Method and Apparatus for Cleaning of Viable Donor Soft Tissue
Year:
Abstract:
A process for cleaning donor soft tissue by removing contaminants by extraction using a fluid at supercritical temperature and pressures while preserving the integrity of the tissue.
Type of document:
Language:
(12) United States Patent
Burns et al.
US008034288B2
US 8,034,288 B2
Oct. 11, 2011
(10) Patent No.:
(45) Date of Patent:
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METHOD AND APPARATUS FOR CLEANING
OF VIABLE DONOR SOFT TISSUE
Inventors: David C. Burns, Ithaca, NY (US);
Anthony R. Eisenhut, Lansing, NY
(US); Renee Christopher, Dryden, NY
(US); Tim W. Christensen, Greenville,
NC (US)
Assignee: Novasterilis, Lansing, NY (US)
Notice: Subject to any disclaimer, the term of this
patent is extended or adjusted under 35
U.S.C. 154(b) by 390 days.
Appl. No.: 12/019,047
Filed: Jan. 24, 2008
Prior Publication Data
US 2008/0166266 A1 Jul. 10,2008
Related U.S. Application Data
Continuation-in-part of application No. 11/515,926,
filed on Sep. 6, 2006, now abandoned, which is a
continuation of application No. 10/869,052, filed on
Jun. 17, 2004, now Pat. No. 7,108,832.
Provisional application No. 60/480,410, filed on Jun.
23, 2003.
Int. Cl.
A61L 2/20 (2006.01)
A01N 1/02 (2006.01)
U.S. Cl. ......................................... .. 422/33; 435/1.1
Field of Classification Search .................. .. 422/33;
435/ 1 .1
See application file for complete search history.
Air
Compressor
(56) References Cited
U.S. PATENT DOCUMENTS
4,681,839 A * 7/1987 Swartz ......................... .. 435/1.1
4,944,837 A 7/1990 Nishikawa et al.
5,213,619 A 5/1993 Jackson et al.
5,370,740 A 12/1994 Chao et al.
5,422,377 A 6/1995 Aubert
5,725,579 A * 3/1998 Fages et al. ................. .. 128/898
5,851,483 A 12/1998 Nicolle et al.
5,996,155 A 12/1999 Chao et al.
6,149,864 A 11/2000 Dillow et al.
6,506,213 B1 1/2003 Mandel et al.
6,518,307 B2 2/2003 McKenzie et al.
6,613,278 B1 9/2003 Mills et al.
6,620,356 B1 9/2003 Wong et al.
6,716,457 B1 4/2004 Eagles et al.
7,033,813 B2 4/2006 Castor et al.
7,108,832 B2 9/2006 Christensen et al.
7,160,492 B2 1/2007 King
(Continued)
FOREIGN PATENT DOCUMENTS
EP 1782839 11/2005
OTHER PUBLICATIONS
Akkus et al., “Fracture Resistance of Gamma Radiation Sterilized
Cortical Bone Allografts”, Journal of Orthopaedic Research, 2001,
19: 927-934.
(Continued)
Primary Examiner — Sean E Conley
Assistant Examiner — Kevin Joyner
(74) Attorney, Agent, or Firm — Welsh Flaxman & Gitler
LLC
(57) ABSTRACT
A process for cleaning donor soft tissue by removing con-
taminants by extraction using a fluid at supercritical tempera-
ture and pressures while preserving the integrity of the tissue.
8 Claims, 1 Drawing Sheet
US 8,034,288 B2
Page 2
U.S. PATENT DOCUMENTS
7,560,113 B2 7/2009 Christensen
2003/0027125 A1* 2/2003 Mills et al. ................... .. 435/1.1
2003/0072677 A1 4/2003 Kafesjian et al.
2003/0120852 A1 6/2003 McConnell et al.
2004/0033269 A1 2/2004 Hei et al.
2010/0080790 A1 4/2010 Matthews et al.
OTHER PUBLICATIONS
Cornu et al., “Effect of Freeze-Drying and Gamn1a Irradiation on the
Mechanical Properties of Human Cancellous Bone”, Journal of
Orthopaedic Research, 2000, 18(3): 426-431.
Duffy et al., “An Epidemic of Corneal Destruction Caused by Plasma
Gas Sterilization”, Arch. Ophthalmol., Sep. 2000, 118: 1167-1176.
Godette et al., “Biomechanical Effects of Gamma Irradiation on
Fresh Frozen Allografts in Vivo”, Orthopedics, Aug. 1996, 19(8):
649-653.
Holyoak et al., “Toxic Effects of Ethylene Oxide Residues on Bovine
Embryos in Vitro”, Toxicology, 1996, 108: 33-38.
Ikarashi et al., “Cytotoxicity of Medical Materials Sterilized with
Vapour-Phase Hydrogen Peroxide”, Bion1aterials, 1995, 16(3): 177-
183.
Jahan et al., “Long-Term Effects of Gamma-Sterilization on Degra-
dation of Implant Materials”, Appl. Radiat. Isot., 1995, 46(6/7):
637-638.
Kamihira et al., “Sterilization of Microorganisms with Supercritical
Carbon Dioxide”, Agric. Biol. Chem., 1987, 51(2): 407-412.
Lin et al ., “Inactivation of Saccharomyces cerevisiae by Supercritical
and Subcritical Carbon Dioxide”, Biotechnol. Prog., 1992, 8: 458-
461.
Schiewe et al., “Toxicity Potential of Absorbed-Retained Ethylene
Oxide Residues in Culture Dishes on Embryo Development in Vitro”,
Jour. Animal Science, 1985, 60(6):1610-18.
Spilimbergo et al., “Microbial Inactivation by High-Pressure”, Jour-
nal of Supercritical Fluids, 2002, 22: 55-63.
Windebar1k et al., “Residual Ethylene Oxide in Hollow Fiber
Hemodialysis Units is Neurotoxic in Vitro”, Annals of Neurology,
Jul. 1989, 26(1): 63-68.
* cited by examiner
Oct. 11, 2011 US 8,034,288 B2
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US 8,034,288 B2
1
METHOD AND APPARATUS FOR CLEANING
OF VIABLE DONOR SOFT TISSUE
CROSS REFERENCE TO RELATED
APPLICATIONS
This application is a continuation in part of U.S. patent
application Ser. No. 1 1/ 515,926, entitled “STERILIZATION
METHODS AND APPARATUS WHICH EMPLOY ADDI-
TIVE-CONTAINING SUPERCRITICAL CARBON DIOX-
IDE STERILANT”, filed Sep. 6, 2006, which is now aban-
doned, which is a continuation of U.S. patent application Ser.
No. 10/869,052, entitled “STERILIZATION METHODS
AND APPARATUS WHICH EMPLOY ADDITIVE-CON-
TAINING SUPERCRITICAL CARBON DIOXIDE STER-
ILANT”, filed Jun. 17, 2004, which is now U.S. Pat. No.
7,108,832, which claims the benefit of U.S. Provisional
Application Ser. No. 60/480,410, entitled “STERILIZA-
TION METHODS AND APPARATUS WHICH EMPLOY
ADDITIVE-CONTAINING SUPERCRITICAL CARBON
DIOXIDE STERILANT”, filed Jun. 23, 2003.
FIELD OF THE INVENTION
The present invention relates generally to the process of
cleaning human, animal and in vitro-produced soft tissue and
an apparatus in which a supercritical fluid such as carbon
dioxide is employed as a penetrating fluid used to extract
antigenic matter that can cause an inflammatory response in
recipients. After the cleaning occurs the soft tissue is repack-
aged and then sterilized.
BACKGROUND OF THE INVENTION
The commercial viability of allograft tissues is in part a
function of the physical appearance, the biocompatibility, and
the mechanical properties of the tissue. Individuals respon-
sible for the decision to use or not use a given allograft often
evaluate the aesthetics of the product in reaching a decision.
For example, ligament allograft material that is “yellow” is
often rejected by the surgeon for implantation in favor of an
allograft that is not discolored. Likewise for soft tissue, in
particular, dermis and cardiovascular tissue, color and
appearance are deciding factors used by most surgeons in the
operating room.
Tissue banks responsible for the processing of allografts
employ many different cleaning, rinsing, soaking, and wash-
ing steps in an effort to produce a product that is safe, viable
for implantation, and commercially desirable. While many of
the steps used meet these goals, they often fall short of effec-
tively producing a commercially desirable and functional
product. This shortcoming can stem from inadequacy of the
existing process to clean the product or it may stem from
damage caused by the cleaning treatment that negatively
impacts the biological and biomechanical properties of the
allograft.
Additionally, the numerous steps required to achieve an
acceptable product for distribution add to the cost of the final
graft. These steps require extra processing time and person-
nel, and can often vary in effectiveness. Ideally a process for
preparing allografts would include a step that could preserve
the essential properties of the allograft, remove the antigenic
matter and any discoloration from the allograft, take a mini-
mum amount of processing time, prepare the allograft for
sterilization and increase the commercial desirability by posi-
tively impacting the aesthetics of the product.
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Generally, soft tissue grafts are manually cleaned to purify
them of all materials that adversely affect their implantation.
Currently, most prior art techniques are found to impair both
the biomechanical properties and inductive properties of the
soft tissue. The prior techniques used for extraction of impu-
rities disrupt the collagen network of the soft tissue by cross-
linking or degradation, further affecting the mechanical prop-
erties of the soft tissue graft. Since, the implanting of soft
tissue grafts is generally carried out for the purpose of repair-
ing damaged soft tissue or replacing an impaired soft tissue, it
is desirable to eliminate the problem of recolonization
because of reduced or minimal blood flow, which is essential.
It would therefore be advantageous to have available soft
tissue grafts with biomechanical properties that are almost
equivalent to those of natural soft tissue.
There are inherent risks involved with allografts since soft
tissue is being taken from a donor generally with an unknown
medical history. For example, an infectious disease from the
donor could be passed on to the recipient. Apart from the risks
of infection, the main complications related to the use of
allografts are rejection, inflammatory response from residual
foreign material in the transplanted graft and, when appropri-
ate, the unsuccessful recolonization of the implanted soft
tissue. The unsuccessful recolonization of the grafts today
poses a particularly significant problem.
To mitigate these risks, various attempts aiming to reduce
or eliminate these complications have been made. These pro-
cedures are generally based on the principle of extracting the
blood or blood constituents and lipids from the soft tissue
before implantation. Such residual blood or blood constitu-
ents and lipids contained in the soft tissue are the cause of
significant rejection reactions. These rejection reactions are
also related to the presence of contaminants such as endotox-
ins in the tissue.
The use of organic solvents to extract blood, blood con-
stituents and lipids from soft tissue is known. The most com-
monly used solvents are ethylene diamine, hydrogen perox-
ide, ethanol, acetone and various chlorinated solvents such as
chloroform or dichloromethane. However, the solvents used
for protein extraction are often highly toxic. Because of this
toxicity, the soft tissues must be carefully rinsed, which often
proves to be diflicult, given their density and delicate struc-
ture (collagenous network).
In accordance with the need for proper preparation of
donor soft tissue, gentle and reliable sterilization methods are
needed that result in greater than 106 log reductions of micro-
bial contaminants without impacting the properties of the
donor soft tissue being sterilized.
A need has developed for sterilization of biological tissues,
including macromolecular biopolymers, due to the common
practice of tissue implantation. However, most sterilization
techniques for soft tissue have been found to be incompatible
with the tissue. Steam and gamma radiation result in a sig-
nificant decrease in tissue integrity and soft tissue strength
due to cross-linking. Cross-linking disrupts the collagenous
network, increasing the stiffness of the collagen fibers and
decreasing the mobility of the graft. Certain antibacterial
washes have been used to disinfect tissue, but incomplete
sterilization is achieved and the washes leave residual toxic
contaminants in the tissues. Ethylene oxide also reacts with
biological tissue and is thus an undesirable sterilant for such
reason.
Recently, in U.S. Pat. No. 7,108,832, incorporated herein
by reference and commonly owned by assignee of this appli-
cation, a highly effective sterilization process is disclosed.
It therefore would be highly desirable to provide a process
for cleaning soft tissue prior to the tissue being sterilized.
US 8,034,288 B2
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SUMMARY OF THE INVENTION
The present invention relates to a process for cleaning
donor soft tissue to preserve the integrity of the soft tissue.
First, a donor soft tissue is obtained and the topical contarni-
nants are mechanically removed from the surface of the soft
tissue. The soft tissue and an absorbent material are placed
into a gas permeable package and the package sealed. The
sealed package is then introduced into a reactor pressure
vessel and supercritical fluid is introduced into the pressure
vessel. Contact between the supercritical fluid and the soft
tissue in the package is maintained while mechanically agi-
tating the fluid for a time sufficient to solubilize contaminants
contained in the soft tissue and separate the contaminants
from the soft tissue by absorption into the absorbent material.
The package is removed from the pressure vessel, and the
tissue separated from the absorbent material in the package,
thereafter the soft tissue is rinsed with a sterile solution.
The supercritical fluid used is carbon dioxide and it is
introduced and removed from the pressure vessel at a rate of
from about 0.01 to 5 psi/second.
It is an object of the present invention to provide an
implantable biomaterial whose mechanical properties, par-
ticularly tensile strength, are at least equivalent to those of
natural soft tissue.
It is an object of the present invention to provide an
implantable tissue part that is free from infection and safe
with respect to use with the immune system of a donee.
It is a further object of the present invention to provide an
implantable soft tissue that is cosmetically and visually
acceptable to surgeons.
Other objects and advantages of the present invention will
become apparent from the following detailed description
when viewed in conjunction with the accompanying draw-
ings, which set forth certain embodiments of the invention.
BRIEF DESCRIPTION OF THE
ACCOMPANYING DRAWINGS
Reference will hereinafter be made to the accompanying
drawings, wherein like reference numerals throughout the
various FIGURES denote like structural elements, and
wherein;
FIG. 1 is a schematic view of the cleaning/ sterilizing appa-
ratus of the present invention.
FIG. 2 is a schematic view of the reactor pressure vessel
used with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The detailed embodiment of the present invention is dis-
closed herein. It should be understood, however, that the
disclosed embodiment is merely exemplary of the invention,
which may be embodied in various forms. Therefore, the
details disclosed herein are not to be interpreted as limiting,
but merely as the basis for the claims and as a basis for
teaching one skilled in the art how to make and/or use the
invention.
The present invention employs a cleaning process and an
apparatus used therewith using supercritical fluid such as
carbon dioxide as an extractant to clean viable donor soft
tissue for subsequent use such as implantation into a donee.
Soft tissue as discussed in the present invention generally
relates to all tissue, other than bone tissue, including but not
limited to: dermis, tendons, ligaments, cardiovascular con-
duits, nerve tissue, heart valves, corneas, and fascia. These
soft tissues contain potential contaminants of blood, blood
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constituents and lipidic organic matter such as fats. These
potential contaminants are capable of becoming toxic, if
untreated, upon implantation of the tissue into a donee human
body.
The present invention provides an implantable tissue part
with comparable strength to that of natural tissue that is free
from infection and safe for use with the immune system of a
donee, as the implant does not contain toxic products. The
present invention achieves these goals while at the same time
rendering those tissues acceptable in visual appearance to
surgeons. The donor tissue may include thermally or hydro-
lytically sensitive, medically important materials, and is
treated for implantation or transplantation. It is, therefore, an
aim of the invention to propose an implantable biomaterial
whose mechanical properties, particularly tensile strength,
are at least equivalent to those of natural soft tissue. The
invention also aims to propose a biomaterial that improves the
eflicacy of soft tissue grafts both from the mechanical and
from the biological point of view.
With these goals in mind, and as will be discussed below in
greater detail, the present invention concerns a process for
treating animal or human tissue to obtain biomaterial which
can be implanted in a human and is suitable for sustaining
mechanical stresses after implantation.
According to the invention, the process for cleaning or
decontarninating soft tissue having potential contaminants of
blood, blood constituents and lipidic organic matter present in
the tissue includes the steps of: a) cleaning the soft tissue
mechanically of all the organic matter on the surface thereof,
that is removing extraneous tissue, blood and fat product; b)
cutting the soft tissue into a desired size and shape part; c)
contacting and impregnating the soft tissue with an extractant
in the form of a fluid in a supercritical state suitable for
solubilizing contaminants such as blood, blood constituents
and lipidic organic matter present in this tissue; d) maintain-
ing the contact between extractant and the contaminants in the
tissue for a time period suflicient to form a solute containing
the contaminants in this tissue in the extractant, and e) sepa-
rating the extractant containing the solute from the soft tissue
thereby cleaning (i.e. removing of bio-products) the soft tis-
sue by removing the constituents harmful to a successful
re-implantation.
The soft tissue is generally first rinsed in a warm saline
solution. The tissue is then mechanically cleaned prior to
further processing to remove external lipids and other organic
material on the surface of the soft tissue. Suitable methods of
extemal mechanical cleaning are well known to those skilled
in the art and include soft scrubbing procedures and the like.
The soft tissue is manipulated to the desired size, shape or
configuration by mechanical cutting to form a tissue part.
Suitable cutting means include the use of a scalpel and other
means known to those skilled in the art.
Following the topical preliminary cleaning and cutting of
the soft tissue specimen, the cleaning process to remove con-
taminants such as blood, blood constituents, minerals and
lipidic organic matter potentially present in or on soft tissue is
achieved in the following manner.
The soft tissue is wrapped into an absorptive material. In
accordance with a preferred embodiment, the absorptive
material is any medical absorbent material, such as gauze,
abdominal dressing or other wound dressings. An abdominal
dressing is also called a laparoscopy material, and is a mate-
rial made of several layers of gauze in a rectangular shape
used as a sponge for packing wounds of the viscera and
abdomen. The absorbent material functions to collect the
extracted material from the soft tissue as it is subsequently
treated with an extractant. The wrapped soft tissue is placed
US 8,034,288 B2
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into a single microporous plastic film pouch, such as Tyvek®
envelopes by Dupont. The pouch must be porous to permit the
passage of the supercritical fluid through the bag so as to
contact the wrapped soft tissue. The pouch is then sealed and
placed into a reactor pressure vessel.
The present invention utilizes a supercritical fluidto extract
contaminants from the soft tissue. While numerous extract-
ants may be used, the following description is restricted to the
use of carbon dioxide for purposes of illustration only and is
not limiting in the use of other supercritical fluids that are
known in the art.
One presently preferred embodiment of an apparatus 10
according to the present invention is depicted in accompany-
ing FIGS. 1 and 2. In this regard, it can be seen that the
apparatus includes a standard compressed gas cylinder 12
containing a fluid capable of entering a supercritical state
such as carbon dioxide, and a standard air compressor 14 used
in operative association with a carbon dioxide booster 16
(e.g., Haskel Booster AGT 7/30). Altematively, the air com-
pressor 14 and carbon dioxide booster 16 can be replaced with
a single carbon dioxide compressor. An additive cycle is also
provided by means of an inlet port 18 which allows additive
contained in reservoir 20 to be added to a reactor pressure
vessel 22 through valve 24 and additive line 26. Altematively,
the additive can be introduced by soaking it into an absorbent
pad and placing the pad in the reactor pressure vessel 22 with
the material to be treated. The carbon dioxide is introduced to
the reactor pressure vessel 22 from header line 27 via valve
and regulator (herein called valve 28) and CO2 supply line 30.
A filter 32 (e.g., a 0.5 micron filter) is provided in the supply
line 30 to prevent the escape of material from the vessel. A
pressure gauge 34 is provided downstream of CO2 shut-off
valve 36 in supply header line 27 to allow the pressure to be
visually monitored. A check valve 38 is provided in the
header line 27 upstream of the CO2 shut-off valve 36 to
prevent reverse fluid flow into the carbon dioxide booster 16.
In order to prevent an overpressure condition existing in
header line 27, a pressure relief valve 9 may be provided.
An outlet line 40 through valve and regulator (herein called
valve 52) allows the reactor pressure vessel 22 to be depres-
surized. In this regard, the depres surized fluid exits the reactor
pressure vessel 22 via outline line 40, is filtered by filter unit
42 and then is directed to separator 44 where filtered CO2 gas
may be exhausted via line 48, and liquid additive collected via
line 50 for possible reuse. Valves 52, 54 may be provided in
lines 46 and 27, respectively, to allow fluid isolation of
upstream components.
The reactor pressure vessel 22 is most preferably con-
structed of stainless steel (e.g. 316 gauge stainless steel) and
has a total intemal volume sufficient to accommodate the
materials being cleaned either on a laboratory or commercial
scale. For example, in laboratory studies, an intemal volume
of 600 ml (e.g., approximately 8 inches long by about 2.5
inches inside diameter) was deemed adequate As is perhaps
more clearly shown in FIG. 2, the reactor pressure vessel 22
includes a vibrator 60, a temperature control unit 62, and a
mechanical stirring system most preferably comprised of an
stirring impeller 64 and a magnetic driver 66. The reactor
pressure vessel 22 contains a conventional basket (not shown)
which is also preferably constructed of 316 gauge stainless
steel. The basket serves to hold the wrapped soft tissue to be
cleaned as well as to protect the wrapped soft tissue from the
stirring impeller 64 and direct the extractant fluid in a prede-
termined marmer.
The reactor pressure vessel 22 may be operated at a con-
stant pressure or under continual pressurization and depres-
surization (pressure cycling) conditions without material
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losses due to splashing or turbulence, and without contami-
nation of pressure lines via back diffusion. The valves 24, 28
and 52 allow the reactor pressure vessel 22 to be isolated and
removed easily from the other components of the apparatus
10. The top 68 of the reactor pressure vessel 22 may be
removed when depressurized to allow access to the vessel’s
interior.
In use, the wrapped soft tissue material to be cleaned is
placed in a microporous pouch or package that is introduced
into the basket in the interior space of the reactor pressure
vessel 22 along with any initial portion of liquid additive from
reservoir 20 or an additive pad. The temperature control unit
62 is operated so as to set the desired initial temperature for
cleaning and sterilization. The reactor pressure vessel 22 may
then be pre-equilibrated with carbon dioxide from gas cylin-
der 12 at atmospheric pressure, following which the magnetic
driver 66 is operated so as to activate the stirring impeller 64.
The reactor pressure vessel 22 may thereafter be pressurized
to a desired pressure by introducing additional carbon dioxide
gas from gas cylinder 12 via the air compressor 14 linked to
carbon dioxide booster 16.
In order to affect a pressure cycling of the reactor pressure
vessel 22, an amount of carbon dioxide may be released
therefrom via depressurization outline line 40 by momen-
tarily opening valve 52 sufficient to partially reduce pressure
within the reactor pressure vessel 22. Additive may be intro-
duced into the reactor pressure vessel 22 for any given pres-
sure cycle by opening valve 24 which allows liquid additive to
flow from reservoir 20 into inlet port 18. It will be understood
that the cleaning promoter additives may be introduced prior
to pressurization and/or during pressure cycling. Prior to
pressurization, additives are introduced directly into the reac-
tor pressure vessel 22 prior to sealing and/ or via the additive
port 18. The additives are most preferably introduced during
the cycling stages by measured addition to the additive port 18
at ambient pressures. The port 18 is subsequently sealed and
the additive chamber is pressurized so that the additive may
enter the reactor pressure vessel 22 without altering the inter-
nal pressure. The exact mechanism of addition may be modi-
fied such that the process is more eflicient and/ or convenient.
Following additive introduction, the reactor pressure ves-
sel 22 may be repressurized to a desired pressure following
introduction of the liquid additive therein. Such depressuriza-
tion/repres surization with introduction of liquid additive may
be repeated for any number of cycles that may be desired. The
cycle of depressurization and repressurization as well as the
introduction of the carbon dioxide and liquid additive may be
automatically controlled via a controller screen which
sequences the various valves discussed previously so as to
achieve the desired pressure conditions and cycles.
In the treatment of the wrapped soft tissue it has been found
that it is desirable to precisely control the pressurization and
depressurization rates in the sterilization vessel to maintain
the physical structure and appearance of the soft tissue. For
these products, the input or flow of CO2 through valve 24 into
the reactor pressure vessel 22 is regulated to 0.01 to 5 psi/
second. Regulating the rate of pressurization is also intended
to control mass flow (1000 mg/ second) of CO2 into the reactor
pressure vessel 22. In the initial fill, the valve 24 is opened and
allowed to flow at the regulated rate using the ambient pres-
sure of the CO2 supply from the gas cylinder 12. The CO2
supply pressure can range from 75 psi to approximately 900
psi or greater. Once the pressure in reactor pressure vessel 22
reaches equilibrium with the CO2 supply source pressure, the
pumping of the CO2 using the carbon dioxide booster 16
begins. The CO2 booster rate of pressurization is regulated to
not exceed 5 psi/ second. Once the reactor pressure vessel 22
US 8,034,288 B2
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reaches its operating pressure of 1500 psi, the process is
allowed to continue through its normal path. Upon comple-
tion of the desired time period at the operating temperature
and pressure, depressurization of the reactor pressure vessel
22 then occurs. At this point the output Valve 52 is opened
enough that the rate of depressurization is regulated to less
than 5 psi/ second. Regulating the rate of depressurization is
also intended to control of mass flow of CO2 out of the reactor
pressure vessel 22. The rate of depressurization is controlled
at this rate until the ambient pressure in the reactor pressure
vessel 22 is zero or at equilibrium with the atmospheric pres-
sure. Ambient conditions are generally zero psi and 25° C.
The pressurization and depressurization rates discussed
above where found to be critical, that is no damage resulted to
the collagenous network of the tissue being cleaned when
these rates were employed.
Most preferably, periodic agitation to the contents of reac-
tor pressure vessel 22 is effected using a vibrator 60 through
the entire process. Intermittent or continuous agitation of the
reactor pressure vessel 22 and its contents is performed by
vibrating the reactor pressure vessel 22 during cleaning. Agi-
tation enhances mass transfer of the carbon dioxide and addi-
tives by eliminating voids in the fluid such that the material
being cleaned comes into more complete contact with extrac-
tant. The specific means of agitation may be adjusted to
accommodate the particular apparatus employed and to opti-
mize sterilization times, temperatures, and pressure cycles.
When cleaning is complete, the reactor pressure vessel 22 is
depressurized, the magnetic driver 66 is stopped thereby stop-
ping the stirring impeller 64, and the package or pouch con-
taining wrapped soft tissue is removed by opening top 68 of
reactor pressure vessel 22.
Upon run completion, each tissue sample is removed from
its pouch, unwrapped from the absorbent material, which is
generally filled with blood and blood constituents, and other
extracted residuals, and rinsed in a sterile fluid such as saline
to remove any blood or constituent residuals on surface. The
tissue samples are then packaged under sterilization condi-
tions.
The extractant that is used to clean and penetrate the soft
tissue is a fluid in a supercritical state suitable for cleaning
(i.e. killing of microbial contaminants) the soft tissue. The
fluid in the supercritical state is caused to penetrate through-
out the soft tissue thereby cleaning by extraction the potential
contaminants on the surface or within the tissue.
According to the invention, the fluid in the supercritical
state penetrates the soft tissue that is potentially contaminated
with blood, blood constituents and/or lipidic organic matter
present in the tissue. These contaminants are solubilized in
the fluid, extracted and separated from the soft tissue. The
extraction thus effected by this supercritical fluid has proper-
ties particularly suitable to the treatment and sterilization of
the soft tissue without having a deleterious effect of the physi-
cal properties of the tissue.
More particularly, this extraction is beneficial for the fol-
lowing reasons. Under normal conditions blood supplies oxy-
gen and nutrients while removing waste products from tissue.
Any residual blood in the allograft likely contains metabolic
waste and ions from the donor and can cause inflammation if
left in the allograft. In addition, blood plasma contains 90%
water, 7-8% proteins (albumin, fibrinogen, plasminogen,
thrombin, basically the clotting proteins), 1% electrolytes
(NaCL, K+, Ca2+) and 1% substances in transit (hormones,
urea, lipids, vitamins, amino acids and glucose). On the sur-
face of red blood cells are various substances, among which
29 different compounds have been identified, including the
antigens and Rh factor. If a patient is exposed to blood group
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antigens or foreign material not recognized by its immune
system, such exposure triggers an immune response leading
to a potentially life-threatening inflammatory response.
The cleaning process of the present invention is practiced
using an extractant such as carbon dioxide at pressures
between about 1000 to about 3500 psi, at temperatures in the
range between about 25° C. to about 60° C. Most preferably,
the donor tissue to be cleaned is subjected to carbon dioxide
at or near such pressure and temperature conditions for times
ranging from about 1 minutes to about 12 hours. The carbon
dioxide employed in the practice of the present invention is
most preferably substantially pure. Thus, trace amounts of
other gases may be tolerated provided that the cleaning or
extracting properties of the carbon dioxide are not impaired.
For ease of further discussion below, the term “supercritical
carbon dioxide” will be used, but it will be understood that
such a term is non-limiting in that carbon dioxide within the
pressure and temperature ranges as noted immediately above
may be employed satisfactorily in the practice of the present
invention.
To determine the amount of blood and blood constituents
and “other material” extracted, pre and post process weight of
the tissue are taken and recorded. The extraction/cleaning
process is run multiple times to ensure that no additional
material is extracted. Although, this may take multiple runs,
the amount of extracted material significantly decreases on
each run.
This process of placing the tissue part and absorbent mate-
rial in a gas permeable package permits removal of organics
and microbial contamination without creating cross donor
issues as the contaminates do not escape from the individual
packages being simultaneously processed.
More specifically, the preferred process of cleaning the soft
tissue occurs by the following process.
The soft tissue is rinsed in a warm saline solution. The
saline solution includes approximately 9 grams of salt per
liter and has a pH of between 7.2 and 7.4 and maintained at a
temperature of above room temperature up to around 40° C.
The tissue is then mechanically cleaned prior to further pro-
cessing to remove extemal lipids and other organic material
on the surface of the soft tissue.
The soft tissue is manipulated to the desired size, shape or
configuration by mechanical cutting to form a tissue part,
which is then placed into a wide mouth screw top container
and rinsed in the saline solution 4 to 8 times while the con-
tainer is constantly agitated. Each rinse last about 5 minutes
and between rinses the soft tissue part is blotted with an
absorptive material to remove excess saline solution and
residual materials on the tissue surface.
Thereafter, the tissue part is packaged in a single gas per-
meable sleeve or pack, such as Steripack®, wrapped in or
along with an absorptive pad loaded with 16 ml of the warm
saline solution. The sleeve or pack is sealed and placed into a
basket. The basket is then loaded into a reactor vessel.
The reactor vessel generally holds three stacked baskets
and it is preferred to place the packages in the middle basket
leaving the top and bottom baskets empty. The lid on the
vessel is closed and operation begins upon activation of the
start button.
The reactor vessel is programmed to run 20 minutes at the
standard parameters, that are 1436 psi, 700 rpm, 33° C. The
700 rpm is the speed at which the basket is agitated during
processing. Once the reactor vessel activated and the follow-
ing occurs 1) Pressurization to supercritical in 5-15 minutes;
2) Process runs for 20 minutes at the above parameters; and
then 3) Depressurization within in 12-25 minutes to 0 psi
US 8,034,288 B2
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After depressurization the lid is opened, the baskets are
removed, the package from middle basket is retrieved and
once again the tissue part is rinsed with the warm saline
solution in a container while being agitated for 5 minutes and
then blotted dry to remove excess saline solution.
If desired or needed the tissue part is repackaged into a new
sleeve with an absorbent pad and the process in the reactor
vessel repeated until there is no extracted material visible in
the absorptive pad.
Once processing in the vessel is completed the package is
removed and the tissue part is put into a container and rinsed
with 495 mls the warm saline solution plus 5 mls TX-100
(surfactant solution). The container filled with the solution is
then placed on a shaking water bath for 30 minutes, which
runs at 325 rpm and 40° C. The shaking water bath made be
any well known device such as the SBS30 by Equilabs
Canada Inc.
The solution in the container is then emptied and the tissue
part rinsed again with the saline solution 1-4 times while the
container is constantly agitated. Each rinse last about 5 min-
utes and between rinses the soft tissue part is blotted with an
absorptive material to remove excess saline solution and
residual materials on the tissue surface.
The solution in the container is then emptied and the tissue
part is put into a container back in the container and rinsed
with a solution comprising water and 3% H202 that is a 30 ml
of 50% H202 and 470 ml of water solution. The container
filled with the solution is then placed on a shaking water bath
for 30 minutes, which runs at 325 rpm and 40° C.
The solution in the container is then emptied and the tissue
part rinsed again with the saline solution 1-3 times while the
container is constantly agitated. Each rinse last about 5 min-
utes and between rinses the soft tissue part is blotted with an
absorptive material to remove excess saline solution and
residual materials on the tissue surface.
The solution in the container is then emptied and the tissue
part is put into a container back in the container and rinsed
with a solution comprising water and 70% isopropanol. The
container filled with the solution is then placed on a shaking
water bath for 30 minutes, which runs at 550 rpm and 40° C.
The solution in the container is then emptied and the tissue
part rinsed again with the saline solution 1-3 times while the
container is constantly agitated. Each rinse last about 5 min-
utes and between rinses the soft tissue part is blotted with an
absorptive material to remove excess saline solution and
residual materials on the tissue surface.
The solution in the container is then emptied and the tissue
part rinsed with deionized water 1 -2 times while the container
is constantly agitated. Each rinse last about one minute and
then the tissue part is removed and blotted with a paper towel.
Utilization of this cleaning process improves the resulting
graft product, resulting in a better healing process for the
recipient of the tissue. In particular, for transplanted soft
tissue, skin, etc there are several stages of healing and the
present cleaning process improves the graft product resulting
in a better healing process. The healing phases include:
Inflammatory phase—The blood in the region (blood
cells), platelets predominantly secrete factors (growth fac-
tors, fibrin) and other extracellular matrix molecules that lay
a temporary “bed” in the area of transplant (around the
edges). The fact that donor blood is not present in the graft
allows the host’s system to begin the healing process as
opposed to the rejection/ inflammatory response. If there is an
inflammatory response, the host will produce cells that attack
the unknown blood product or material in the region, causing
swelling, redness, immobility and possibly destruction of the
graft.
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The provisional matrix (allograft and the host cells sur-
rounding the graft) then allows endothelial cells and fibro-
blasts to begin moving in and binding in the region. The
cleaning process not only removes inhibitory elements but it
also creates a more open structure allowing for more consis-
tent penetration of host factors.
Proliferative phase—will secrete more extracellular matrix
proteins (fibronectin, collagen) adding and building the
matrix. The local cells (macrophages, endothelial cells) con-
tinually remodel the matrix.
Repopulation of host cells—The cells are proliferating
during this time. Capillaries are formed from the endothelial
cells (revascularization).
Maturation phase—this is where the cells continue to
remodel the collagen and in where the scar is formed.
The present cleaning process reduces the required time
down to 1 hour from the 20 hours commonly required in
conjunction with previously available cleaning processes. In
addition, the present cleaning process has lower exposure
time to harmful chemicals and therefore minimizes the
amount of collagen crosslinking, which maintains important
physical properties such as elasticity.
Sterilization
In accordance with a preferred embodiment, once the
cleaning is complete and the appropriate amount of biomate-
rials are removed sterilization is accomplished by the process
set forth in commonly owned U.S. Pat. No. 7,108,832 which
incorporated herein by reference.
The invention claimed is:
1. A process for cleaning donor soft tissue to preserve the
integrity of the soft tissue comprising:
obtaining a donor soft tissue;
mechanically removing extemal lipids and other organic
material on the surface of the soft tissue;
cutting the soft tissue into the desired size and shape to
form a tissue part;
placing tissue part and an absorbent material into a gas
permeable package and sealing the package;
placing the package into a reactor pressure vessel;
introducing supercritical carbon dioxide fluid to the pres-
sure vessel;
maintaining the tissue part in contact with the fluid while
mechanically agitating the fluid for a time suflicient to
impregnate the tissue part with carbon dioxide and to
extract excessive organic matter from the tissue part; and
removing the tissue part from the package and separating
from the absorbent material and rinsing the tissue part
with a sterile solution.
2. The process for cleaning donor soft tissue of claim 1
wherein the supercritical carbon dioxide fluid is introduced
and removed from the pressure ves sel at a rate of from about
0.01 to 5 psi/second.
3. A process for cleaning donor soft tissue to preserve the
integrity of the soft tissue comprising:
obtaining a donor soft tissue;
mechanically removing topical contaminants from the sur-
face of the soft tissue;
placing the soft tissue and an absorbent material into a gas
permeable package and sealing the package;
placing the package into a reactor pressure vessel;
introducing supercritical fluid into the pressure vessel;
maintaining contact between the supercritical fluid and the
soft tissue in the package while mechanically agitating
the fluid for a time suflicient to solubilize contaminants
contained in the soft tissue and separate the contami-
nants from the soft tissue by absorption into the absor-
bent material; and
US 8,034,288 B2
11 12
removing the package from the pressure vessel, separating maintaining contact between the supercritical extractant
the tissue from the absorbent material in the package and fluid and soft tissue for a time suflicient to impregnate
rinsing the tissue With 21 Sterile S0111ti0I1. the soft tissue with the supercritical extractant fluid and
4~ The Proeess for eleaning donor soft tissue of Claim 3 extracting excessive organic matter from the soft tissue;
wherein the supercritical fluid is introduced and removed 5 and
from the pressure vessel at a rate of from about 0.01 to 5 reeevering the Soft tissue from the paekage and Separating
1351/ Second‘ the soft tissue from the absorbent material in the pack-
5. The process for cleaning donor soft tissue of claim 3
wherein the supercritical fluid used is carbon dioxide.
6. A process for cleaning donor soft tissue to preserve the
integrity of the soft tissue comprising:
obtaining a donor soft tissue;
placing the soft tissue and an absorbent material into a gas
permeable package and sealing the package;
placing the package into a reactor pressure vessel;
introducing a supercritical extractant fluid capable of 15
extracting excessive organic matter from the soft tissue
into the pressure vessel; * * * * *
age.
7. The process for cleaning donor soft tissue of claim 6
10 wherein the supercritical fluid is introduced and removed
from the pressure vessel at a rate of from about 0.01 to 5
psi/second.
8. The process for cleaning donor soft tissue of claim 6
wherein the supercritical fluid used is carbon dioxide.
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