end (13) of the body (10) and the corresponding second end (25) of the plunger (20) may be positioned with respect to the sterile vessel (2) once the sterile face connectors (14, 14a) have been connected to create a sterile path (8) between the system (1) of the invention and the sterile vessel (2). The plunger (20) illustrated in FIG. 4 has a flat second end (25).

[0063] Another exemplary plunger configuration is illustrated in FIG. 5 wherein the second end (25) of the plunger (20) is formed into a spike of narrower diameter to the main body of the plunger (20). A hole in the second end of the plunger allows the probe (30) contained therein (not visible in FIG. 5) to come into contact with liquid in the sterile vessel (2) once inserted through the septum (7). FIG. 6 shows the arrangement of FIG. 5 but where the plunger (20) has pierced the septum (7) and its second end (25) is within the sterile vessel (2).

[0064] A selection of other spike arrangements is shown in FIGS. 3A-C. FIG. 3A shows a spike having an opening to the side to permit fluid flow into the sensor. FIG. 3B shows a spike at the second end of the plunger wherein the sensor lies nonaxially away from the spike in order to protect it as the plunger pierces the septum. Alternatively, where the sensor can withstand being pierced into the septum, an arrangement such as illustrated in FIG. 3C may be considered where the sensor is positioned axially in the plunger and protrudes from the second end of the plunger to act as a point.

[0065] FIGS. 3D and 3E show examples of probe sheaths that may be used to protect a delicate sensor while still permitting fluid to come into contact with the sensor. Such probe sheaths can also act as a point that protrudes from the second end of the plunger helping to pierce the septum.

[0066] The septum is a film or seal that can be punctured by the plunger and probe arrangement. In one embodiment, the septum creates a liquid-tight seal around the plunger after the plunger has pierced the septum so that no liquid from the sterile vessel enters the path between the system and the sterile vessel, i.e. no backward leaking. Suitable septa for use with the present invention will be well-known to those of skill in the art, e.g. made from an elastomeric material such as rubber or silicone.

[0067] In one embodiment the sterile vessel (2) of the invention is a biocontainer. In a more particular embodiment, the sterile vessel (2) is a bioreactor. In yet more particular embodiment the sterile vessel (2) is a flexible bag supported within a rigid holder. An example of this latter arrangement is illustrated in FIG. 1 where the inside of the flexible bag is shown by reference number (2), the wall of the bag by reference number (3), and the wall of the rigid holder by reference number (4). FIG. 1 also illustrates in cross-section an example of the system (1) where said sterile vessel comprises a wall (3) including a vessel sterile face connection (14a) and wherein said system (1) is connected to said sterile vessel (2) by mating said body sterile face connection (14) of said body (10) with said vessel sterile face connection (14a).

[0068] In one embodiment the sterile vessel (2) of the present invention comprises a wall (3) including a vessel sterile face connection (14a) and wherein the system (1) of the invention is connected to the sterile vessel (2) by mating said body sterile face connection (14) of the body (10) of said system (1) with said vessel sterile face connection (14a). In one embodiment, the body sterile face connection (14) and said vessel sterile face connection (14a) is each a single-use aseptic connection.

[0069] The system of the present invention allows for the placement of a sterile probe into a sterile vessel even when the sterile vessel is full. This is an advantage as it is preferred to insert expensive sensors after integrity testing of the sterile vessel. The presence of a septum on the side of the sterile vessel is helpful in this context as it acts to prevent the head pressure exerted by liquid in the vessel on the sterile face connection, which at least in the case of certain sterile face connectors may be relatively weak.

[0070] In one embodiment, the sterile vessel of the invention includes more than one of the system of the invention. This can be of particular use where the sterile vessel is relatively large. For example, when the sterile vessel is a 2000L bioreactor bag, a problem can be very expensive to fix. Another scenario where this would be useful is where the sterile vessel is being used for a process that takes a relatively long time, i.e. beyond the life of just one probe. Having the facility to simply add a new probe at another site on the sterile vessel wall overcomes any issues encountered due to failures or life of the probe arrangement.

[0071] In a third aspect, the present invention provides a method for the insertion of a sterile probe (30) into a sterile vessel (2) wherein said sterile probe (30) is provided along with the system (1) of the invention as defined herein and wherein said sterile vessel (2) comprises a vessel sterile face connection (14a), wherein said method comprises: [0072] (a) mating said body sterile face connection (14) of the body (10) of said system (1) with said vessel sterile face connection (14a); [0073] (b) actuating the handle (50) of the plunger (20) of said system (1) so as to move said plunger (20) from said first to said second position.

[0074] In one embodiment, of the method of the present invention said actuating step comprises rotating said handle (50) around the longitudinal axis of said system (1).

[0075] All embodiments of the system (1) of the invention as described hereinabove are equally applicable to the sterile vessel (2) and the method of the invention.

[0076] One skilled in the art will appreciate further features and advantages of the invention based on the above-described embodiments. Accordingly, the invention is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety.