Differential Air Flow System for Promoting Bottom-Up Freezing of Blood Plasma in Compressed Bags

Abstract

This disclosure relates to a method and system for fast freezing of a biological product (such as blood plasma) contained in an individual bag or a plurality of bags. This disclosure relates to a method and system for freezing plasma in an individual bag or a plurality of bags, favoring bottom-up ice-growth, by implementing a differential air flow on top and bottom surfaces of a horizontally placed bag or bags filled with plasma. This disclosure relates to a method and a differential air flow system for freezing plasma, wherein the heat transfer coefficient on a bottom of a bag is at least 10 times larger than at a top. This disclosure relates to a differential air flow system and method for freezing plasma, wherein the differential air flow on top and bottom surfaces of a plasma bag is imposed by at least one fan or blower.

Claims

1. A method for freezing biological fluid in a bag, favoring bottom-up ice-growth, comprising the following steps: providing a controlled temperature chamber having cold air at a temperature sufficient to freeze the biological fluid; placing an air flow system into the controlled temperature chamber; placing the bag or a case containing the bag on a support of the air flow system; compressing the placed bag or case against the support; and driving the cold air inside the controlled temperature chamber using the air flow system in order to obtain a differential air flow for freezing the biological fluid in the bag, wherein the differential air flow is obtained by blowing the cold air below the compressed bag or case such that the velocity of the cold air below the bag or case is higher than the velocity of the cold air above the bag or case, allowing bottom-up ice-growth of the biological fluid in the bag.

2. The method of claim 1, wherein the heat transfer coefficient of the freezing biological fluid at a bottom of the bag is at least 10 times larger than at a top of the bag.

3. (canceled)

4. The method of claim 2, wherein the heat transfer coefficient at the top of the bag is less than 5 W/(m.sup.2.° C.) and the heat transfer coefficient at the bottom of the bag is greater than 20 W/(m.sup.2.° C.), wherein the velocity of the cold air below the bag or case is in a range from approximately 1 m/s to approximately 10 m/s.

5. The method of claim 4, wherein the heat transfer coefficient at the top of the bag is less than 2 W/(m.sup.2.° C.) and the heat transfer coefficient at the bottom of the bag is greater than 50 W/(m.sup.2.° C.), wherein the velocity of the cold air below the bag or case is in a range from approximately 2 m/s to approximately 8 m/s.

6. The method of claim 1, wherein the air flow system comprises a fan and a flow conveyor, and the differential air flow is further obtained by blowing the cold air through the flow conveyor and at a bottom of the bag or case or at the support using the fan.

7. The method of claim 1, wherein the support is a heat transfer plate.

8. (canceled)

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. An air flow system for placing in a controlled temperature chamber having cold air at a temperature sufficient to freeze biological fluid in a bag, favoring bottom-up ice-growth, comprising: a support for holding the bag or a case containing the bag; and compression means to compress the held bag or case against the support, wherein the air flow system is configured to drive the cold air inside the controlled temperature chamber in order to obtain a differential air flow for freezing the biological fluid in the bag, wherein the differential air flow is obtained by blowing the cold air below the compressed bag or case such that the velocity of the cold air below the bag or case is higher than the velocity of the cold air above the bag or case, allowing bottom-up ice-growth of the biological fluid in the bag.

15. (canceled)

16. The air flow system according to claim 14, wherein the heat transfer coefficient at a top of the bag is less than 5 W/(m.sup.2.° C.) and the heat transfer coefficient at a bottom of the bag is greater than 20 W/(m.sup.2.° C.).

17. (canceled)

18. (canceled)

19. The air flow system according to claim 14, further comprising at least one fan and a controller for controlling a velocity of the at least one fan.

20. The air flow system according to claim 19, further comprising a flow conveyor to drive the cold air from the at least one fan to a bottom surface of the compressed bag or case.

21. (canceled)

22. (canceled)

23. The air flow system according to claim 14, wherein the bag comprises a plurality of bags arranged in a horizontal plane configuration on the support, or the bag comprises a plurality of bags contained in a corresponding plurality of cases arranged in a horizontal place configuration on the support, or the bag comprises a plurality of bags contained in a corresponding plurality of cases arranged in a vertical stacked configuration on the support and comprising at least 2 layers, each layer including at least one of the plurality of cases.

24. (canceled)

25. (canceled)

26. (canceled)

27. The air flow system according to claim 23, wherein the plurality of cases are arranged in the vertical stacked configuration and further comprise air flow channels between layers to allow the cold air to flow such that in each layer, a bottom of each bag or case in the layer is exposed to a higher velocity of the cold air flow than a top of the bag or case.

28. (canceled)

29. The air flow system according to claim 14, wherein the support comprises fins.

30. The air flow system according to claim 29, wherein the support and the fins are made of high heat conductive material.

31. The air flow system according to claim 19, wherein the support presents a horizontal surface to the compressed bag or case, and the at least one fan drives the cold air in a direction parallel to the horizontal surface.

32. (canceled)

33. The air flow system according to claim 14, further comprising a case to receive a bag, wherein a bottom of the case has an opening or a thin film of a high heat conductive material.

34. The air flow system according to claim 14, further comprising a case to receive a bag, wherein the case is made of a low heat conductivity material.

35. The air flow system according to claim 14, further comprising a case to receive a bag, wherein a top of the case has a layer of a low heat conductive material.

36. (canceled)

37. The air flow system according to claim 14, wherein the compressing means is made of a rigid material with low heat conductivity.

38. (canceled)

39. The air flow system according to claim 14, further comprising an automated mechanical actuator to operate the compressing means.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0046] These and other objects, features and advantages of the disclosure will be evident from the following detailed description when read in conjunction with the accompanying drawings.

[0047] FIG. 1 shows the recovery of the Factor VIII, after freezing two plasma bags inside a controlled temperature chamber at −45° C., by using a differential air flow system for promoting the bottom-up ice-growth, according to the present disclosure.

[0048] FIG. 2 shows a schematic representation of a differential air flow 200 system for freezing bags 100, favoring bottom-up ice-growth, wherein the heat transfer coefficient on the bottom 101 of the bag is larger than in the top 102.

[0049] FIG. 3 is schematic and elevated view of a differential air flow system for bags 100 by implementing a differential air flow 200 on the upper 102 and bottom 101 surface of the bag 100 placed in a support 500, by using a fan 300, according to the present disclosure.

[0050] FIG. 4 is an elevated cross-section view of a differential air flow system with a flow conveyor 400, with an entry 401, a channel 402 and an exit 403, to drive the air from the fan 300 through the fins 501 connected to the support 500, to obtain the maximum heat transfer from the air to the support 500, and consequently to the bottom 101 of the bag 100.

[0051] FIG. 5 is an elevated cross-section view of a differential air flow system, showing the support 500 connected to the fins 501 to transfer the heat to the bottom of the bag 100, according to the present disclosure.

[0052] FIG. 6 is an elevated view of a differential air flow system for freezing a plurality of bags 100, comprising a plurality of fans 300, according to the present disclosure.

[0053] FIG. 7A is a bottom view of a case 600 to receive a bag 100, with an opening 601 at the bottom to promote the heat transfer in the bottom surface 101 of the bag.

[0054] FIG. 7B is an elevated cross-section view of a case 600 to receive a bag 100, with an additional layer 602 of a low heat conductive material in the top of the case.

[0055] FIG. 8 is an elevated view of a differential air flow system for freezing a plurality of bags 100 inside cases 600, with a compressing means 700 to compress the bags.

[0056] FIG. 9 is an exploded elevated view of the system.

[0057] FIG. 10 is a cross-section view of the system.

[0058] FIG. 11 is a cross-section view of the system.

[0059] FIG. 12 is a bottom view of the system.

[0060] FIG. 13 is an elevated view of the system.

[0061] FIG. 14 is a cross-section view of the system in a different configuration. 402 represents the channel for air flow 200.

[0062] FIG. 15 is an elevated view of the system in a different configuration.

DETAILED DESCRIPTION

[0063] In this section, it will be described the fundamentals of the operation of the object of disclosure and of proposed embodiments.

[0064] As described above, one of the major limitations of preservation of biological liquids, such as blood plasma, is the freezing step. During freezing, using the existing methods and equipment, the ice growth from the walls to the middle of the container, and the solutes will be increasingly concentrated in the middle of the plasma bag, and the molecules of Factor VIII will be exposed to a high concentration of salts, resulting in their inactivation and thus loss of Factor VIII. Therefore, we found that by applying a differential air flow (different air flow velocities) on the top and bottom surfaces of a plasma bag (horizontally placed), and by favoring heat transfer from the bottom, a bottom-up freezing geometry was achieved, leading to a high recovery of the Factor VIII (FIG. 1). In this disclosure, differential air flow means that the heat transfer coefficient on the bottom of the bag is different from the heat transfer coefficient on the top of the bag, preferentially the heat transfer coefficient on the bottom of the bag is 10 times larger than in the top, to favor a bottom-up freezing geometry. If we control different heat transfer coefficients, we do not need to control different temperatures, or even add insulation, to achieve the bottom up-freezing geometry. In fact, to attain different heat transfer coefficients, we only need to apply a differential air flow by blowing more air on the bottom of the bag than the top. This method greatly simplifies the system herein disclosed compared to existing systems. Any chamber with controlled temperature can be converted into a high-efficiency, low-maintenance plasma freezer.

[0065] Therefore, herein, it is disclosed a method and system for freezing an individual bag 100 or a plurality of individual bags, favoring bottom-up ice-growth, by implementing a differential air flow 200 on the upper 102 and bottom 101 surface of a bag horizontally placed. (see FIG. 2 for example illustration)

[0066] It is also disclosed a differential air flow system to attain the previously described method, favouring bottom-up ice-growth, by implementing a differential air flow 200 on the upper 102 and bottom 101 surface of a plasma bag 100. In a preferred embodiment, the differential air flow 200 on the upper 102 and bottom 101 surface of a plasma bag 100 is imposed by at least one fan 300. In the embodiment, a fan or a blower can be used, preferentially a fan is used. In another embodiment, the differential air flow system may comprise a plurality of fans, preferably one fan per bag. In a preferred embodiment, said fan should be suitable for use in a cryogenic environment. In another embodiment, the velocity of the fan may be controlled to conveniently increase or decrease the heat transfer accordingly to the freezing process. In a preferred embodiment, the velocity of the fan is controlled so that the heat transfer coefficient on the bottom of the bag is 10 times larger than in the top. In another embodiment, the heat transfer coefficient on the top of the bag must be less than 5 W/(m.sup.2.° C.), preferentially less than 2 W/(m.sup.2.° C.); and the heat transfer coefficient on the bottom of the bag must be higher than 20 W/(m.sup.2.° C.), preferentially higher than 50 W/(m.sup.2.° C.). (see FIGS. 2 to 8 for example illustration)

[0067] In another embodiment, the differential air flow system comprises a flow conveyor 400 to drive the air from the fan 300 to the bottom 101 surface of the plasma bag. In an embodiment, the flow conveyor 400 may have an entry 401 to the air from the fan 300, a channel 402 through bottom of the bag to drive the air and an exit 403 to the air. In a preferred embodiment, the air within the flow conveyor has a velocity in a range from approximately 1 m/s to approximately 10 m/s, and more preferably from approximately 2 m/s to approximately 8 m/s. In a preferred embodiment, the flow conveyor is made of a low heat conductivity, such as plastic, polymer or other material having low conductivity. (see FIGS. 4 to 8 for example illustration)

[0068] In an embodiment, the differential air flow system comprises a support 500 to receive the bag 100. In a preferred embodiment the support 500 is a grid or a solid metal plate. In an embodiment, the support 500 may comprise fins 501 to obtain the maximum heat transfer from the air to the support 500, and consequently to the bottom 101 of the bag. The fins 501 might be attached to the support 500 by means of screws, any type of glue or paste, or by other means, assuring a good thermal conductivity. The fins may have several configurations, assuring the maximum heat transfer from the air to the support. The support and the fins may be made of high heat conductive materials such has aluminum, stainless steel, copper, or other. The dimensions of the support may vary so it can receive one bag or several. The thickness of the support can be from 1 mm up to 10 mm. The support dimensions in a specific configuration are such to have in account the characteristics from the entire system, allowing to have a well-known global thermal conductivity and inertia. (see FIGS. 4 to 8 for example illustration)

[0069] In another embodiment, the flow conveyor is designed accordingly to the support and fins to obtain the maximum heat transfer from the air to the bottom of the bag.

[0070] In another embodiment, the fan 300 or a plurality of fans, is perpendicular to the support, directly connected to the flow conveyor 400. In another embodiment, the fan 300 or a plurality fans, can be located below the support 500 and the fins 501. In another embodiment, the differential air flow system may comprise a plurality of fans, preferably one fan per bag. (see FIGS. 2 to 8 for example illustration)

[0071] One exemplary embodiment of the present disclosure is a case 600 to receive a bag 100, for increasing the freezing consistency, to prevent the nucleation on the top of the bag when compressed and for protection during the freezing and storage of the bag. In a preferred embodiment, the case 600 may have an opening 601 at the bottom to promote the heat transfer in the bottom surface 101 of the bag. The case can be made of polymers, paperboard or other materials that have low heat conductivity. In another embodiment, the case can be made of a compressible material, so that when an even-distributed pressure is applied, the case maintains its integrity. Preferably, the case is made of materials that maintains its integrity even at low temperatures, as for example −50° C. In another embodiment, the bottom surface of the case may have an opening or a thin film of a high heat conductive material, such as aluminum, to assure the heat transfer to the bottom of the bag inside the case. In another embodiment, the top surface of the case may have an additional layer 602 of a low heat conductive material in order to prevent the nucleation at the top of the bag. In another embodiment, the case can also have embodiments from any other materials with several functionalities. For example, the case may have an additional opening to assure the reading of information in the bag. The case may have a barcode or a chip to identify the sample. In an embodiment, the case can be designed accordingly to the bag used. In another embodiment, the case can be designed to receive one bag or a plurality of bags. (see FIG. 7 for example illustration)

[0072] In an embodiment, the heat transfer coefficient on the top of the case 600, which is the thermal conductivity of the material divided by its thickness 602, must be less than 5 W/(m.sup.2.° C.), preferentially less than 2 W/(m.sup.2.° C.). In an example, if the case 600 is made of corrugated cardboard (with an average thermal conductivity of 0.064 W/m.° C.), the top of the case 602 must have 1.2 cm of thickness, to obtain a heat transfer coefficient of 5 W/(m.sup.2.° C.). In another example, if we use extruded polystyrene (with an average thermal conductivity of 0.025 W/m.° C.) and maintaining the same thickness, we obtain a heat transfer coefficient of W/(m.sup.2.° C.).

[0073] In another embodiment, the differential air flow system comprises a compressing means 700, to compress the bag 100 or the case 600, to increase the contact of the bottom 101 surface against the support 500. In an embodiment, the compressing means is made of a rigid material with low heat conductivity, such as plastic, polymer or other material having high rigidity and low conductivity. In a preferred embodiment, the compressing means is made of a transparent material. In another embodiment, the compressing means 700 may have a furrowed surface 701 in contact with the bag or case, to minimize the heat transfer to the top of the bag. In a preferred embodiment, the compressing means may have a rib- or wave-pattern on the surface 701 in contact with the bag or case. This pattern will allow a good contact to compress the box, while decreasing the heat transfer to the top of the bag, preventing the nucleation on the top. (see FIG. 8 for example illustration)

[0074] In another embodiment, the compressing means may mechanically actuate to compress the bag or case against the support. The compressing means have two positions, open or closed. In an embodiment, the open position is set to load or unload the bags/cases in the differential air flow system and the closed position is set to compress the bags/cases against the support to allow a good heat transfer on the bottom surface of the bag. Moreover, when setting close the compressing mean, all the bags will achieve the same format, allowing a homogenous and reproducible freezing in a plurality of bags. In another embodiment, the compressing means can also be operated by an automated mechanical actuator.

[0075] In a preferred embodiment, the method and system herein disclosed, are designed to be used inside a controlled temperature chamber. The controlled temperature chamber can have or not convection and may be cooled or heated. Briefly, by using the method and differential air flow system herein described, the cold air inside the controlled temperature chamber, will be driven by the fans and the flow conveyor to the fins and to the support, cooling it. When the support is cooled, the case containing the bag is placed on the support, promoting the heat transfer from the support to the bottom of the bag. Finally, the case with the bag is compressed by compressing means, increasing the contact of the bottom bag with the support. This method and differential air flow system will enable the bottom-up ice-growth in a plasma bag, while assuring its homogeneity and integrity.

[0076] In a preferred embodiment, the method and system here disclosed allows to use any controlled temperature chamber for freezing of an individual bag or a plurality of individual bags containing a biological product, in particular blood plasma.

[0077] In a preferred embodiment, the present disclosure relates to a method for freezing plasma bags by using a differential air flow system for promoting the bottom-up ice-growth, comprising: [0078] providing a controlled temperature chamber; [0079] placing the differential air flow system into the controlled temperature chamber; [0080] driving the cold air inside the controlled temperature chamber, by the fans and the flow [0081] conveyor to the fins and to the support, cooling it; [0082] placing the bag or the case containing the bag horizontally on the support; [0083] compressing the bag or the case against the support by the compressing means; [0084] freezing the bag.

[0085] In an embodiment, a temperature probe may be located at one or more points of the differential air flow system or within a case. The temperature probe may provide an indication of the time-temperature profile during the freezing process. The temperature probe may comprise a thermocouple, a thermistor, or other conventional temperature sensing devices suitable for use in a cryogenic environment.

[0086] In another embodiment, an air velocity probe may be located at one or more points of the differential air flow system, preferentially in the flow conveyor, to provide information about the air flow velocity at a particular location. The air velocity probe may comprise an anemometer, pitot tube, or other conventional sensing devices suitable for use in a cryogenic environment.

[0087] In an embodiment, the method and differential air flow system of the present invention may be used not only for freezing, but also for thawing.

[0088] In an embodiment, as illustrated in FIG. 9 as an exploded view and in FIG. 10 and FIG. 11 as a cross-section view, the present disclosure describes a case 600 to receive a bag 100 that can be used for freezing, transport, storage and/or thawing. In an embodiment, the case 600 may have a heat transfer plate 604 at the bottom to promote the heat transfer in the bottom surface 101 of the bag. The heat transfer plate 604 at the bottom surface of the case 600 could be made of a high heat conductive material, such as aluminium, to assure the heat transfer to the bottom of the bag inside the case.

[0089] In an embodiment, as illustrated in FIGS. 9 and 12, the heat transfer plate 603 at the bottom may further comprise perforated holes 604 to achieve a high heat transfer coefficient at the edges of the bag thus ensuring nucleation and uniform bottom-up freezing. In addition, the perforated plate allows the air to flow through the tubes 605 of the bag, promoting its controlled freezing.

[0090] In an embodiment, as illustrated in FIG. 10, the heat transfer plate 603 at the bottom surface is configured to ensure a good thermal contact with the bottom and edged of the bag. The heat transfer plate can be shaped or folded depending on the shape of the bag 100.

[0091] In an embodiment, as illustrated in FIG. 11, the metal plate 603 is configured to cover the whole case to function as a heat transfer plate at the bottom of the bag 101 and also for physical protection of the whole case 600.

[0092] In an embodiment, the case 600 is made of polymers or materials that have low heat conductivity. For example, the case may be made of extruded polystyrene.

[0093] In an embodiment, as illustrated in FIG. 9, FIG. 10 and FIG. 11, an additional layer of a phase-change material 606 may be placed at the top surface of the bag 102 in order to further prevent ice growth at the top of the bag, while promoting bottom-up freezing.

[0094] In an embodiment, as illustrated in FIG. 9 and FIG. 13, the bottom of the case 600 is configured to receive the bag 100 and the tubing assembly 605 ensuring that the tubes are fixed in place.

[0095] In an embodiment, the case 600 comprises a top lid 607 to close the case. The case can also be used as a carried to transport the bag.

[0096] In an embodiment, as illustrated in FIG. 14 as a cross-section view and FIG. 15 as an elevated view of the system, the system may be configured in a stacked configuration. The cases are configured to be stacked so that multiple cases may be used at the same time. The cases 600 in the stacked configuration are configured such that they comprise channels 402 for driving the air flow 200 from the bottom of the bag placed in a first case, to the bottom of the bag in a second case that is stacked immediately vertically on top of the first case. FIG. 14 illustrates how the differential air flow 200 circulates in the system configured in a stacked configuration. 402 represents the channel for air flow 200.

[0097] In an embodiment, the stacked configuration of the system comprises multiple layers, preferably at least 2 layers, more preferably at least 3 layers.

[0098] The term “bottom of the bag” whenever used in this document is intended to refer to the portion of the bag that is in contact with the higher air flow velocity, or the heat transfer plate, or the support on which the bag is placed on.

[0099] The term “comprising” whenever used in this document is intended to indicate the presence of stated features, integers, steps, components, but not to preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0100] It will be appreciated by those of ordinary skill in the art that unless otherwise indicated herein, the particular sequence of steps described is illustrative only and can be varied without departing from the disclosure. Thus, unless otherwise stated the steps described are so unordered meaning that, when possible, the steps can be performed in any convenient or desirable order.

[0101] The disclosure should not be seen in any way restricted to the embodiments described and a person with ordinary skill in the art will foresee many possibilities to modifications thereof.

[0102] The above described embodiments are combinable. The following claims further set out particular embodiments of the disclosure.