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MEDICAL DEVICE LITIGATION

William F. Horsley
William F. Horsley, P.A.
Greensboro, NC
www.horsleylawfirm.com

[NOTE: Portions of this paper were also presented at an earlier Academy Product Liability Seminar April 20, 2001.]

Medical technology is a key component of modern patient care. Entrepreneurial device manufacturers now make everything from tongue depressors to Jarvik-7 artificial hearts. Medical devices are a multi-billion dollar industry, with even more growth forecast in the coming years. However, accompanying this growth, and in part because of it, are significant product liability risks. For the patient, there is usually a very small margin for error. The pacemaker either hums along perfectly, or a serious medical crisis may result. If a life-support ventilator does not function flawlessly, the patient may die or become brain-damaged. When things go wrong, the stakes can be high.

I. RELEVANT REGULATORY BACKGROUND

Medical devices are regulated by the Federal government. The Medical Devices Amendments to the Food, Drug and Cosmetic Act (MDA), enacted in 1976, were expressly intended to protect consumers from “increasingly complex devices with pose serious risk if inadequately tested or improperly designed or used.” S. Rep. No. 33, 94th Cong., 2d Sess. 5, reprinted in 1976 U.S. Code Cong. & Admin. News., 1070, 1075.\

Under this law, the Food and Drug Administration (FDA) is required to promulgate regulations classifying devices into one of three discrete categories. See 21 U.S.C. §360c. Class devices are defined as those which generally pose little or no threat to public health or safety. See 21 U.S.C. §366c(a)(1)(A). This class includes devices such as tongue depressors, bedpans, crutches and elastic bandages. See 21 C.F.R. §§880.5075, 880.6230, 880.6730, 890.3150. Class II devices are those which are more complex than Class I devices, and which pose a somewhat greater risk to health. See 21 U.S.C. §360c(a)(1)(B). Examples include such items as oxygen masks, tampons and syringes. See 21 C.F.R. §§868.5580, 884.5470, 880.5570. Finally, Class III devices are those which “present a potential unreasonable risk of illness or injury.” See 21 U.S.C. §360c(a)(1)(C).

Each type of device is subject to a different degree of regulation. Class I devices are subject only to “general controls,” which apply to all medical devices, such as the Device Labeling and Good Manufacturing Practice Regulations. See 21 U.S.C. §360c(a)(1)(A) & 21 C.F.R. §801.109c & (d) & §820.1 et seq. Class II devices may be subjected to “special controls” including the promulgation of performance standards, postmarket surveillance, patient registries, and guidelines if the FDA determines, through regulatory action, that such controls are necessary to provide a reasonable assurance of safety and effectiveness for a specific device. See 21 U.S.C. §360c(a)(1)(B). Class III devices must receive premarket approval (PMA) from the FDA. See 21 U.S.C. §360c(a)(1)(C) & 360e. By statute, the FDA cannot grant PMA without first determining that there is a “reasonable assurance that such device is safe under the conditions of use prescribed, recommended or suggested in the proposed labeling thereof.” 21 U.S.C. §360e(d)(2). For the FDA to make such a finding, an applicant for PMA must furnish the agency with safety and efficacy data from non-clinical laboratory studies and controlled prospective studies conducted in accordance with protocols approved by the FDA. See 21 U.S.C. §360e c & 21 C.F.R. §814.20.

If a manufacturer wants to generate the scientific data required to obtain PMA, which it must do in order to market a Class III device, it may do so under the Investigational Device Exemption (IDE) provisions of the Food, Drug and Cosmetic Act (the Act). 21 U.S.C. §360j(g) and 21 C.F.R. §813, et seq. These provisions authorize the FDA to grant an exemption permitting experimental devices to be used without PMA under stringent conditions established and actively supervised by the agency. 21 U.S.C. §360j(g) and 21 C.F.R. §813, et seq. Among the requirements the FDA imposes on IDE clinical trials are:

  • the requirement that the investigation receive approval from the Institutional Review Board (IRB) at any hospital in which study patients will be treated;
  • the requirement that investigators participating in the study at these institutions will be approved and will be qualified by training and experience to conduct the investigation;
  • the requirement that the study sponsor will limit training in the use of the investigational device to such approved and qualified investigators;
  • the requirement that each participating investigator sign an agreement committing the investigator to conduct the study in accordance with the study protocol and in compliance with all conditions stated in the IDE approval;
  • the requirement that the sponsor will ship the device under study, properly labeled, only to approved investigators;
  • the requirement that the sponsor will select a study monitor to assure compliance by the IRB and approved investigators and to promptly resolve any reports of adverse device effects;
  • the requirement that the reports concerning the progress of the IDE trials be supplied to the FDA in a timely manner; and
  • the requirement that patients consent to participation in the study after being informed of the experimental nature of the therapy proposed.

21 C.F.R. §§812.1 and 812.110. When the FDA grants an IDE, the device in question is considered an “investigational device.” 21 C.F.R.§812.7. Under FDA regulations, an IDE sponsor, investigator or any person acting for or on behalf of a sponsor or investigator may not “promote or test market an investigational device, until the FDA has approved the device for commercial distribution” or “represent that an investigational device is safe or effective for the purpose for which it is being investigated.” 21 C.F.R. §812.7(a) & (d).

The MDA makes a distinction between devices “in commerce” prior to the effective date of the legislation, May 28, 1976, and new devices. All devices which were in commerce prior to that date may remain in commerce without further regulatory action by the FDA. 21 U.S.C. §§360c(2)(C), 360c(f)(1), 360(k) and 21 C.F.R. §807.100.

As to new devices, not in commerce prior to the effective date of the MDA, the MDA provides that they may not be introduced into commerce without PMA in the absence of one of the following two circumstances:

First, a post-enactment device may be introduced into commerce without PMA if it is reclassified into a Class I or Class II device by the FDA in response to a reclassification petition pursuant to 21 C.F.R. §860.1 et seq., 21 U.S.C. §360c.

The second way in which a post-enactment device may be introduced into commerce without PMA is by an FDA determination that it is “substantially equivalent” to a “predicate device.” 21 U.S.C. §§360c(2)(C), 360c(f)(1), 360(k) & 21 C.F.R. §807.100. A predicate device is one which was in commerce prior to the effective date of MDA or which was introduced thereafter and which as reclassified as a Class I or Class II device. Id. Under the law, a device is not “substantially equivalent” to a predicate device unless:

  1. The device has the same intended use as the predicate device; and
  2. The device:

    (a) Has the same technological characteristics as the predicate device, or:
    (b) (A) Has different technological characteristics, such as a significant change in the materials, design, energy source, or other features of the device from those of the predicate device;
    (B) The data submitted establishes that the device is substantially equivalent to the predicate device and contains information, including clinical data if deemed necessary by the Commissioner, that demonstrates that the device is as safe and as effective as a legally marketed device; and

    © Does not raise different questions of safety and effectiveness than the predicate device.

21 C.F.R. §807.100. See, also 21 U.S.C. §360c(I).

Substantial equivalence is claimed and either accepted or rejected by the FDA via a notification submitted under Section 510(k) of the Act, 21 U.S.C. §360(k), which requires a first-time marketer to submit a premarket notification to the FDA advising the agency of its intent to market a new medical device. 21 U.S.C. §510(k) and 21 C.F.R. §807.81 et seq.

It is important to understand that a device is defined in terms of its “intended use.” 21 U.S.C. §321(h)(2)-(3). The FDA regulations define “intended use” as:

[T]he objective intent of the persons legally responsible for the labeling of devices. The intent is determined by such persons’ expressions or may be shown by the circumstances surrounding the distribution of the article. This objective intent may, for example, by shown by labeling claims, advertising matter, or oral or written statements by such persons or their representatives.

21 C.F.R. §801.4. Since the intended use of an article defines its character as a device, the intended use specified by the person submitting a premarket notification delineates the scope of the FDA’s review of such notifications. 21 C.F.R.§814.20(b)(3)(ii); 21 C.F.R. §807.87(e). Moreover, because the intended use of a given article determines its existence as a device, different intended uses for the same physical article give rise to different devices, each of which must receive premarket approval or clearance pursuant to a 510(k) notification. Id.

The Medical Device Amendments make it unlawful for any person to sell a new medical device which has not received PMA or which has not been reclassified as a Class I or Class II device or which has not been cleared as substantially equivalent to an existing predicate device under the Section 510(k) premarket notification process. 21 U.S.C. §351(f)(1)(B); 21 C.F.R. §352 (o); §§360c(a)(1)(c), 360c, 360c(f)(1) & 360e; United States v. Various Articles of Device, 814 F. Supp. 32 (E.D. Tenn. 1992); United States v. An Article of Device, 687 F. Supp. 990 (W.D. Mich. 1985). Such conduct is considered unlawful adulteration and/or misbranding of the device in violation of the provisions of the Act. Id. Moreover, is a supplier is promoting an intended use which has not been approved or cleared, he is in effect selling a new device without appropriate regulatory approval or clearance and is guilty of adulteration and misbranding in violation of the Act. 21 U.S.C. §351(f)(1)(B); 21 U.S.C. §352(o). Similarly, where the agency grants an IDE to conduct clinical trials concerning an “investigational use” of a device, the commercial promotion of the device for that investigational use is unlawful and also constitutes adulteration and misbranding of the device. 21 C.F.R. §812.7. This is a crime. 21 U.S.C. §333; 18 U.S.C. §2.

II. OFF-LABEL USE

The use of a device for a purpose other than its “intended use” is “off-label.” Heretofore, the FDA has been fairly active in policing the promotion of devices for off-label uses. The FDA cannot prevent or regulate an off-label use, only the promotion of the device for an off-label use.

In Washington Legal Foundation v. Shalala, 13 F. Supp 2d 51 (D. D.C. 1998), the District Court for the District of Columbia limited the FDA’s ability to control what manufacturers or sellers of medical devices may say regarding unapproved or off-label uses of approved pharmaceuticals and medical devices. The FDA has long been concerned that allowing manufacturers to, in effect, promote or advertise off-label uses for products would lead doctors to prescribe or use the products based on incomplete information, and would discourage manufacturers from seeking FDA approval of new uses.

The Washington Legal Foundation sought to enjoin the FDA from enforcing policies expressed in two guidance documents that restricted certain activities relating to the dissemination of off-label information. The activities included:

  • pharmaceutical manufacturers’ sponsorship of continuing medical education seminars (the CME Guidance); and
  • the free distribution of journal articles or textbook excerpts describing the off-label uses (the Enduring Materials Guidances).

The CME Guidance was an effort by the FDA to stop the growing practice of manufacturers’ sponsoring seminars for physicians in which the sole, or a major, purpose was to take advantage of the “learned intermediary doctrine” by inducing physicians to use or prescribe for one purpose a device which had been approved by the FDA for another purpose. The Enduring Materials Guideline was intended to prevent corruption of medical literature.

An example of how this works involved the so-called “pedicle screw” spinal fixation devices heavily promoted and used in the late 1980s and early to mid-1990's. Initially, the manufacturers never conducted any animal, clinical or pre-clinical studies of these devices, which were to be used in lumbar fusion surgery. The devices were aggressively marketed, beginning in about 1984, without any filing the required Section 510(k) notification. The FDA ordered a cessation of this marketing effort, after which the Section 510(k) notification was filed by Acromed, the first manufacturer. This notification represented that the device was intended for use in spinal surgery. The FDA quickly determined that the device was not substantially equivalent to any device in commerce prior to May 28, 1976, and notified Acromed that its device was a Class III device which required PMA. In making its decision, the FDA declined to consider the data Acromed submitted with the notification, since it consisted entirely of information from Dr. Arthur Steffee, who, as a principal shareholder in Acromed had a direct financial interest in the commercial exploitation of the device.

Not to be deterred, Acromed filed another Section 510(k) notification, again claiming substantial equivalence to predicate devices, again without success. A third notification was then filed, claiming substantial equivalence to bone screws used for fixation of the long bones of the body, even though the expressed intended use of the device was in spinal fusion surgery. The name of the product was then changed and in its premarket notifications Acromed made no mention of spinal surgery. In fact, Acromed’s representative stated in the notification that “[m]ore specifically . . . the Acromed plates are intended for use in appropriate fractures of long bones of both the upper and lower extremity . . . .” Based upon this representation, the FDA concluded that the “bone screws” were substantially equivalent to predicate devices. Acromed then applied for an IDE in order to conduct clinical trials of the device in the human spine. In the IDE application, Acromed represented that the trials would be limited to 10 hospitals and 250 patients. Meanwhile, it aggressively marketed the device for spinal fusion surgery.

The marketing and promotional effort extended well beyond expanded sponsorship of CME seminars. Once it had obtained marketing clearance from the FDA, Acromed established a “Medical Advisory Panel” of selected spine surgeons. The members of this panel received attractive stock options through which they could participate in the expected growth of the company and profits derived from the anticipated public offering of its stock. The company paid for panel members to attend meetings at choice vacation spots. In exchange for these potentially lucrative arrangements, the members of Acromed’s Advisory Panel contractually obligated themselves to:

[P]articipate in the education, including participation in seminars and conferences, and training of other surgeons in the use of the Corporation’s products.

Additionally, spine surgeons who were members of Acromed’s Medical Advisory Panel, and who took money and benefits from the company, actively undertook to publish a substantial portion of the medical literature bearing on the subject of pedical screw fixation. Acromed funded the research in some of these papers (without being identified), and company employees often participated in drafting or rewriting portions of the papers. In none of these papers, which appeared in several “peer-reviewed” journals, was the economic interest of the authors divulged.

Often, the “peer review” panels were also Advisory Panel members.

The sum result of this effort, which also included many other strategies employed by the industry, was that pedical screw devices won wide acceptance among spine surgeons and, ultimately, were given limited approval by the FDA.

The Acromed experience provides insight as to the raison d’etre of the two Guidances attacked in Washington Legal Foundation v. Shalala. The court held that these two Guidances were an unconstitutional violation of the pharmaceutical and medical device industries’ First Amendment right to disseminate truthful and non-misleading information. The court held that information concerning off-label uses was not inherently misleading, though it had the potential to be misleading. The court also noted that prescribing an approved product for unapproved use is not unlawful and, therefore, speech that promoted such activity was not inherently unlawful. Although the court recognized the FDA’s interest in protecting the health and safety of the public, the court rejected as overly paternalistic the Agency’s asserted interest in insuring that physicians are not misled.

The FDA, in 1998, issued a final rule pursuant to Section 401 of the Food and Drug Administration Modernization Act of 1997 (DAMA). Manufacturers may now disseminate information concerning off-label use so long as they make the following disclosure: “This information concerns a use that not been approved or cleared by the Food and Drug Administration.” 63 C.F.R. §****. Then, in a supplemental ruling to its original W.L.F. case, the court held that its original ruling (on the two Guidances) was not limited to the specific guidance documents at issue, but rather extended to the policies underlying the Guidances. Thus, there is serious doubt as to the constitutionality of Section 401 of DAMA and its implementing regulations.

III. PREEMPTION

The MDA contains language that prevents the states from having different requirements for safety and labeling of medical devices. Section 360k of the MDA provides:

[N]o State or political subdivision of a State may establish or continue in effect with respect to a device intended for human use any requirement

(1) which is different from, or in addition to, any requirement applicable under this chapte to the device, and

(2) which relates to the safety or effectiveness of the device or to any other matter included in a requirement applicable to the device under this chapter.

21 U.S.C. §360k(a) (1994). As seen above, there is little review by the FDA of §510k (equivalent) devices already on the market prior to 1976. This lack of review and few FDA requirements for these devices, they do not raise preemption issues. The anticipated closer scrutiny of a device by the FDA under the PMA process may result in preemption of suits involving these devices.

Medtronics, Inc. v. Lohr, 518 U.S. 470 (1996) was a claim against the manufacturer of a cardiac pacemaker which failed. Medtronic argued that the MDA preempted state common law actions for negligent manufacturing and failure to warn, but conceded that claims based on negligent design were allowed. The Court held that the MDA did not deny a state the right to provide traditional remedies for violations of common law duties when those duties paralleled federal requirements. Preemption would have the effect of granting complete immunity from design defect liability to an entire industry that needed stringent regulation because there was no explicit private cause of action against manufacturers in the MDA.

In Haidak v. Collagen Corp., 67 F. Supp.2d 21 (D. Mass. 1999), plaintiff sued the manufacturer of a cosmetic collagen injection for selling a defective product. A prior, 1st Circuit, case had determined that the PMA review of the product by the FDA preempted the claim. However, in the meantime, the Supreme Court had decided Medtronic v. Lohr, which the Haidak court ruled did not carve out an exception for PMA devices and, therefore, public policy mitigates against extending preemption without specific Supreme Court approval. Collagen’s motion for summary judgment was denied.

A state court holding disapproving preemption is Weiland v. Teletronics Pacing Systems, Inc., 721 N.E.2d 1149 (Ill. 1999), which involved cardiac pacemakers which received PMA review as Class III devices. The court found that PMA for pacemakers only approves or rejects the manufacturer’s design - the FDA does not propose a design and thus imposes no requirements on the final design of the device. Thus, in the court’s view, there is no preemption under the MDA unless the FDA specifies and approves the final device design.

IV. AVAILABLE CLAIMS

Product liability claims arising out of the use of a medical device have the same basis in law as any other product claim. Claims sound in negligence and breach of warranty (express and implied). Cases in the area of pharmaceutical and medical device liability are a fairly diverse group. A potential drug liability claim can arise from having been prescribed or given the wrong medication from the physician or pharmacist, or from having been injured by a dangerous or defective prescription or over-the-counter drugs. Cases involving medical device liability can arise from the improper implantatin of a prosthesis, total or partial hip or knee replacement, pacemakers and heart valves, IUDs, and breast or penile implants. Common failures include loosening, imadequate bonding to bone or tissue, leaking, or chipping or breakage. Medical device claims can also be predicated on defective medical tools, such as syringes or surgical instruments.

One or more of the following legal theories may apply:

  • Defective or inadequate warnings, or a failure to warn. This can be to a drug’s danger or side effects, including reactions with other medications, and as to dangers from medical devices
  • Inadequate testing on a medication prior to its use, which can include issues of testing on animals or humans
  • Overpromotion. The increase in aggressive marketing and advertising efforts by manufacturers of prescription drugs has led to a corresponding increase in liability for injuries attributed to the drugs being marketed
  • Defectively designed drug or device, one that is arguably unfit for its intended purpose or is not merchantable
  • Tainted or contaminated drugs.

General product liability concepts of negligence and breach of warranty apply in medical device or product cases and are discussed below. All, or nearly all, of the above possible claims arose in the context of litigation over the food supplement, L-tryptophan, in the 1980s and 90s.

L-tryptophan is an essential amino acid, usually found in dairy products or meat. L-tryptophan and products containing it, were sold in the U.S. as “nutritional supplements.” As such, they were not regulated by the FDA. The products were promoted by distributors as effective in treating disorders such as insomnia, depression, and premenstrual syndrome. One of the largest manufacturers, a Japanese company called Showa Denko, began manufacturing raw L-tryptophan using genetically-engineered bacteria in an unusual fermentation process. Because its manufacturing process allowed it to undercut its competitor’s prices, Showa Denko was able to capture the lion’s share of the U.S. market for bulk L-tryptophan.

In the mid-1980s, people began developing an illness identified as Eosinophilia-myalgia syndrome, characterized by intense eosinophilia, a blood condition, and severe muscle pain, weakness, joint pain, swelling, fever, and skin rash. Some people died. The link to L-tryptophan was established and the FDA requested a voluntary recall of the products using L-tryptophan. Investigation focused on the Showa Denko product as the most likely culprit, and it was discovered that Showa Denko was aware, early on, that its product contained unknown impurities. The presence of these impurities was first noted by a German customer, which rejected a shipment of food-grade product. Showa Denko’s own testing confirmed the presence of the impurities and it attempted to modify its manufacturing process to address the problem. Unfortunately, the manufacturing modifications only led to an increase in one impurity, which is the one associated with the EMS outbreak. Knowing of the contamination, Showa Denko continued to manufacture and sell its product.

L-tryptophan was ultimately banned in the U.S. Showa Denko was shown to have altered its manufacturing by eliminated several quality control measures, which led to the development of the impure product. When the contamination was discovered, the company not only failed to warn customers and the using public of the presence of the contaminant, it actively attempted to cover up the problem. The product, while used as if it was a drug, was marketed as a nutritional supplement, for the sole purpose of avoiding FDA regulation in the U.S. It was regulated in Europe. The defective product was not tested until the German customer rejected a batch due to the contaminant. That batch was tested, the rejected batch was then relabeled, and sold for use in animal feed.

The FDA still cannot regulate nutritional supplements.

A. Negligence

The essential elements for a product liability claim based on negligence include (1) evidence of a standard of care owed by the reasonably prudent person under the same or similar circumstances, (2) breach of that duty, (3) injury proximately caused by breach of the duty, and (4) loss or damage due to the injury. McCollum v. Grove Mfg. Co., 58 N.C. App. 283, 293 S.E.2d 632, aff'd, 307 N.C. 695, 300 S.E.2d 374 (1983). To determine what constitutes “reasonable care,” look to the intended use of the product, foreseeable uses (and misuses), and potential hazards and risk of injury.

The duty placed on a product manufacturer to exercise reasonable care extends throughout the entire manufacturing process, including the obligation to make the product free of any potentially dangerous defect in manufacturing or design. Red Hill Hosiery v. Magnetek, Inc., 138 N.C. App. 70, 530 S.E.2d 321 (2000).

Remember that the negligence of the manufacturer must be one of the proximate causes of injury to the plaintiff. Also, there is no inference of negligence in design or formulation, or of a product defect, from the mere fact of a product malfunction. DeWitt v. Eveready Battery Co., 144 N.C. App. 143, 550 S.E.2d 511 (2001), 355 N.C. 672, 565 S.E.2d 140 (2002).

Proximate cause is that cause which, in a natural and continuous sequence, unbroken by any new and independent cause, produces the plaintiff's injuries, and without which those injuries would not have occurred. Shumaker v. United States, 714 F. Supp. 154, 162 (MDNC 1988); MCI Telecomm. Corp., at *13.

The test of proximate cause is whether the risk of injury, not necessarily in the precise form in which it actually occurs, is within the reasonable foresight of the defendant. Proximate cause is ordinarily a question of fact for the jury, to be solved by the exercise of good common sense in the consideration of the evidence of each particular case. It is only in exceptional cases, in which reasonable minds cannot differ as to foresee-ability of injury, that a court should decide proximate cause as a matter of law.

Id. (emphasis added). See also, Griggs, 82 N.C. App. at 133, 345 S.E.2d at 431 ("Causation is an inference of fact to be drawn from other facts and circumstances. However, it is only when the facts are all admitted and only one inference may be drawn from them that the court will declare whether an act was the proximate cause of an injury. But, that is rarely the case. Therefore, proximate cause of an injury is ordinarily a jury question.")(citations omitted).

Foreseeability is an inherent part of the standard of care, and has been since the earliest court decisions in the product liability field. If it is “reasonably foreseeable” that a defect may cause injury, the manufacturer may be held liable if the defect resulted from negligence. Cases involving pharmaceutical products and medical devices can present particularly murky issues of foreseeability, especially with increasing “off label” use of such products. For example, the drug Tegretol was originally approved and marketed for use in preventing seizures. After it was on the market, doctors began to prescribe it for treatment of bipolar disorder as an alternative to Lithium.

(1) Types of Negligence Claims

Enhanced Injury or Crashworthiness: North Carolina has recognized that the manufacturer of a motor vehicle (and by inference any product) is under a duty to anticipate foreseeable accidents and to design vehicles in a manner to avoid unreasonable risk of injury. Warren v. Colombo, 377 N.C. App. 249, 377 S.E.2d 249 (1989). It is not necessary that the specific defect cause the underlying accident, so long as the defect either caused the injury giving rise to the claim, or made the injury worse than it otherwise would have been.

The question of whether the contributory negligence of the plaintiff in the underlying accident would bar his or her claim may still be undecided in North Carolina. However, in Miller v. Miller, 273 N.C. 228, 160 S.E.2d 65 (1968), the Court held that plaintiff’s failure to use a seat belt was not contributory negligence, since that failure was not a cause of the underlying collision. The Court stated:

It would be a harsh and unsound rule which would deny all recovery to the plaintiff, whose mere failure to buckle his seat belt in no way contributed to the accident, and exonerate the active tortfeasor but for whose negligence the plaintiff’s omission would have been harmless.

273 N.C. at 237. The General Assembly later enacted N.C.G.S. §20-135.2A(d) (1989) which provides that a party’s failure to wear a seat belt as required by statute may not be introduced into evidence in any suit for damages for personal injury.

Query, however, whether N.C.G.S. §99B-4(3) would allow the defense to raise the claimant’s contributory negligence as a bar in a crashworthiness case.

Negligent Assembling, Processing or Handling: A “design defect” is an injury-producing hazard occurring during or as a result of normal (foreseeable) use of the product. The defect may result from a number of factors, including negligent selection of materials, failing to make a reasonable inspection, or in the manner in which the product is ultimately put together. A “manufacturing defect” is the result of a miscarriage in the manufacturing process which produces an unintended result. Boudreau v. Baughman, 332 N.C. 331, 368 S.E.2d 849 (1988).

“Marketing defects” include not only the manner in which the product is placed in the stream of commerce, but also the manner in which the product is labeled. A product may present a risk of harm if used in a certain way and the lack of an adequate warning may give rise to a claim if injury results from the use of the product in that manner.

NCGS §99B-6 codified defenses to claims based on negligent design and formulation. This section, too, adds little, if anything, to existing common law. Again, the manufacturer’s conduct must be unreasonable. The statute provides two options for proving negligent design or formulation: the manufacturer unreasonably failed to use a safer alternative design or formulation, that would prevent or substantially reduce the risk of injury without substantially impairing the usefulness, practicality or desirability of the product; or, the design was so unreasonable that a reasonable person, aware of the relevant facts, would not use the product.

These two options represent versions of the tests typically used in design defect cases, the risk vs. utility test and the consumer expectation test.

Subsection (b) lists seven factors to be considered in determining whether a manufacturer acted unreasonably. These are the typical risk/utility considerations encountered in product liability law and have their genesis in the old Learned Hand formula: liability depends on whether the burden of adequate precautions is less than the injury, multiplied by the probability of its occurrence. United States v. Carroll Towing Co., 159 F.2d 169, 173 (2d Cir. 1947).

The seven factors are:

  1. The nature and magnitude of the risks of harm associated with the design or formulation of the product in light of the intended and reasonably foreseeable uses, modifications, or alterations of the product.
  2. The likely awareness of product users, whether based on warnings, general knowledge, or otherwise, of those risks of harm.
  3. The extent to which the design or formulation conformed to any applicable government standard that was in effect when the product left the control of the manufacturer.
  4. The extent to which the labeling for a prescription or nonprescription drug approved by the FDA conformed to any applicable government or private standard that was in effect when the product left the control of the manufacturer.
  5. The utility of the product, including the performance, safety, and other advantages associated with that design or formulation.
  6. The technical, economic, and practical feasibility of using an alternative design or formulation at the time of manufacture.
  7. The nature and magnitude of any foreseeable risks associated with the alternative design or formulation.

The first two factors deal with risks associated with the design and the consumer’s awareness of the risks. Factor number 5 is a utility vs. benefit consideration. Factors 6 and 7 balance feasibility of alternative design against risks of that alternative design. Factors 3 and 4 represent a deviation from the standard risk/benefit analysis by allowing an evaluation of the product in the light of government standards. This may give greater weight to the defense that a product conformed to a government standard, even though the standard itself was minimal, at best.

One problem with the language in option (a)(2) is the use of “so unreasonable”, which might be taken to mean that plaintiff must actually prove gross negligence. The statute could be read so that “some” unreasonableness can be tolerated. If this is so, if a product was “so unreasonable” that no consumer, aware of the relevant facts, would use it, then a manufacturer who is aware of the relevant facts acts recklessly in selling the product in the first place. But, if the manufacturer is not aware of the facts, notwithstanding the unreasonableness of the product, then it would seem plaintiff must prove that the lack of awareness amounted to more than mere ordinary negligence. If that is the case, that is that ordinary negligence alone will not suffice, then plaintiff’s best option, and the most expensive option, is proof of a viable and reasonable alternative design.

Compare this to the holding in Barker v. Lull Engineering, 573 P.2d 443 (Cal. 1978), where the court said that “a product may be found defective in design if plaintiff establishes that the product failed to perform as safely as an ordinary consumer would expect when used in an intended or reasonably foreseeable manner.” 573 P.2d 443, 455-56. This is consistent with the Restatement of Torts (Second). So, while the Restatement (Second) view, and that of the Barker court turn on the consumer’s expectations of safety, North Carolina’s view is now that the product must be so unreasonably dangerous that an informed consumer wouldn’t use it. In other words, the prior law (even in North Carolina) was that the danger to the consumer must be unexpected, while the present law is that the danger to the consumer must be intolerable.

Negligent marketing (misrepresentation, fraud, deceit): Sometimes, the manner in which a product is advertised or is otherwise marketed may give rise to liability. Note, however, that in North Carolina merely imprinting the retailer’s label on a product will not, in itself, give rise to liability. Morrison v. Sears, Roebuck & Co., 80 N.C. App. 224, 341 S.E.2d 40, rev’d on other grounds, 319 N.C. 298, 354 S.E.2d 495 (1987).

Statements in advertising may create express warranties (see below).

Sometimes, the marketing of a product can involve elements of fraud, deceit, or unfair or deceptive trade practices.

Again, with reference to the pedical screw devices used in spinal fusion surgery involved claims that the defendant-manufacturers obtained FDA approval of the devices through fraud. The genesis of this theory is found in Silkwood v. Kerr-McGee Corp., 464 U.S. 238 ( 1984), the famous Karen Silkwood case. Silkwood was employed at a facility operated by defendant and died as a result of exposure to escaping plutonium. There was a large and highly publicized verdict, including $10 million in punitive damages, which was in part predicated upon upon defendant’s fraud and misrepresentations regarding safety and plutonium exposure. The 10th Circuit reversed, stating that punitive damages could not be awarded, as such an award was pre-empted by governmental regulation of a nuclear facility. The U.S. Supreme Court took the case and, in a typically fractured set of opinions, reversed, holding that an award of punitive damages based on state law was not pre-empted.

In the pedical screw cases, it was alleged that the defendant device manufacturers, along with consultants hired for that purpose, defrauded the FDA in order to obtain final market approval for the devices. It was clear from the evidence that a fraud on the FDA had taken place, as the scheme concocted by defendants involved renaming the product in order for it to be “grandfathered” in by virtue of a supposed substantial equivalent to a device which was on the market before the Medical Devices Amendments of 1976 to the Food, Drug and Cosmetic Act. The manufacturers then set about securing a market for the product by giving stock options to various well known spinal surgeons, sponsoring fellowships, and paying doctors to write positive articles to be submitted to medical journals, including SPINE, the Journal of the North American Spine Society. The editors allegedly received stock options as well and accommodated the manufacturers by printing favorable articles without disclosing the above and without peer review.

Relying on Silkwood and Lohr, suits were filed. Ultimately, the cases wound up in the Supreme Court, which recently (February, 2001) decided the case, holding that state law fraud-on-the-FDA claims conflicted with and were therefore preempted by the FDA’s regulatory authority. Buckman Company v. Plaintiff’s Legal Committee, 121 S.Ct. 1012 (2001).

Following the Buckman decision, Sandoz Pharmaceutical, a defendant in an Alabama case, sought to amend its answer and move for summary judgment in a case which also involved numerous other claims, including fraud on the medical community and the adequacy of warnings contained on the FDA approved package insert. The U.S. District Court agreed that Buckman preempted the fraud on the FDA claims, but was unpersuaded that remaining claims of misrepresentation, suppression, negligence and inadequate warnings were preempted. The court said:

Although Buckman precludes a plaintiff from seeking damages because the defendant lied to the FDA, it is something completely different to contend that plaintiff is precluded from seeking damages for injuries due to lies to her. Notwithstanding that information may have been misrepresented to or concealed from the FDA, once defendant undertook to misrepresent those facts to plaintiff, or to conceal from plaintiff facts it was bound to disclose, the plaintiff’s claim no longer rests simply on the assertion that the agency was defrauded but on the additional fact that she was defrauded.

Globetti v. Sandoz Pharmaceutical Corporation, 111 F.Supp.2d 1174 (N.D. Ala. 2000).

From the Globetti decision, it would appear that where a defendant manufacturer engages in fraud and misrepresentation in marketing a product, which product is defective and subsequently causes harm, plaintiff can pursue claims based on fraudulent misrepresentation to plaintiff, or perhaps to others such as the medical community, but not if the fraud was directed against the government agency with regulatory authority over the product.

Failure to Warn and Inadquate Warnings: N.C.G.S. §99B-4(1) bars a claim if the use of the product was contrary to any express and adequate instructions or warnings “delivered with, appearing on, or attached to” the product or on its original container or wrapping, if the user knew or should have known of the existence of the warnings.

In the case of many medical devices, the patient/consumer rarely sees or has access to any warnings or instructions. Frequently, even an implanting physician does not see instructions or warnings that come packaged with the device. In the case of implants, the device is purchased by the hospital and unpackaged by hospital staff in preparation for surgery. Sometimes, indeed frequently, a manufacturer’s representative is present in the operating room to assist the surgeon by identifying parts or even by instructing the surgeon in the use of the devices. Other medical devices also belong to the hospital and are prepped by hospital staff. The surgeon is sometimes unaware of these instructions or warnings.

In such a case, who is the “user” contemplated by the statute? Is it the implanting physician or the patient? If a sales rep is in the operating room assisting the surgeon, are instructions given by the sales rep sufficient to override any instructions or warnings found in the package insert? The statute clearly requires not only that any warning or instruction be both express and adequate, but also that the “user” have actual or implied knowledge.

In order to establish a claim based on an inadequate warning, N.C.G.S. §99B-5(a) requires plaintiff to show: (1) “the manufacturer or seller acted unreasonably in failing to provide such warning or instruction,” (2) “the failure to provide adequate warning or instruction was a proximate cause of the harm for which damages are sought,” and (3) either section 99B-5(a)(1) or 99B-5(a)(2) has been satisfied” (emphasis added). N.C.G.S. §99b-5(a)(1) applies if the manufacturer or seller becomes aware of the need to warn while the product is still in its control and if the product, without the warning, creates an unreasonably dangerous condition that the manufacturer or seller knew or should have known posed a substantial risk of harm to a reasonably foreseeable claimant. N.C.G.S. §99B-5(a)(2) deals with situations in which the manufacturer or seller becomes aware of the need to warn or instruct after the product has left its control. In such a case, plaintiff must prove that:

. . . after the product left the control of the manufacturer or seller, the manufacturer or seller became aware of, or in the exercise of ordinary care should have known that the product posed a substantial risk of harm to a reasonably foreseeable user or consumer and failed to take reasonable steps to give adequate warning or instruction or to take other reasonable action under the circumstances.

Evans v. Evans, et al., 153 N.C. App. 54, 569 S.E.2d 303, 311 (2002).

When it comes to package inserts with pharmaceutical products, the prescribing or administering physician will almost always testify that he/she did not rely on the manufacturer’s package inserts or promotional material. If the doctor is an interested witness (i.e., a co-defendant) Holley v. Burroughs-Wellcome Co., 74 N.C. App. 736, 330 S.E.2d 228 (1985), aff’d 318 N.C. 352, 348 S.E.2d 772 (1986) provides that the doctor’s testimony, alone, will not support summary judgment. Health care providers are foreseeable users of pharmaceuticals and medical devices and the manufacturer and seller therefore have a duty to warn them. Id. at 74 N.C. App. 746. Nor is the physician’s alleged reliance on his/her own expertise, does not necessary constitute an intervening cause so as to relieve the defendants’ of liability. Id. at 747. Thus, the “learned intermediary” rule may not apply to these situations. Too, the defendant manufacturers admittedly used the medical literature, sources relied upon by the physician, to keep the medical community apprised of the information contained in the package inserts. The physician may rely, indirectly, on the adequacy of the warnings found in the inserts without actually reading them.

Information found in instruction or operating manuals may give rise to a claim. In Driver v. Burlington Aviation, Inc., 110 N.C. App. 519, 430 S.E.2d 476 (1993), plaintiffs suffered injury when their aircraft crashed. They alleged that the manufacturer produced an instructional manual which gave inadequate instructions regarding carburetor icing. The Court of Appeals, in reversing the lower court’s summary judgment, allowed plaintiffs to proceed on a theory that the injuries resulted from the negligent failure to provide adequate warnings.

B. Breach of Warranty

(1) Breach of implied warranty. Warranty is essentially an element of contract law, and thus deals with consumer expectations. Because it “sounded in assumpsit,” it was generally felt before the enactment of Chapter 99B that contributory negligence (negligence being a creature of torts) could not be a defense. NCGS §99B-1.2 cleared up any confusion over that by declaring that the defenses allowed in Chapter 99B apply to breach of warranty claims (unless specified otherwise).

The Uniform Commercial Code (Chapter 25 of the General Statutes) establishes two types of implied warranty: the implied warranty of merchantability(NCGS §25-2-314) and the implied warranty of fitness for a particular purpose (NCGS §25-2-315).

Be aware that a merchant may disclaim all implied warranties. See, NCGS §25-2-316(2) and §25-2-719(1)(A). The disclaimer must be conspicuous. Muther-Ballenger v. Griffin Electric Consultants, Inc., 100 N.C. App. 505, 397 S.E.2d 247 (1990).

(a) Merchantability. The implied warranty of merchantability applies only to a seller of the product, who is also a merchant with respect to the product. NCGS §25-2-314(1). This implied warranty applies to both a manufacturer and a retailer of a product. Gillispie v. Thomasville Coca-Cola Bottling Co., 17 N.C. App. 545, 195 S.E.2d 45, cert. denied, 283 N.C. 393, 196 S.E.2d 275 (1973). The factors used to determine whether a product is “merchantable” are listed in NCGS §25-2-314(2), and merchantability is determined as of the time of the sale. Bryant v. Adams, 116 N.C. App. 448, 448 S.E.2d 832 (1994), cert. denied, 339 N.C. 736, 454 S.E.2d 647 (1995).

In order to prove breach of implied warranty of merchantability, plaintiff must prove five things: (1) a merchant sold the product, (2) the product was not “merchantable,” at the time of the sale (i.e., was defective and therefore unfit for the ordinary purpose for which it was used),
(3) plaintiff was injured by the product, (4) the injury was proximately caused by the defect in the product, and (5) the plaintiff gave timely notice to the seller. Reid v. Eckerd Drugs, Inc., 40 N.C. App. 476, 253 S.E.2d 344, cert. denied, 297 N.C. 612, 257 S.E.2d 219 (1979); Maybank v. S. S. Kresge Co., 46 N.C. App. 687, 266 S.E.2d 409 (1980), aff’d in part, rev. in part, 302 N.C. 129, 273 S.E.2d 681 (1981).

The Reid case is particularly useful in a claim based on breach of the implied warranty of merchantability. Plaintiff used an aerosol deoderant, purchased from Eckerd’s Drugs, and then lit a cigarette, igniting the alcohol from the deoderant, which still hung in the air, and was burned. The court held that the failure to warn of this potential danger could render the product unmerchantable. See also, Nicholson v. American Safety Utility Corp., 124 N.C. App. 59, 476 S.E.2d 672 (1996), rev’d on other grounds, *** N.C. ***, 488 S.E.2d 240 (1997), holding that failure to adequately warn renders a product unmerchantable.

Reid also provided that compliance with minimum government standards was not a bar to recovery on a breach of warranty theory. Query whether that remains the law following the 1995 amendments to Chapter 99B, particularly the provisions of NCGS §99B-6 which makes the extent to which the design or formulation conformed to any applicable government standard that was in effect when the product left the control of the manufacturer one of the considerations to be considered in determining whether a manufacturer acted unreasonably.

The decision in Reid also noted that the instructions for use which accompany a product may be an integral part of the implied warranty of merchantability.

(b) Implied warranty of fitness. Although the fitness of the product for the ordinary purposes for which such products are used is part of the implied warranty of merchantability, there is a separate statute which creates an implied warranty of fitness for a particular purpose. NCGS §25-2-315. This statute states:

“Where the seller at the time of contracting has reason to know any particular purpose for which the goods are required and that the buyer is relying on the seller’s skill or judgment to select or furnish suitable goods, there is unless ex-cluded or modified under the next section [G.S. 25-2-316] an implied warranty that the goods shall be fit for such purpose.”

The differences in the two statutes are that the implied warranty of fitness requires proof that the seller had reason to know of the particular purpose for which the product was to be used, and that the buyer relied on the seller’s skill or judgment in purchasing the product.

A ‘particular purpose’ differs from the ‘ordinary’ purpose for which the product is used in that it envisions a specific use of the product, as opposed to a general use of the product. In Tyson v. Ciba-Geigy Corp., 82 N.C. App. 626, 347 S.E.2d 473 (1986), plaintiff farmer consulted defendant’s salesman about no-till cultivation of soybeans. The salesman recommended a particular herbicide which, when used, damaged plaintiff’s crop. The court held this amounted to a breach of the implied warranty of fitness.

(c) Privity. N.C.G.S. §99B-2(b) eliminated the privity defense for implied warranty actions against manufacturers for specific classes of plaintiffs, including:

  • buyer
  • buyer’s guest
  • buyer’s family
  • buyers’ family guest, or
  • buyer’s employee

A question remains concerning whether lack of privity would be a defense in a claim against the manufacturer arising out of an injury proximately caused by a defect in a leased product.

If the plaintiff does not belong to the specific classes listed above, horizontal privity may remain a problem. For example, the court has held that the members of a church lacked privity, and could not pursue a claim against the manufacturer, where the minor plaintiff suffered frostbite when she was locked in a walk-in refrigerator. Also, merely installing or assembling the product does not make the installer a “manufacturer” and thus the installer/assembler has no duty to warn absent actual or constructive notice that the product is unreasonably dangerous. Crews v. W.A. Brown & Son, Inc., 106 N.C. App. 324, 416 S.E.2d 924 (1992).

(d) Breach of express warranty. NCGS §25-2-313 establishes the basic principles of express warranty. Express warranties are created by sellers by:

(a) Any affirmation of fact or promise made by the seller to the buyer which relates to the goods and becomes part of the basis of the bargain creates an express warranty that the goods shall conform to the affirmation or promise.

(b) Any description of the goods which is made part of the basis of the bargain creates an express warranty that the goods shall conform to the description.

(c) Any sample or model which is made part of the basis of the bargain creates an express warranty that the whole of the goods shall conform to the sample or model.

Mere expressions of value do not create express warranties.

A prima facie case for breach of express warranty was established in W. A. Davis Realty, Inc. v. Wakelon Agri-Products, Inc., 84 N.C. App. 97, 351 S.E.2d 816 (1987), in which plaintiff contracted with defendant for a quantity of Number 2 milling wheat, a commodity with few defective kernels, but an inferior wheat, containing a high percentage of defective kernels, was actually delivered. This breached both the implied warranty of merchantability and the seller’s express warranty that the product delivered was the Number 2 wheat for which plaintiff contract

Some language clearly establishes express warranty. Where the president of defendant corporation wrote a letter in which he stated “We guarantee our programming with full return and refund privileges for the software and printer should our programming not perform as warranted,” the statement created an express warranty, as a matter of law. Sharrard, McGee & Co. v. Suz’s Software, Inc., 100 N.C. App. 428, 396 S.E.2d 815 (1990). On the other hand, statements merely expressive of opinion, or which are merely puffing, do not create express warranties. A statement that defendant’s product is “reliable,” for example, was held to be puffing in Warzynski v. Empire Comfort Systems, 102 N.C. App. 222, 401 S.E.2d 801 (1991). In the Tyson case, cited above, in which the court found a breach of implied warranty of fitness, a statement that the herbicide in question would “do a good job” was mere opinion, and not an express warranty.

Although not specifically stated in NCGS §25-2-313, the phrase “which is made part of the basis of the bargain” carries an implication of reliance on the part of the buyer in order to establish a claim for relief. Reliance was clearly a requirement under the Uniform Sales Act (supplanted by the UCC) and many older, pre-UCC, cases turn on the question of reliance.

In North Carolina, most of the litigation has revolved around whether certain statements amounted to an express warranty, without much, if any, discussion of reliance. For that reason, the degree to which plaintiff will have to prove reliance on the warranty is unclear in North Carolina.

A case typical in states in which proof of reliance is a key element in the case is Thomas v. Amway Corp., 488 A.2d 716 (R.I. 1985). Plaintiff bought a bottle of liquid soap, identified as “Nature’s Shower,” from Amway. After using the soap, plaintiff developed an ugly and painful rash, which lasted for over a year. The bottle’s label stated that Nature’s Shower “leaves skin feeling silky clean,” that the soap is “gentle for all uses,” and that “everyone in the family will enjoy the convenience of this versatile body cleanser.” The trial court directed a verdict for defendant and was affirmed by the Rhode Island Supreme Court. The court said: “the plaintiff who claims breach of express warranty has the burden of proving that the statements or representations made by the seller induced her to purchase that product and that she relied upon such statements or representations.”

Reliance may be inferred from the mere fact of purchase if the natural tendency of the representations in question is to induce purchase. Bernick v. Jurden, 306 N.C. 435, 293 S.E.2d 405 (1982).

Some courts apply tests other than reliance. Wisconsin’s approach is typified in Ewers v. Eisenzopf, 276 N.W.2d 802 (Wis. 1979), in which plaintiff bought a saltwater aquarium and seventeen fish. Defendant owned a “rock shop” where plaintiff purchased some decorations for the aquarium. A friend with the plaintiff asked the store clerk if the decorations were suitable for a saltwater aquarium and was assured by the clerk that they were. Within a week all plaintiff’s expensive fish died. The Wisconsin court at first stated that the buyer’s reliance was “irrelevant” to the formation of an express warranty:

The true test is not whether the seller actually intended to be bound by his statement but rather whether he made an affirmation of fact the natural tendency of which was to induce the sale and which did in fact induce it.

citing Pritchard v. Liggett & Myers Tobacco Co., 350 F.2d 479, 487 (3rd Cir. 1965), cert. denied, 382 U.S. 987 (1966). Thus, although reliance was deemed “irrelevant,” the court stated that the linchpin in the determination is whether the statement had the “natural tendency” to induce the buyer.

Other courts apply an intermediate knowledge standard, in which the plaintiff buyer need not prove reliance on defendant’s representation, but only that plaintiff read, heard or saw the statement. For example, in Cipollone v. Liggett Group, Inc., 893 F.2d 541 (3rd Cir. 1990), aff’d in part and rev’d in part, 112 S.Ct. 2608 (1992), plaintiffs sued defendant cigarette manufacturers contending that Mrs. Cipollone contracted lung cancer from smoking. One of plaintiffs’ contentions was that the defendants breached an express warranty contained in various print and broadcast mediums. The Third Circuit said:

We believe that the most reasonable construction of section 2-313 is neither Liggett’s reliance theory, which fails to explain how reliance can be relevant to “what a seller agreed to sell” or the district court’s purely objective theory, which fails to explain how an advertisement that the buyer never even saw becomes part of the “basis of the bargain.” Instead, we believe the New Jersey Supreme Court would hold that a plaintiff effectuates the “basis of the bargain” requirement of section 2-313 by proving that she read, heard, saw, or knew of the advertisement containing the affirmation of fact or promise.

Id. at 548 n.1.

Some courts apply an objective, nonreliance, test. In Daughtry v. Ashe, 413 S.E.2d 336 (Va. 1992), the Virginia court commented on UCC § 2-313. In October, 1985, plaintiff Daughtry consulted Ashe, a jeweler, about purchasing a $15,000 diamond bracelet for his wife as a gift. Ashe “knew” and “classified” the diamonds in the bracelet with on of the highest ratings available for diamonds, “v.v.s.” While plaintiff was in defendant’s presence, defendant merely stated that the diamonds were “nice.” Later, Daughtry telephoned Ashe and agreed to buy the bracelet. An appraisal certificate, prepared by Ashe, stated the diamonds were of “H color and v.v.s. quality.” In February, 1989, Daughtry discovered the diamonds were not of “v.v.s.” quality and demanded defendant replace the diamonds. Defendant refused. Daughtry sued. The trial court dismissed plaintiff’s claim based on express warranty. On appeal, the Virginia Supreme Court disagreed, stating:

. . . in our opinion, the “part of the basis of the bargain” language of the Code does not establish a buyer’s reliance requirement. Instead, this language makes a seller’s description of the goods that is not his mere opinion a representation that defines his obligation.

* * *

We conclude from the language used in the Code and the Official Comment thereto that the drafters of the Uniform Commercial Code intended to modify the traditional requirement of buyer reliance on express warranties.

Id. at 339. Clearly, Daughtry did not rely on the certification that the diamonds were “v.v.s.” quality when he agreed to purchase the bracelet. Would he have bought it if the certification described a lesser quality? By the same token, at the time he agreed to the purchase, he had not been induced to do so by the certification of quality. Nevertheless, the certification amounted to a representation of quality and, in Virginia, an express warranty.

C. Proof of Defect

In cases arising out of alleged breach of warranty, there is no requirement that plaintiff prove the specific defect, if the product failed when put to its ordinary and intended use. Red Hill Hosiery, op cit. See also, Maybank v. Kresge Co., op cit. holding that the explosion of a flash cube under ordinary use is not merchantable, even without proof of the specific defect which caused the explosion.

There are some types of product malfunctions which give rise to a “fair inference” of a product defect. City of Thomasville v. Lease-Afex, Inc., 300 N.C. 651, 268 S.E.2d 190 (1980).

Conversely, if the claim arises out of negligence in design or formulation, there is no inference of product defect from the mere failure or malfunction of the product. DeWitt v. Eveready Battery Co., Inc., op cit.

In the context of medical devices, defects fall into one of these two categories: design defects and manufacturing defects. Design defects are, in a manner of speaking, intended. That is, the defect is inherent in the design of the device. Manufacturing defects, on the other hand, are not intended. For example, a syringe might be designed to be safe, but if it is manufactured incorrectly, the syringe would be said to have a manufacturing defect. A manufacturing defect is a mistake in the manufacturing process.

A manufacturing defect case presupposes that if the device had been flawlessly manufactured according to its design, the injury would not have occurred. Proof in a manufacturing defect case usually consists, in part, of the manufacturer’s own design or marketing standards. A design defect case attacks those very standards as inadequate. Devices are not defected merely because they may be dangerous. Many risks cannot be eliminated without also sacrificing features of the product that make it useful and desirable.

Occasionally, advancing technology can create a legal dilemma when a company introduces a safer product. Can the new and old products co-exist in the marketplace, or does the introduction of the safer model mean that the old product is de facto defective?

In Hansen v. Baxter Healthcare Corp., 764 N.E.2d 35 (Ill. 2002), the technology at issue was IV tubing sets with friction pit couplings, and the new technology was IV tubing sets with Luer-lock connections. The injury occurred in 1991, and the Luer-lock IV sets had been available for about 20 years at the time. Plaintiff was admitted to the hospital for stomach ulcer surgery, and had a central venous line started to allow infusion of blood and other fluids as necessary. While recovering from the surgery, the friction fit IV connector on the central line came apart. Plaintiff suffered an ultimately fatal air embolism. The estate sued the hospital, the doctors, and Baxter Healthcare, the manufacturer of the tubing. There was no evidence of a manufacturing defect, i.e., the connector was made correctly, it just came apart due to patient movement or from some other external movement. Plaintiff settled with the hospital and doctor and went to trial against Baxter Healthcare, claiming:

  • the tubing was unreasonably dangerous because it was designed, manufactured, and sold without a Luer-lock connection;
  • the friction-fit connection failed when the product was used in a reasonably foreseeable manner; and
  • Baxter failed to warn of the likelihood of unintentional disconnection and the need to use tubing equipped with the Luer-locking device.

The jury found for plaintiff. The intermediate appellate court found that the evidence was sufficient to justify the verdict based on the defective design theory, but that the verdict could not be sustained on the claim of failure to warn. Since the verdict was a “general” verdict, the court refused to disturb it and allowed it to stand. Baxter appealed to the Illinois Supreme Court, arguing that the Court of Appeals erred in finding that the verdict could be supported by the defective design theory. Plaintiff cross-appealed, arguing that the court should reverse the lower court’s holding that Baxter had no duty to warn the medical profession of dangers inherent in the product.

While plaintiff had experts to support its theory, the most effective testimony came from defendant’s own personnel, called as adverse witnesses. These witnesses confirmed that Baxter was aware at the time of the injury that friction-fit connectors sometimes failed due to patient movement, causing air embolisms in central line applications. They conceded that friction-fit connectors were inadequate for central line use and that, in such instances, medical professionals should use Luer-locks. Further, Baxter salesmen were not encouraged to recommend the Luer-locks for central line applications. Baxter simply made both products available to its customers.

Baxter’s chief engineer in charge of the IV product line testified that friction-fit connectors could accidentally disconnect, resulting in air embolisms. He actually recommended using the Luer-locks in central line applications. He added, however, that Baxter did not advise hospitals to use one product over the other, and that Baxter had not developed Luer-locks to prevent accidental disconnections or to increase patient safety. Rather, the Luer-lock mechanism was a competitive response to industry demands. He admitted that adding Luer-locks to all connectors was technically feasible and would add between 3¢ and 5¢ to the cost of each unit.

Plaintiff used Baxter’s patent application to rebut the testimony that Luer-locks were not developed for safety reasons. In the patent application, Baxter stated that the Luer-lock was designed to “overcome the problem of inadvertent disconnection that occurs with friction-fit connectors.”

This evidence that the Luer-locks were safer, and this safety was critical for central lines, was the heart of plaintiff’s case. Plaintiff argued that Baxter had a duty to warn about the dangers of using the friction-fit connectors and, more fundamentally, since the incremental cost of the safer product was so low, and since it posed no additional risks to offset its benefits, they rendered the friction-fit connectors defective and therefore such connectors should no longer be marketed. Baxter raised the learned intermediary defense, in that the medical community was aware of the risks of friction fittings disconnecting since there were ample medical literature and studies on these risks. It was the hospital’s negligence, said Baxter, and not Baxter’s failure to warn, that resulted in the tragedy.

The appeals court found that plaintiff’s claim was essentially that the friction fitting was defective because it could and did come apart due to patient movement. Reviewing the standards fro design defect claims in Illinois, the court focused on the traditional key to design defect cases - the alternative design. Here, there was no need to hypothesize about alternative designs, since the same manufacturer sold an alternative inexpensive design. Based on this, the court concluded that using either the consumer expectations or risk/benefit, the jury could properly find that friction fit connectors were rendered defective by the Luer-lock connectors.

The Supreme Court disagreed with the appellate court on the duty to warn claim. It found that there was sufficient conflicting testimony on what the defendant medical care providers, and the medical care providers in general knew, about the risks of disconnection that the issue could properly go to the jury. In considering the design defect claim, the court analyzed Baxter’s claim that it was improper to use a consumer expectations test for a medical device. It found that such connectors were purchased and used by nurses, without physician supervision. This non-physician use of this medical device was properly judged a consumer expectations test, rather than a physician’s expectations test. The court also disagreed with Baxter’s contention that the risk/benefit test should not apply because the product was simple and the risks easily appreciated and avoided. The Court referred to the patent application claims that the Luer-locks were needed for patient safety and thus the product was intended as a safety device. If such a device were in fact needed, and if the device was cheap and posed no additional risk, if it was not in universal use it could be assumed that the dangers were not obvious and thus the risk/benefit calculation was merited.

Is it legally justifiable to continue selling a less safe product when it has been superseded by a safer product with no significant disadvantages? More generally, is is legally justifiable to sell products with important safety devices as options?

D. Potential Defendants

Potential defendants may include:

  • Pharmaceutical company who manufactured and marketed a medication
  • Medical device manufacturer
  • Physician prescribing medication or use of medical device
  • Physician performing medical/surgical procedure involving the device
  • Distributor of medication
  • Nurse or other health care professional administering the medication
  • Hospital employing the physician or other health care professional
  • Hospital which allows the use of an experimental device without compliance with applicable regulations

If a product fails, causing injury, the manufacturer is usually the first suspect. However, discovering the identity of the actual manufacturer may be difficult. Many large retailers contract with several manufacturers to produce a product which is sold as the retailer’s own brand. If a seller holds itself out to the public as the manufacturer of the product, it cannot use N.C.G.S. §99B-2(a) as a defense, but will be treated as a manufacturer. Warzinsky v. Empire Comfort System, op cit. However, in Morrison v. Sears, Roebuck & Co., 80 N.C. App. 224, 341 S.E.2d 40, rev’d on other grounds, 319 N.C. 298, 354 S.E.2d 495 (1987) the Court held that imprinting the retailer’s trademark in a shoe was insufficient to bring the retailer within the §99-B definition of manufacturer.

The seller may also be a suspect, but §99-B makes it difficult to pursue the seller on most grounds. In Jones v. GMRI, Inc., et al., 144 N.C. App. 558, 551 S.E.2d 867 (2001), plaintiff was injured when she bit into a meatball at an Olive Garden restaurant. Suit was filed against the owner or fanchisee of the restaurant and the company which allegedly supplied or manufactured the meatball. The restaurant could not (or would not) produce an incident report which allegedly identified the supplier of the meatball so the suspected manufacturer was dismissed due to lack of evidence. The defendant’s uncontradicted evidence showed that the meatballs came to it in sealed plastic bags and it did not slice or cut into the meatballs or otherwise inspect them before dumping them into tomato sauce, heating and serving. The jury found that defendant, while having breached the implied warranty of merchantability, nevertheless did not have a reasonable opportunity to inspect the food in a way which would have revealed the defect and, therefore, awarded no damages. The Court noted that plaintiff produced no evidence tending to show that the Olive Garden was the “apparent manufacturer.”

Even had the restaurant inspected the meatballs, absent proof that the inspection was negligently conducted, such inspection does not convert the seller to a manufacturer. Nicholson v. American Safety Utility, Corp., op cit.

V. CONCLUSION

Any situation involving injuries caused by drugs or defective medical devices should be evaluated thoroughly and critically for a potential legal claim. These claims often involve other theories of recovery, such as medical negligence. The frequently devastating nature of the damages inflicted justify the kind of investigation necessary to evaluate the claim. The obstacles are many and sometimes harsh, but success can be very gratifying.

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