BACKGROUND
[0001] Intermittent catheters are typically used by patients suffering from urinary incontinence or by individuals unable to enjoy voluntary urination. In our highly mobile culture, the ability to have the freedom to leave home for the day or longer is an important part of life. To accommodate this need single use, pre-lubricated catheters have been developed to allow patients to perform self catheterization. An individual requiring catheterization will typically utilize several catheters each and every day. This results in the usage of a large number of catheters over time, driving a demand for inexpensive catheters without sacrificing safety and comfort.
[0002] The high daily utilization rate for intermittent urinary catheters also results in the need for individuals requiring catheterization to transport several catheters with them whenever they leave the house for any extended period of time. Packaged catheters tend to be large and bulky, rendering it difficult to discretely transport a supply of catheters.
[0003] Accordingly, a need exists for an inexpensive and efficiently packaged intermittent urinary catheter, particularly one that is self-contained and ready for use immediately upon removal from the packaging.
[0004] A particular complication encountered with the production and transport of inexpensive, single use, pre-lubricated, ready for use catheters for self-catheterization is constraining the lubricant to the insertion portion of the packaged catheter so as to prevent lubrication of the fixture end portion of the catheter which must be gripped during insertion and removal of the catheter.
[0005] Accordingly, a particular need exists for an inexpensive method for packaging a single use, pre-lubricated, ready for use catheter for self-catheterization that constrains the lubricant to contact with the insertion portion of the packaged catheter during packaging, and results in a packaged catheter that restrains migration of the lubricant within the package into contact with the fixture end of the catheter under normal storage and transport conditions.
SUMMARY OF THE INVENTION
[0006] A first aspect of the invention is an efficiently packaged, ready to use intermittent urinary catheter. The packaged catheter includes, and except for appropriate labeling and marking preferably only includes, (i) an intermittent urinary catheter, (ii) packaging formed from first and second layers of film, and (iii) a lubricant. The catheter has a longitudinal axial length, an insertion end, a funnel end and a top view profile, and is hermetically packaged between the first and second layers of film within a retention chamber formed from the films. The retention chamber has a top view profile conforming to the top view profile of the catheter and retains a supply of lubricant. In an alternative embodiment, the lubricant is predominately retained within an enlarged lubricant retaining compartment formed in the retention chamber intermediate the insertion and funnel ends of the catheter.
[0007] A second aspect of the invention is a method of efficiently packaging a precision lubricated ready to use intermittent urinary catheter having an insertion end, an insertion end length, a fixture end, and a fixture end length. The method includes the steps of (a) obtaining a base film having a pocket with a first end and a second end, wherein the pocket is configured to retain the intermittent urinary catheter with the insertion end proximate the first end and the fixture end proximate the second end, (b) injecting a limited amount of lubricant into the pocket proximate the first end of the pocket so as to form a lubricant containing pocket, (c) placing the intermittent urinary catheter into the lubricant containing pocket so as to form a catheter containing pocket, with the insertion end of the intermittent urinary catheter proximate the first end and the fixture end of the intermittent urinary catheter proximate the second end, (d) sealing a cover film to the base film with an unsealed opening proximate the second end of the pocket so as to form an enclosed catheter containing retention chamber accessible through the opening, (e) drawing a vacuum on the enclosed catheter containing retention chamber through the opening sufficient to compress the retention chamber and cause lubricant to circumferentially flow around and coat a portion of the exterior surface area of the insertion end length of the catheter within the retention chamber without reaching and coating the fixture end length of the catheter within the retention chamber, and thereafter (f) sealing the opening so as to form a hermetically packaged intermittent urinary catheter having a circumferentially lubricated insertion end length and a lubricant-free fixture end length.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008]
Figure 1 is a top view of one embodiment of the invention.
Figure 2 is a top view of another embodiment of the invention
Figure 3 is a side view of the invention depicted in Figure 2.
Figure 4 is an enlarged cross-sectional side view of a portion of the invention depicted in Figures 2 and 3 taken along line 4-4.
Figure 5 is a perspective view of one embodiment of a base layer and a cover layer suitable for use in hermetically packaging an intermittent urinary catheter in accordance with the invention.
Figure 6 is a perspective view of the base layer depicted in Figure 5 after injection of lubricant into the pocket of the base layer in accordance with the invention.
Figure 7 is a side view of the base layer depicted in Figure 6 after placement of a catheter into the lubricant containing pocket of the base layer and heat sealing of the cover layer to the base layer, but prior to pulling of a vacuum in accordance with the invention.
Figure 8 is a side view of the invention depicted in Figure 7 after pulling of a vacuum and complete sealing of the catheter within the packaging in accordance with the invention.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
Nomenclature
[0009]
- 10
- Packaged Intermittent Urinary Catheter
- 20
- Catheter
- 20Pf
- Top View Profile of Catheter
- 20x
- Axial Length of Catheter
- 21
- Insertion End of Catheter
- 21x
- Axial Length of Insertion End Portion of Catheter
- 22
- Fixture End or Funnel End of Catheter
- 22x
- Axial Length of Fixture End Portion of Catheter
- 25x
- Pre-vacuum Axial Length of Catheter In Contact with Lubricant Within the Pocket (Alpha Length)
- 30
- Fixture or Funnel
- 40
- Base Layer of Packaging
- 50
- Pocket in Base Layer of Packaging
- 50Pf
- Top View Profile of Pocket
- 51
- First End of Pocket
- 52
- Second End of Pocket
- 60
- Cover Layer of Packaging
- 70
- Packaging
- 70Py
- Peripheral Edge of Packaging
- 75
- Margins of Packaging
- 75w
- Width of Margins
- 80
- Retention Chamber
- 80Pf
- Top View Profile of Retention Chamber
- 80Py
- Periphery of Retention Chamber
- 80Lube
- Lubricant Containing Compartment
- 80Neck
- Metering Neck Area of Retention Chamber
- 81
- First End of Retention Chamber
- 82
- Second End of Retention Chamber
- 83
- Sides of Retention Chamber
- 90
- Lubricant
- x
- Longitudinal or Axial Direction
- y
- Lateral (Radial) Direction
- z
- Transverse (Radial) Direction
Definitions
[0010] As utilized herein, including the claims, the term
"fixture" means and refers to the well known commercially available components commonly attached to the proximal non-insertion end of urinary catheters, including specifically but not exclusively funnels, luer locks, clamps, valves, etc.
[0011] As utilized herein, including the claims, the term
"predominant" means at least 80%.
Description
PACKAGED CATHETER
[0012] The invention is an efficiently packaged, ready to use intermittent urinary catheter
10. Referring to Figures 1-3, the packaged catheter
10 includes, and in a preferred embodiment only includes the functional components of, (i) an intermittent urinary catheter
20 equipped with a fixture
30 at one end, (ii) packaging
70 formed from a base layer
40 and cover layer
60 of film, and (iii) a lubricant
90.
[0013] The catheter
20 has an axial length
20x with an insertion end
21, an insertion end axial length portion
21x, a fixture end
22, and a fixture end axial length portion
22x. The catheter
20 defines a top view profile
20Pf. The packaging
70 may be used with substantially any commercially available catheter
20, but is particularly suited for use with shorter female urinary catheters.
[0014] The catheter
20 is hermetically packaged within a retention chamber
80 formed between base layer
40 and cover layer
60 films sealed together, preferably by heat seal, within a peripheral margin
75 of the packaging
70. The films
40 and
60 may have originated from separate and independent rolls or sheets of film, or they may have been formed by simply folding a single length of film back upon itself. The packaging
70 formed by the base layer
40 and cover layer
60 films defines an outer peripheral edge
70Py. The retention chamber
80 has a periphery
80py defining a top view profile
80Pf that generally conforms to the top view profile
20Pf of the catheter
20, except for an optional enlarged compartment
80Lube intermediate the insertion
21 and funnel
22 ends of the catheter
20 in which lubricant
90 can be stored for coating the catheter
20 when it is withdrawn from the packaging
70 for use. The optional enlarged compartment
80Lube is preferably axially aligned with the balance of the retention chamber
80 such that the catheter
20 passes through the enlarged compartment
80Lube.
[0015] Referring to Figures 1 and 2, the margins
75 have a preferred width
75w of between 0.2 and 5 cm, most preferred between about 0.3 and 2 cm, around the entire periphery of the retention chamber
80.
[0016] The packaging layers
40 and
60 may be constructed from the same or different films, with the films selected from materials that are impervious to the lubricant
90, and suitable for hermetically sealing the catheter
20 within a retention chamber
80 formed from the films
40 and
60. Suitable materials include specifically but not exclusively, films of polyester, polyethylene, polypropylene, Surlyn®, Tyvek®, aluminum, Mylar®, etc.
[0017] Referring to Figures 1 and 2, the retention chamber
80 has a top view profile
80Pf that tightly matches the top view profile
20Pf of the catheter
20 along a predominant portion of the axial length
20x of the catheter
20 for purposes of maintaining lubricant
90 retained within the retention chamber
80 in close proximity to the catheter
20 so that the lubricant
90 will adhere to and coat the insertion end portion
21x of the catheter
20 as the catheter
20 is withdrawn from the packaging
70. The profiles are preferably matched such that the axial cross-sectional area of the retention chamber
80 (i.e., the cross-sectional area of the retention chamber
80 in a plane extending in the lateral
y and transverse
z directions and perpendicular to the longitudinal
x axis of the catheter
20) is between 1.2 and 1.8 times the corresponding axial cross-sectional area of the catheter
20 along at least 50%, preferably along at least 80% and preferably along at least 90% of the axial length of the insertion end portion
21x of the catheter
20.
[0018] Referring to Figure 2, when the retention chamber
80 includes an expanded lubricant containing compartment
80Lube, the axial cross-sectional area of the lubricant containing compartment
80Lube is between 2 and 4 times the largest axial cross-sectional area of the catheter
20 lying within the compartment
80Lube as packaged. The lubricant containing compartment
80Lube necks down at the longitudinal
x end of the compartment
80Lube proximate the fixture end
22 of the catheter
20, preferably necking down at both longitudinal x ends, to an axial cross-sectional area that is between 1.2 and 1.8 times the largest axial cross-sectional area of the catheter
20 lying within the compartment
80Lube as packaged. This necked down area
80Neck formed from the packaging films
40 and
60, serves to meter the coating of lubricant
90 on the catheter
20 as the catheter
20 is withdrawn from the packaging
70 for use.
METHOD OF PACKAGING READY TO USE CATHETER
[0019] A preferred method of packaging the ready to use intermittent urinary catheter
10 employs a novel lubricant placement and spreading technique.
[0020] Referring to Figure 5, the method employs a base film
40, a cover film
60 and lubricant
90.
[0021] The base film
40 has a blister or pocket
50 with a first end
51 and a second end
52. The pocket
50 preferably has a top view profile
50Pf conforming to the top view profile
20Pf of the intermittent urinary catheter
20, and is configured to retain at least a portion and preferably the entire urinary catheter
20 within the pocket
50, with the insertion end
21 of the catheter
20 proximate the first end
51 of the pocket
50 and the fixture end
22 of the catheter
20 proximate the second end
52 of the pocket.
[0022] The cover film
60 is preferably a planar sheet.
[0023] Referring to Figure 6, an amount of lubricant
90 is inserted into the pocket
50 in the base film
40 along a substantial axial length x of the insertion end portion
21x of the pocket
50 so as to form a lubricant containing pocket
50. The lubricant
90 is preferably applied so as to extend along at least about 30% of the axial length of the insertion end portion
21x of catheter
20, with a preference for a continuously applied axial x length of at least 50% of the axial length of the insertion end portion
21x, more preferably at least 70% and most preferably at least 80%.
[0024] Referring to Figure 7, a urinary catheter
20 is then placed into the lubricant containing pocket
50 with an alpha axial length
25x of the insertion end portion
21x resting atop and in fluid communication with the lubricant
90 so as to form a catheter containing pocket
50, with the insertion end
21 of the urinary catheter
20 proximate the first end
51 of the pocket
50 and the fixture end
22 of the urinary catheter
20 proximate the second end
52 of the pocket
50. The alpha axial length
25x of the insertion end portion
21x resting atop and in fluid communication with the lubricant
90 is preferably between 30% and 90% of the insertion end length of the catheter, more preferably between 50% and 80% and most preferably 40% and 60%.
[0025] The cover film
60 is placed over the base film
40 and sealed, such as by heat sealing, to the base film
40 around the profile of the pocket
50Pf except along a length proximate the second end
52 of the pocket
50 so as to form a catheter containing retention chamber
80 between the base film
40 and the cover film
60 which is sealed except for an opening proximate the second end
82.
[0026] Referring to Figure 8, a vacuum is drawn on the catheter containing retention chamber
80 through the opening sufficient to compress the retention chamber
80 and thereby cause lubricant
90 to circumferentially flow around and coat a substantial percentage of the surface area of the alpha axial length
25x of the insertion end portion
21x resting atop and in fluid communication with the lubricant
90, with a preference for coating at least 70% of the surface area of the alpha axial length
25x and most preferably 90%.
[0027] Pulling of a vacuum with resultant compression of the retention chamber
80 will also tend to draw lubricant
90 an axial distance x towards the second end
52 of the pocket
50. The vacuum should be applied at a pressure and for a duration sufficient to effect substantially complete circumferential coating of that portion of the insertion end portion
21x of the catheter
20 placed atop the lubricant
90, but without causing the lubricant
90 to travel an axial distance x that results in coating any portion of the fixture end
22 of the catheter
20.
[0028] The lubricant
90 preferably has a viscosity of between about 15,000 and about 500,000 centipoise at 72°F. When the viscosity is less than about 15,000 cp it is difficult to control the axial x length of the insertion end portion
21x of catheter
20 which is coated with lubricant
90 when pulling the vacuum, along with an increased likelihood that lubricant
90 will migrate into contact with the fixture end portion
22x of the catheter
20 under normal storage and transport conditions. Generally, when a high lubricity embodiment is desired the lubricant
90 preferably has a viscosity of between 15,000 and 50,000 centipoise at 72°F, and when superior control over lubricant
90 coverage during packaging and lubricant
90 migration during normal storage and handling is desired the lubricant
90 preferably has a viscosity of between 100,000 and 400,000 centipoise at 72°F.
[0029] The opening into the retention chamber
80 is then sealed, such as by heat sealing, to form a hermetically packaged intermittent urinary catheter
10 having a lubricated insertion end portion
21x and a lubricant-free fixture end portion
22x. The vacuum may be and preferably is at least partially released and more preferably is fully released prior to sealing of the opening.
1. A method of hermetically packaging an intermittent urinary catheter having an insertion end, an insertion end length defining an exterior surface area, a fixture end, and a fixture end length, comprising the steps of:
(a) obtaining a base film having a pocket with a first end and a second end, wherein the pocket is configured to retain the intermittent urinary catheter with the insertion end proximate the first end and the fixture end proximate the second end,
(b) injecting a limited amount of lubricant into the pocket proximate the first end of the pocket so as to form a lubricant containing pocket,
(c) placing the intermittent urinary catheter into the lubricant containing pocket so as to form a catheter containing pocket, with the insertion end of the intermittent urinary catheter proximate the first end and the fixture end of the intermittent urinary catheter proximate the second end,
(d) sealing a cover film to the base film with an unsealed opening proximate the second end of the pocket so as to form an enclosed catheter containing retention chamber accessible through the opening,
(e) drawing a vacuum on the enclosed catheter containing retention chamber through the opening sufficient to compress the retention chamber and cause lubricant to circumferentially flow around and coat a portion of the exterior surface area of the insertion end length of the catheter within the retention chamber without reaching and coating the fixture end length of the catheter within the retention chamber, and thereafter
(f) sealing the opening so as to form a hermetically packaged intermittent urinary catheter having a circumferentially lubricated insertion end length and a lubricant-free fixture end length.
2. The method of claim 1 wherein the intermittent urinary catheter has a profile and the pocket has a profile conforming to the profile of the intermittent urinary catheter.
3. The method of claim 1 wherein an alpha length of the intermittent urinary catheter is placed atop and into fluid contact with the lubricant within the pocket in step (c) and the vacuum is sufficient to effect a circumferential flow of lubricant around the alpha length so as to coat at least 70% of the external surface area of the alpha length of the catheter.
4. The method of claim 3 wherein the vacuum is sufficient to effect a circumferential flow of lubricant around the alpha length so as to coat at least 90% of the external surface area of the alpha length of the catheter.
5. The method of claim 3 wherein the alpha length is between 30% and 90% of the insertion end length of the catheter.
6. The method of claim 3 wherein the alpha length is between 50% and 80% of the insertion end length of the catheter.
7. The method of claim 3 wherein the alpha length is between 40% and 60% of the insertion end length of the catheter.
8. The method of claim 1 wherein the lubricant has a viscosity of between 15,000 and 500,000 centipoise at 72°F.
9. The method of claim 1 wherein the lubricant has a viscosity of between 15,000 and 50,000 centipoise at 72°F.
10. The method of claim 1 wherein the lubricant has a viscosity of between 100,000 and 400,000 centipoise at 72°F.
11. The method of claim 1 wherein the cover film is heat sealed to the base film in step (d).
12. The method of claim 1 wherein the opening is heat sealed.
13. The method of claim 1 wherein the cover film is a planar sheet.