Continuous Element Decontamination and Sterilization System

Abstract

The continuous element decontamination and sterilization system includes a set of transition and working chambers, a set of ports, a conveyor system, and containers. The sterilization system uses chambers to form a modular system, with each working chamber sandwiched between a preceding transition chamber and a succeeding transition chamber. The transition chambers act as pre- or post-conditioning devices that condition containers before they enter the working chambers. In this way, conditions within the working chambers do not fluctuate as the containers are moved into the working chambers by the conveyor system. The conveyor system moves containers through the transition and working chambers, allowing users to reload containers to pass through the chambers for subsequent sterilization operations. Ports are integrated into the chambers to allow fluids and cleaning agents to be pumped into and extracted from the chambers.

Description

[Technical Field]

[0001] The present invention relates generally to the decontamination and / or sterilization and / or physicochemical treatment of components and / or equipment for the medical industry, and more specifically to the decontamination and / or sterilization and / or physicochemical treatment of components and / or medical equipment found in hospitals, the pharmaceutical industry, the biotechnology industry, or laboratories, but is not limited to such applications and is also applicable to the food industry, the chemical industry, decontamination of biological waste, and the curing of polymers, rubber, and composites. [Background technology]

[0002] The majority of sterilization systems used in hospitals, laboratories, and other industries perform the sterilization process by a batch method: depending on the machine capacity, related elements are processed within the same cycle parameters and queued until there are enough elements to fill the chamber capacity.

[0003] The chamber capacity has a direct correlation to the financial aspects of running a sterilization cycle, so the number of waiting elements must be a reasonable economic quantity to continue the process. The productivity and idle time of these machines is directly related to the adjustments and changes in ambient conditions within the chamber and the elements within the chamber.

[0004] The above mentioned machines have inherent problems with sterilization process variability in their design, which variability is caused by the so-called "load weight," which is characterized by the distribution, type, and amount of elements loaded into the chamber. Various attempts at improvements to circumvent the distribution and weight problems have been investigated and explored in previous patents.

[0005] One of the primary factors evaluated by users when selecting a sterilization device is resource consumption and waste, which can result in significant costs and environmental impacts. For example, a conventional autoclave must use the total chamber volume to: expel air (vacuum), preheat, fill with steam, compensate for water loss and heat in the form of condensation, release steam, reduce the temperature of the discharged fluid (usually with chilled water) before it reaches the drain, dry the wet elements, and cool the interior. Traditional processes consume significant amounts of energy in the form of heat to generate the vacuum (water ring pump), mechanical work for the vacuum pump, and water in the form of steam as a coolant.

[0006] In patent EP0138688A2, the system refers to one or more baskets as flow directing devices with fan(s) that create a cross flow of gas or mixture, but like common prior art equipment used in various industries, this equipment describes one chamber in which all elements and baskets are treated simultaneously with exactly the same cycle conditions, and in fact the main objective of EP0138688A2 is to homogenize the treatment conditions along all baskets in the embodiment.

[0007] Patent US20140301895A1 describes an in-line sterilization apparatus with a conveyor that moves the elements to be processed through separated chambers by a system of sliding doors. This system does not demonstrate the concept of standardizing conditions using what we refer to as transition chambers in our embodiments. Although there is mention of dwell chambers, these are used in the same way as what we refer to as pre-conditioning or post-conditioning chambers in our embodiments. Because it does not include a standardization or equalization chamber, it is not possible to maintain constant conditions in the various chambers while the elements are being processed and transported.

[0008] Thus, the components to be sterilized cannot flow continuously or semi-continuously through the steps of the cycle without affecting the surroundings of each module. To implement an embodiment as a continuous, serial processing sterilizer, the chambers must be adapted so that the process opens the doors of the chambers to which the modules are connected. The above patent also limits the concept to serial connection of modules.

[0009] Patent US4707334A relates to a sterilization system. The patent describes a chamber that generates an atmosphere containing toxic vapors and is separated from the surrounding environment by air pressure. This separation technique allows the object to be sterilized to be transported into and removed from the chamber without leaking steam or air into the chamber.

[0010] US4707334A is only applicable to processes where the sterilization method does not require pressurization or low / medium vacuum, so the scope of application is limited. Therefore, an invention that overcomes the above drawbacks is needed. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic diagram of one embodiment of the operational sequence of the method of the present invention. [Figure 2] FIG. 10 illustrates multiple vessels traversing from a working chamber to a transition chamber. [Figure 3] FIG. 10 illustrates multiple vessels traversing from a transition chamber to a working chamber. [Figure 4] FIG. 1 is a diagram showing the configuration and arrangement of a system according to the present invention. [Figure 5] FIG. 10 illustrates another configuration and arrangement of the system of the present invention. [Figure 6] FIG. 1 is an isometric perspective view of a transition chamber of the present invention. [Figure 7] FIG. 2 is a right side view of the transition chamber of the present invention. [Figure 8] FIG. 8 is an enlarged view of multiple transition chambers of the present invention as shown in FIG. 7. [Figure 9]FIG. 2 is a front view of the transition chamber of the present invention. [Figure 10] FIG. 2 is a left side view of the transition chamber of the present invention. [Figure 11] FIG. 12 is a rear view of the transition chamber of the present invention. [Figure 12] FIG. 2 is a top view of a transition chamber of the present invention. [Figure 13] FIG. 1 is a bottom view of the transition chamber of the invention. [Figure 14] FIG. 1 is an isometric perspective view of a working chamber of the present invention; [Figure 15] FIG. 2 is a right side view of the working chamber of the present invention. [Figure 16] FIG. 16 is an enlarged view of multiple working chambers of the present invention as shown in FIG. 15. [Figure 17] FIG. 1 is a front view of the working chamber of the present invention. [Figure 18] FIG. 2 is a left side view of the working chamber of the present invention. [Figure 19] FIG. 2 is a rear view of the working chamber of the present invention. [Figure 20] FIG. 2 is a top view of the working chamber of the present invention. [Figure 21] FIG. 2 is a bottom view of the working chamber of the present invention. [Figure 22] FIG. 1 is an isometric perspective view of one container of the plurality of containers of the present invention. [Figure 23] FIG. 2 is a front view of one of the containers of the present invention. [Figure 24] FIG. 2 is a top view of one of the containers of the present invention. [Figure 25] FIG. 1 is a schematic diagram of a working chamber sandwiched between two transition chambers for use in the present invention. [Figure 26] FIG. 1 is an isometric perspective view of a container in an open configuration. [Figure 27] FIG. 1 is an isometric perspective view of a container in a closed configuration. DETAILED DESCRIPTION OF THE INVENTION

[0012] All illustrations in the drawings are for the purpose of illustrating selected versions of the invention and are not intended to limit the scope of the invention.

[0013] Referring to Figures 1-24, the present invention is a decontamination and disinfection system designed to perform various types of disinfection processes. The system includes a plurality of working chambers 3 and a plurality of transition chambers 2. A conveyor system 15 traverses each of the plurality of working chambers 3 and each of the plurality of transition chambers 2. Elements to be sterilized move via the conveyor system 15 throughout the system. The elements move within a container 18 that moves through the structure and series of working chambers 3 and transition chambers 2. The internal conditions of each working chamber 3 and each transition chamber 2 are varied to perform specific processing steps that ensure a complete disinfection cycle.

[0014] A preferred embodiment of the present invention comprises a plurality of transition chambers 2, a plurality of working chambers 3, a plurality of transition ports 4, a plurality of working ports 8, at least one conveyor system 15, and at least one container 18. The plurality of transition chambers 2 comprises a collection of tubular structures that function as intermediate points between various chambers of the system. The plurality of working chambers comprises a collection of chambers used to perform steps along a sterilization process. The plurality of transition ports 4 comprises a collection of ports located on a transition chamber of the plurality of transition chambers 2. The transition ports 4 allow fluids and / or the like to enter or exit the transition chamber of the present invention. The transition ports 4 of the plurality of transition ports 4 are circular in geometric outline, but the geometric outline may be any shape that meets manufacturing, design, and use requirements. Similarly, the plurality of working ports 8 comprises a collection of ports located on a working chamber of the plurality of working chambers 3. The working ports allow fluids and / or the like to enter or exit the working chamber of the present invention. The working ports of the plurality of working ports 8 are circular in geometric outline, but the geometric outline may be any shape that meets manufacturing, design, and use requirements. The conveyor system 15 of the present invention is a continuous conveyor system 15. In a continuous conveyor system 15, an object placed at a starting point is continuously displaced through the system until it reaches the end of the cycle, and this movement is maintained in time. In a preferred embodiment of the present invention, the conveyor system 15 is designed and arranged to match a configuration of multiple working chambers 3 and multiple transition chambers 2. Therefore, the present drawings are intended solely for the purpose of illustrating the present invention, and the conveyor system 15 is not limited to the above configuration and is not limited in scope to such. The container 18 of the present invention is a permeable container having a cylindrical outer shape. However, the present invention is not limited to such a geometrical shape and may have any geometrical shape that meets manufacturing, design, and / or use requirements. Each of the multiple working chambers is connected between a preceding chamber 16 and a succeeding chamber 17. As a result, the physicochemical conditions in the first working chamber are separated from the physicochemical conditions in the second working chamber.

[0015] Additionally, the leading chamber 16 and the trailing chamber 17 form multiple transition chambers 2. This configuration allows the working chambers 3 and the transition chambers 2 to form a continuous sterilization unit in which a collection of contaminated items undergoes a series of physicochemical operations to sterilize the items. The configuration of multiple working chambers 3 and multiple transition chambers 2 also allows the present invention to separate each working chamber, thereby optimally maintaining the required conditions for each operation and allowing processing to be performed without changing the physicochemical environmental characteristics used in any of the working chambers 3. That is, the multiple transition chambers 2 function as a control channel between the operating conditions of the multiple working chambers 3. Furthermore, any of the multiple transition ports 37 is integrated into each of the multiple transition chambers 2, and any of the multiple transition ports 37 is a transition port among the multiple transition ports 4. As a result, any of the multiple transition ports 37 among the multiple transition ports 4 provides an access point to control the environment of the transition chamber 2. Thus, the transition port 4 allows the entry and exit of fluids and / or the like utilized during the sterilization cycle. Similarly, any of the plurality of working ports 38 is integrated into each of the plurality of working chambers 3, and any of the plurality of working ports 38 is a working port from the plurality of working ports 8. Thus, any of the plurality of working ports 38 among the plurality of working ports 8 provides an access point to control the environment of the working chamber 3. Thus, the working port allows for the entry and exit of fluids and / or the like utilized during a sterilization cycle. Also, the conveyor system 15 of the present invention is operatively connected between the plurality of working chambers 3 and the plurality of transition chambers 2, and the conveyor system 15 moves the containers 18 between the plurality of working chambers and the plurality of transition chambers 2. Thus, the containers 18 move reliably and safely through the plurality of transition chambers 2 and working chambers 3. The fixation of the containers 18 ensures proper sterilization when the present invention is in use.

[0016] The plurality of working chambers 3 further comprises at least one pre-conditioning chamber 39, at least one sterilization chamber 40, and at least one post-conditioning chamber 41. The pre-conditioning chambers allow for pre-conditioning of the components within the container 18. To achieve a level of performance and reliability during the sterilization cycle, it is important to perform several different steps or sub-cycles that accommodate the components being processed before and after the sterilization step or sub-cycle. Therefore, the application of the steps performed within the pre-conditioning chamber 39 is essential, and thus the presence of the pre-conditioning chamber 39 is necessary for continuous processing. The sterilization chamber 40 of the present invention allows for the sterilization of the components within the container 18. In the sterilization chamber 40, the environment is under the correct physicochemical conditions to successfully sterilize the components within the container 18. The post-conditioning chamber 41 allows for post-conditioning of the components within the container 18. Similar to the pre-conditioning chamber 39, the post-conditioning chamber 41 allows for changes in temperature, pressure, reduction of chemical concentration levels, or any other physicochemical adjustments after the components within the container 18 have been sterilized. Therefore, the post-conditioning chamber 41 also avoids undesirable effects such as thermal shock and thermal fatigue. The pre-conditioning chamber 39, the sterilization chamber 40, the post-conditioning chamber 41, and the multiple transition chambers 2 are connected in series. As a result, the pre-conditioning chamber 39 is always located before the sterilization chamber 40, and the post-conditioning chamber 41 is always located after the sterilization chamber 40. Additionally, the transition chambers are always located before and after the pre-conditioning chamber 39, the sterilization chamber 40, and the post-conditioning chamber 41. As described above, the sterilization chamber 40 is located between the pre-conditioning chamber 39 and the post-conditioning chamber 41. As a result, the present invention ensures that the steps in the cycle are performed continuously with minimal or no system downtime while the containers 18 undergo the sterilization process. Furthermore, the conveyor system 15 is operably connected between the pre-conditioning chamber 39, the sterilization chamber 40, the post-conditioning chamber, and the multiple transition chambers 2, and the conveyor system 15 moves the containers 18 between the pre-conditioning chamber 39, the sterilization chamber 40, the post-conditioning chamber, and the multiple transition chambers 2. As a result, the multiple transition chambers 2 according to the present invention cycle between adjacent working chamber conditions, changing ambient conditions to adapt to the adjacent chamber conditions.Specifically, the transition chambers 2 act as conditioning chambers that prepare containers 18 for transfer into subsequent chambers 17. This conditioning action allows each operating chamber 3 to maintain a stable, repeatable sub-cycle, thereby reducing energy losses and time requirements to perform a sterilization operation.

[0017] The present invention also includes at least one working mesh 11. The working mesh 11 is a permeable layer that matches the geometric outline of the plurality of working ports 8. The plurality of working ports 8 further includes at least one working input port 9 and at least one working output port 10. The working input port 9 serves as a direct input port for the input of fluids and / or the like utilized during the disinfection cycle. Similarly, the working output port 10 serves as a direct output port for the exit of fluids and / or the like utilized during the disinfection cycle. The working input port 9 is positioned opposite any working chamber and offset from the working output port 10, which may be from the plurality of working chambers 3. Thus, the working input port 9 and the working output port 10 remain independent of and do not affect each other during use. The working mesh 11 is also attached over the working output port 10. Thus, the working mesh 11 allows for the capture and / or filtering of undesirable substances, such as small particles or fibers, that are stuck in the downward flow component.

[0018] The present invention further includes at least one transition mesh 7. The transition mesh 7 is a permeable layer that conforms to the geometric contours of the plurality of transition ports 4. The plurality of transition ports 4 further includes at least one transition input port 5 and at least one transition output port 6. The transition input port 5 serves as a direct input port for the inlet of fluids and / or the like utilized during the disinfection cycle. Similarly, the transition output port 6 serves as a direct output port for the outlet of fluids and / or the like utilized during the disinfection cycle. The transition input port 5 is positioned opposite any transition chamber and offset from the transition output port 6, which may be from the plurality of transition chambers 2. Thus, the transition input port 5 and the transition output port 6 remain independent of and unaffected by each other during use. The transition mesh 7 is also attached over the transition output port 6. Thus, the transition mesh 7 allows for the capture and / or filtering of undesirable material, such as small particles or fibers, that may be lodged in the downward flow component.

[0019] Additionally, a preferred embodiment of the present invention includes a plurality of transition measurement systems 13. The plurality of transition measurement systems 13 includes sensors selected from the group consisting of temperature sensors, pressure sensors, chemical sensors, biological material sensors, and humidity sensors. Each of the plurality of transition measurement systems 13 is incorporated into a corresponding transition chamber 42, which is one of the plurality of transition chambers 2. Therefore, data measurement and monitoring can be performed during operation. Specifically, the plurality of transition measurement systems 13 monitors the state of the environment within each transition chamber and provides feedback to the control system so that conditions within the transition chamber can be modified to optimize the sterilization operation.

[0020] Similarly, a preferred embodiment of the present invention includes a plurality of work measurement systems 12. The plurality of work measurement systems 12 includes sensors selected from the group consisting of temperature sensors, pressure sensors, chemical sensors, biological substance sensors, and humidity sensors. Each of the plurality of work measurement systems 12 is integrated into a corresponding work chamber 43, and the corresponding work chamber 43 is a work chamber among the plurality of work chambers 3. Thus, data measurement and monitoring can be performed during work. Specifically, the plurality of work measurement systems 12 monitors the state of the environment in each work chamber and provides feedback to the control system so that the state in the work chamber can be corrected to optimize the disinfection work.

[0021] Additionally, preferred embodiments of the present invention further include a plurality of insulating liners 14. The insulating liners 14 of the plurality of insulating liners 14 are structural layers that may be present inside or outside each of the plurality of transition chambers 2 and each of the plurality of working chambers 3. The insulating liners 14 provide thermal insulation for each of the plurality of transition chambers 2 and the plurality of working chambers 3. The insulating liners 14 may have any geometric shape that meets manufacturing, design, and / or use requirements. As described above, each of the plurality of transition chambers 2 and each of the plurality of working chambers 3 is covered by a corresponding liner of the plurality of insulating liners 14. Thus, thermal insulation is maintained in each of the plurality of transition chambers 2 and each of the plurality of working chambers 3. In some embodiments, the insulating liners 14 are overlaid on all pipes, tubing, and other fluid-transporting components and similar connections that contact or are adjacent to instrument ports or chambers.

[0022] Furthermore, the container 18 of the preferred embodiment of the present invention includes a first end cap 23, a second end cap 44, an access door 19, at least one permeable side wall 20, at least one first gasket 21, and at least one second gasket 22. The end caps have a geometric outline of a sturdy plate and are manufactured from any feasible material capable of safely withstanding operational conditions. Preferably, the end caps include an insulating material forming the end cap between two sturdy plates to maintain thermal insulation between the chambers. In some embodiments, the access door 19 is removable from the container 18, which means that elements within the container 18 can enter and exit the container 18. The permeable side wall 20 is a mesh-like structure having a cylindrical geometric outline, but is not limited thereto. The permeable side wall 20 is also manufactured from any material capable of withstanding operational conditions. Furthermore, the access door 19 is integrated into the container 18, allowing a user to open the container 18 and remove items stored therein. The first gasket 21 and the second gasket 22 are ring-shaped structures that provide a seal between the vessel 18 and any transition chambers. The first gasket 21 and the second gasket 22 can be fabricated from any material that can withstand operational conditions while also being non-rigid. The first end cap 23 and the second end cap 44 of the present invention are connected adjacent to opposite ends of the permeable sidewall 20. Specifically, the first end cap 23 is connected to the end of the permeable sidewall 20, and the second end cap 44 is connected to the end of the permeable sidewall 20 opposite the first end cap 23. In some embodiments, the access door 19 is integrated into the permeable sidewall 20 and can be attached and detached by any means, such as screws, hinges, locking pins, or slides, among others. Thus, users can be confident that contaminated items placed within the vessel 18 will not be lost within the multiple working chambers 3 or multiple transition chambers 2. Furthermore, the first gasket 21 is connected around the first end cap 23. Similarly, the second gasket 22 is connected around the second end cap 44. As a result, the first gasket 21 and the second gasket 22 are pressed against the walls of the transition chambers 2 as the container 18 moves between the working chambers 3.This creates an airtight seal that prevents conditions within any one working chamber from seeping into an adjacent working chamber, and the contents of container 18 are safely transported throughout the sterilization cycle. Additionally, permeable sidewall 20 of container 18 allows the contents of container 18 to directly contact the conditions in each of the plurality of transition chambers 2 and each of the plurality of working chambers 3.

[0023] An alternative preferred embodiment of the present invention further includes a plurality of hatches 24. The hatches in the plurality of hatches 24 may be at least one of the following, but are not limited to, horizontal sliding doors, vertical sliding doors, hydraulic sliding doors, pneumatic sliding doors, and electric sliding doors. The hatches allow for separation of each of the plurality of transition chambers 2 from each of the plurality of working chambers 3, and serve as end caps and seals for the vessel 18, as opposed to previous options. A leading hatch 25 is integrated into the connection between the leading chamber 16 and any of the working chambers, which are from the plurality of working chambers 3, and the leading hatch 25 is from the plurality of hatches 24. As a result, the leading hatch 25 serves as a barrier to the exchange of fluids and physicochemical conditions between the leading chamber 16 and any of the working chambers. Similarly, a trailing hatch 26 is integrated into the connection between the trailing chamber 17 and any of the working chambers, which are from the plurality of hatches 24. The trailing hatch 26 therefore acts as a barrier to the exchange of fluids and physicochemical conditions between the trailing chamber 17 and any working chambers.

[0024] Additionally, the preferred embodiment of the present invention further includes a plurality of hatch gaskets 27 and a plurality of insulating hatch liners 28. The hatch gaskets of the plurality of hatch gaskets 27 are malleable sealing components that conform to the geometric contours of the hatches of the plurality of hatches 24 and provide an airtight seal between the gasket and any transition chambers or any working chambers. Each of the plurality of hatch gaskets 27 is integrated around its corresponding hatch. Thus, the hatch gasket hermetically seals the opening of the corresponding hatch. The insulating hatch liners 28 provide insulation similar to the insulating liners 14 found in each of the plurality of working chambers 3 and each of the plurality of transition chambers 2. Each of the insulating hatch liners 28 is also housed within its corresponding hatch. Specifically, each of the insulating hatch liners 28 is incorporated into the sturdy exterior surface of the hatch that is exposed to the interiors of the plurality of transition chambers 2 and the plurality of working chambers 3. As a result, thermal insulation is achieved between each of the plurality of transition chambers 2 and each of the plurality of working chambers 3. Additionally, insulating hatch liners 28 protect against exposure to fluids and chemicals necessary to perform sanitizing operations. Hatches from the plurality of hatches 24 also include safety locking mechanisms that prevent the plurality of hatches 24 from being opened while an unsafe condition exists within the plurality of working chambers 3 and the plurality of transition chambers 2.

[0025] Some embodiments further include a plurality of linear actuators 29. The linear actuators from the plurality of actuators are at least one selected from the group consisting of pneumatic actuators and hydraulic actuators. Each of the plurality of linear actuators 29 is integrated into a sidewall of a corresponding transition chamber 42, which is from the plurality of transition chambers 2. Thus, the linear actuators help overcome the pressure difference experienced by the container 18 when entering any transition chamber from a preceding working chamber, and when entering any working chamber from a preceding transition chamber. Furthermore, the container 18 is operably coupled to the linear actuator of the corresponding transition chamber 42, such that the linear actuator provides sufficient force to overcome the pressure difference between the preceding chamber 16 and any adjacent working chamber from the plurality of working chambers 3. In this case, the linear actuators 29 may take any reliable configuration capable of overcoming the pressure difference. Thus, a possible configuration is a plurality of hydraulic actuators that are activated once the container 18 enters any transition chamber. The hydraulic actuators then contact the container 18 and propel the container through any transition chamber.

[0026] The conveyor system 15 of the present invention further comprises a loading section 30, an unloading section 31, a processing section 32, and a feedback section 33. The loading section 30 is the start of the conveyor system 15 where the containers 18 are placed before a sterilization cycle. The unloading section 31 is the end of the conveyor system 15 where the containers 18 are unloaded after a sterilization cycle. The processing section 32 is the portion of the conveyor system 15 that extends from the first transition chamber to the last transition chamber. Thus, the processing section 32 traverses through the arrangement of each of the plurality of working chambers 3 and each of the plurality of transition chambers 2. The feedback section 33 is the portion of the conveyor system 15 after the unloading section 31 and before the loading section 30. The feedback section 33 of the conveyor system 15 creates a closed loop configuration by returning the containers 18 to the start. The loading section 30 is positioned adjacent to the first leading chamber 34, which is from the plurality of transition chambers 2. As a result, once a container 18 is placed on the loading section 30, the container 18 moves reliably into the first preceding chamber 34. The unloading section 31 is positioned adjacent to the last subsequent chamber 35, which is from the plurality of transition chambers 2. Thus, once a container 18 leaves the last subsequent chamber 35, the container 18 moves reliably into the unloading section 31. The processing section 32 is connected between the loading section 30 and the unloading section 31. Thus, the processing section 32 displaces the container 18 from the start of the disinfection cycle to the end of the disinfection cycle. The processing section 32 traverses across the plurality of transition chambers 2 and the plurality of working chambers 3. As a result, the processing section 32 helps to retain the container 18 within each of the plurality of transition chambers 2 and each of the plurality of working chambers 3. The feedback section 33 is connected between the loading section 30 and the unloading section 31. Thus, the feedback section 33 helps to return the container 18 to the start of the disinfection cycle. The feedback section 33 is positioned offset from the processing section 32 around the conveyor system 15. As a result, the conveyor system 15 allows for a modular configuration, and the sterilization system can be positioned in a variety of locations. Throughout all variations and possible configurations of each of the plurality of transition chambers 2 and each of the plurality of working chambers 3, the sterilization system maintains a continuous working configuration.

[0027] A preferred embodiment of the present invention also includes a programmable controller 36 having a human-machine interface (HMI). The HMI is part of the control system that manages the operation of the present invention. For example, the programmable controller 36 enables the initiation of any operation input or output ports and / or any transition input or output ports, any conveyors, actuators, hatches, or other automated components. The controller also receives signals from various sensors and instruments. The HMI, in turn, may provide options for setting operational parameters such as time, temperature, and pressure. These options are understood by the person operating the machine in terms of the direct operational parameters that result in the desired disinfection end result. The controller then operates based on the settings provided by the HMI to operate components under said control to achieve the required results. Thus, the programmable controller 36 and HMI provide control and monitoring of the operating parameters of the multiple transition chambers 2, the conveyor system 15, and any working chambers and / or transition chambers communicatively coupled to the multiple working chambers 3. As a result, the disinfection system is fully controllable and monitorable via the HMI. Data values ​​and readings from the multiple measurement systems are also visible via the HMI. Various possible manual overrides and programmable automation are implemented in the HMI.

[0028] Although the present invention has been described in terms of preferred embodiments, it should be understood that many other modifications and variations are possible without departing from the spirit and scope of the invention as hereinafter claimed. supplementary explanation Existing problems that this invention solves:

[0029] Idle time of elements or medical equipment: The current system is batch-type and depending on the machine capacity, the elements being processed must remain in the queue until there are enough elements that can be processed with the same cycle parameters and it is reasonably economical to complete the chamber capacity to proceed with the process.

[0030] Faster turnaround time: When a medical device or instrument is reused, for example in a medical application, the element can be processed immediately. Because each stage of the cycle is already under the correct conditions for the process to occur, the element can go through the cycle without having to wait for the machine to adjust chamber conditions intermediately.

[0031] Machine footprint and the entire sterilization sector: The size of the machine can be similar or slightly larger than conventional machines on the market, but can achieve several times the productivity mentioned above. The sterilization sector can use one of the proposed machines to replace several conventional machines, and the shape of the machine can be adapted to the limitations of the room in which it is installed, allowing the sector to optimize its usage space.

[0032] Variability in the sterilization process based on load weight can lead to process failure. Studies have shown variability in the sterilization process based on the type and amount of load (weight and distribution). It is well known that the results show increased time and preconditioning required. The present invention reduces the impact of the above factors on variability and, therefore, cycle effectiveness, because only a few elements are added to the process running at any one time and are easily overcome by the machine. Additionally, the chamber is more stable due to a design that maintains constant internal conditions during operation, and in contrast to conventional machines, there can be no impact on effectiveness due to the distribution of the load within the chamber.

[0033] Energy and Resources (e.g., water, chemicals, etc.): One of the primary factors evaluated by users when selecting a sterilization device is resource consumption, waste, and environmental impact, which can account for significant costs. For example, a conventional autoclave must use the total chamber volume to: expel air (vacuum), preheat, fill with steam, compensate for water and heat losses in the form of condensation, release steam, reduce the temperature of the discharged fluid before it reaches the drain (usually with chilled water), dry the wet elements, and cool the interior. All of these processes consume significant amounts of energy in the form of heat to generate the vacuum (water ring pump), mechanical work for the vacuum pump, and water in the form of steam as a coolant. The proposed design must do the same, but because conditions within each chamber are maintained, the amount of change, water, and energy consumed is significantly less in comparison. Injected steam is only needed to condition the incoming elements and compensate for heat losses from the chamber walls. It is only needed to maintain the vacuum and release the amount of air that will be drawn in with the new load. As with the cooling process, no excess heat is generated from the machine structure, only the elements come from the previous stage, and emissions are reduced because there is no need to exhaust steam and the only steam and water wasted in the process comes from the condensate in the preconditioning stage with the steam pulse. Short description

[0034] It is a system for decontamination and / or sterilization and / or physical treatment of elements and / or equipment for the medical industry, such as hospitals, pharmacies, medical devices, biotechnology, or laboratories. However, it is also applicable to the food and chemical industries, decontamination of biological waste, curing of plastics, rubber, and composites, and any other industry requiring decontamination and / or sterilization and / or physical treatment. The system is demonstrated with a steam sterilizer or autoclave, but is not limited to this type of method, and can also be used with, for example, ethylene oxide, ozone, hydrogen peroxide, formaldehyde (LTSF), or other germicidal chemical or physical conditions. Detailed Description

[0035] The system comprises a set of containers into which elements to be treated are placed, which can enter the system sequentially and move through a series of chambers where the steps required to complete a cycle are performed according to good practice established in the industry.

[0036] Below, we will use a steam sterilizer (autoclave) as an example of the system's application. The selected shape and size of the machine are what we consider to be the simplest form to describe and build, but embodiments can be applied in a variety of shapes, sizes, and methods (e.g., ethylene oxide, ozone, hydrogen peroxide, formaldehyde (LTSF), etc.). The container is a basket that can be made in a cylindrical shape (but can be any shape) using a perforated mesh or permeable material such as corrosion-resistant metal, or other materials such as plastic or fiber.

[0037] The components to be processed are placed in the containers, which are then placed on a conveyor and fed into the machine through hatches into Transition Chamber #1 (TC#1). Several transition chambers exist within the machine, acting as passageways to equalize conditions between chambers and avoid direct transfer and exchange of fluids or temperatures. The hatches may be sliding doors or any other means for opening and tightly closing the chambers. The hatches may be automated by rack-and-pinion drives, pneumatic / hydraulic pistons, or other mechanisms.

[0038] Conveyors are installed within each section of the machine to transport containers through the process stages. The following description relates to an example embodiment applied to a Steam Sterilizer Class B [Transition #1 (T#1), Pre-Conditioning (PrC), Transition #2 (T#2), Sterilization (S), Transition #3 (T#3), Post-Conditioning (PtC), Transition #4 (T#4)]. The conveyors can be of any type (e.g., belt, cable / wire, roller, chain, rack and pinion, pneumatic, etc.).

[0039] The pre-conditioning, sterilization, and post-conditioning chambers can accommodate several containers, while the transition chamber can accommodate one container at a time (or more, depending on the specific design of the application). The chambers have a cylindrical, pipe-like shape, but are not limited to this shape (they may be parallelepiped or any other shape), can be made of stainless steel or any other suitable material that can withstand the operating conditions, and can have walls of appropriate thickness. The chambers have connections to services necessary for their function, such as steam, vacuum, exhaust, instrumentation and inspection ports, and safety devices (e.g., rupture disks and pressure relief valves). The chambers and other exterior surfaces, including hatches, pipes, connections, instrumentation, and operator-reachable exterior surfaces, are insulated with the most appropriate materials, i.e., mineral wool, rock wool, glass wool, ceramic coatings, carbon composites, silica fiber, vacuum, etc. The pipes, connections, valves, and sensors are part of the elements necessary for the function of the embodiments.

[0040] The system utilizes a computer, PLC, or microcontroller for the initiation of conveyors, hatches, valves, and vacuum pump(s). (For simplicity, the example machines used to describe the embodiments assume that steam, water, compressed air, and any other required services are supplied from external sources. If this were not the case, the controller would also need to command the steam generator, compressor, or other service source.) In addition to controlling the automation, the PLC receives input signals from sensors and instruments to make logical decisions about function and safe processing. For safety or traceability reasons, several backup controllers and record-keeping devices may also be included, which are common industry requirements.

[0041] The components are loaded into containers, which are then placed on the first conveyor in a queue. The conveyor is operated by a controller to move the containers while the first hatch is open, placing one container into TC#1 and closing the hatch. Within TC#1, steam is introduced through the input port, while the output port is controlled to exhaust air from the chamber, which is replaced by steam. Once the air is deemed exhausted, the output valve is closed, increasing the pressure in the chamber to approximately 1.5 bar (absolute) to match the conditions at that particular time with the preconditioning chamber. Note that the temperatures and pressures of the cycles presented in this document are for reference only; well-established cycles or others can be used. Generally, they are set within the range of approximately 115°C to 138°C. Some sterilizers can be set to approximately 142°C at the corresponding pressure for saturated steam. The time requirement varies depending on the temperature requirements during the sterilization process. Generally, the time is set to approximately 3 to 60 minutes. Some types of sterilizers can be set to approximately 100 minutes. The pressure in the chamber during the vacuum pre-process (pre-conditioning) is typically set to about 0.03 bar (absolute) to 0.01 bar (absolute), and the same during the drying process (post-conditioning).

[0042] The preconditioning chamber maintains a fluctuating cycle of injected steam pulses, pressurizing it to 1.5 bar (absolute) and then vacuuming it to 0.04 bar (absolute). At the moment the pressure reaches 1.5 bar (absolute), the second hatch between TC#1 and the preconditioning chamber opens, and the third hatch between the preconditioning chamber and TC#2 also opens. The conveyor moves all containers from the transition chamber and preconditioning chamber forward to a single position, introducing containers from TC#1 into the preconditioning chamber and the last container in that chamber into TC#2. The hatches close, and TC#2 adds more steam at 132°C to increase the pressure up to 3 bar (absolute). At this point, conditions in this chamber are equivalent to those in the sterilization chamber. Therefore, the fourth hatch opens, connecting TC#2 to the sterilization chamber, allowing containers to be transported into the aforementioned chamber. TC#3 also meets the conditions of the sterilization chamber. The fifth hatch between the sterilization chamber and TC#3 is opened simultaneously with the fourth hatch, allowing the conveyor to move the last container in the sterilization chamber into TC#3 and move the remaining containers in the sterilization chamber to one position.

[0043] The hatches are closed, and TC#3 is vented through the exhaust port when a valve is opened, connecting the chamber to a vacuum pump. The exhaust continues until 0.04 bar (absolute) is reached, equalizing with the conditions in the post-conditioning chamber, at which point the sixth and seventh hatches are opened to communicate with the PtC. A conveyor moves the containers from TC#3 into the PtC, and then moves all of the containers in the PtC, including the last container in the PtC, to TC#4 in one step.

[0044] Before the seventh hatch is opened, the conditions in TC#4 match those in the PtC. Once a new container is received and the chamber is hidden, air can enter through the filters and valves until TC#4 reaches atmospheric pressure. At this point, the last hatch on the output side of the machine (the eighth hatch) can be opened and a conveyor transports the container out of the machine to the receiving section where an operator removes the components from the container. It is worth noting that TC#1 performs a similar procedure to TC#4; once the container is transferred to the PtC at 1.5 bar (absolute) and the hatch is closed, the vapors in TC#1 are vented and replaced with filtered air that matches atmospheric pressure. Alternative design 1

[0045] An alternative to the hatch system is the use of the aforementioned containers with modified end caps. The caps are sturdy plates, which may be made of, but are not limited to, stainless steel. Around the perimeter, they are fitted with elastic seals or other materials that can withstand the operating conditions and friction. These containers are introduced into the machine and passed through the stages in the same manner as described above. The difference lies in the method of transfer between stages: there are no hatches separating the chambers from each other; the containers themselves are closed or sealed by caps. The transition chamber walls are designed to contact the container cap seals to prevent the exchange of fluids and physical states between them. Another difference from the above method is the need to maintain a recirculation (loop) container, whether or not it contains elements, because the chamber must contain the entire internal volume of the container to maintain the process of sealing and opening the chamber along the cycle. To achieve this recirculation or loop of containers, a conveyor outside the chamber transports the containers from the machine's output (unloading area) to its input (loading area). The various chamber configuration options serve as examples of the design flexibility of the present invention. Alternative design 2

[0046] Regarding this alternative, in a preferred embodiment, we choose to use a parallelepiped-shaped container because it has a larger load capacity and is more suitable for accommodating industry-standard containers. As with Alternative Design 1, two of the faces are solid, what we call caps, and the remaining faces are made of a mesh material, such as stainless steel mesh or other suitable material. The cap is a solid plate that can be made from, but is not limited to, stainless steel. Along the periphery, an elastic seal or other material that can withstand the operating conditions and friction is attached. The edges of the container are rounded, providing the container with a more robust structure, cleanliness, and a better seal between the container and the transition chamber wall through which the container passes. The transition chamber is sized and shaped so that the container can pass through it and the seal on the container can contact the chamber wall to create the desired sealing effect.

[0047] This alternative must also maintain a closed loop of containers to maintain the container transfer sequence with proper separation between chambers. To achieve the container recirculation or loop, a conveyor outside the chambers transports containers from the machine's output (unloading bay) to its input (loading bay).

[0048] The pre-conditioning, sterilization, and post-conditioning chambers are sized to accommodate several containers. Containers are received and transported using a conveyor, described in our embodiment as a vertical chain magazine style (also known as a vertical conveyor elevator). The transition chamber sends the container through one port to the corresponding sequential chamber (PrC / S / PtC), where the container is loaded into the magazine conveyor. The conveyor is controlled by a computer, PLC, or microcontroller in continuous or step mode to move the container until it reaches the exit port to the subsequent transition chamber. The time required to move a container from the entry point to the exit point is the time required to complete a subcycle for that particular container.

[0049] The length, speed, and size of the conveyor and chambers must be designed and programmed based on the product flow (periodicity) required for the application. Magazine conveyors are a very effective way to load several containers into process chambers such as PrC, S, and PtC while maintaining a minimum footprint through the use of vertical space. Instead of capping only two of the six sides, multi-directional displacement of the container can be added if four sides are sealed solid plates and the remaining two sides are made of mesh material. This design allows the container to move in four directions, and by moving the container between chambers with more freedom, the chambers can be organized in various configurations, resulting in space optimization.

[0050] Another possible configuration for achieving multi-directional displacement without adding extra caps (as described above) is to add a rotating base that realigns the axis of the container cap to the same orientation as the chamber into which it is introduced. The processing and transition chambers can be arranged and connected in various positions and configurations. This modular and flexible design of the sequence configuration has the added benefit of allowing the interconnection of chambers so that parallel processes can be accomplished simultaneously and / or different cycle conditions, such as routing containers along different paths within the same machine, can be arranged to process with cycles of saturated steam at 135°C (flash sterilization), 121°C (standard sterilization), and low-temperature sterilization, using other fluids and environmental conditions (e.g., ETO, H2O2, O3, LTSF, etc.). Additional improvements

[0051] Electrical resistance or other heat generating means within the chamber(s) can be added to compensate for heat loss and re-evaporate the condensate, thereby recycling steam and maintaining the volume of steam. These resistances are placed at the end of the condensate channel at the bottom of the chamber. Because only a small amount of heat is required to return the condensed steam to a saturated state, this addition can increase the efficiency of the machine and reduce heat and water consumption. This system can operate without repressurization, for example, whenever a container is introduced or removed from the sterilization chamber, due to its sealed and stable operating state. This is also due to the fact that it matches the state of the container before transfer. If the pressure drops for any reason, such as a leak, a small amount of additional steam can compensate.

[0052] Another efficiency improvement is the use of a vapor recovery system by recovering vapor from T#1, PrC, T#3, and any other vapor traps or separators. As vapor is extracted from each chamber using a vacuum pump or equivalent, it is directed to a vapor recovery tank, repressurized with a vapor compressor or pump, and reheated to the required operating conditions using electrical resistance or other heat generating means. This tank also has a connection to fresh steam from the steam source to replace losses, and from this tank is derived the main vapor distribution line that feeds the chambers. Because there is no vapor to recover and air from T#4 is an undesirable substance, a second vacuum pump is included for PrC and T#4, and the vacuum downstream is discharged to a sewer or air vent.

Claims

1. 1. A continuous element decontamination and sterilization system comprising: a plurality of transition chambers; a plurality of working chambers; a plurality of migration ports; Multiple working ports; at least one conveyor system; at least one container; each of the plurality of working chambers is connected between a leading chamber and a trailing chamber, the leading chamber and the trailing chamber being from the plurality of transition chambers; any plurality of transition ports are integrated into the plurality of transition chambers, and any plurality of transition ports are from the plurality of transition ports; any plurality of working ports are integrated into the plurality of working chambers, and any plurality of working ports are from the plurality of working ports; the conveyor system is operatively connected between the plurality of working chambers and the plurality of transition chambers, the conveyor system moving the container between the plurality of working chambers and the plurality of transition chambers; Equipped with multiple hatches, a leading hatch is integrated into the connection between said leading chamber and any working chamber, said any working chamber being from said plurality of working chambers, and said leading hatch being from said plurality of hatches; a trailing hatch is integrated into the connection between the trailing chamber and any of the working chambers, the trailing hatch being from the plurality of hatches; A plurality of hatch gaskets; a plurality of insulated hatch liners; each of the plurality of hatch gaskets is integrated around a corresponding hatch, and the hatch gasket hermetically seals the opening of the corresponding hatch; A continuous element decontamination and sterilization system, wherein each of the plurality of insulated hatch liners is contained within a corresponding hatch.

2. the plurality of working chambers comprising at least one pre-conditioning chamber, at least one sterilization chamber, and at least one post-conditioning chamber; the pre-conditioning chamber, the sterilization chamber, the post-conditioning chamber, and the plurality of transition chambers are connected in series; the sterilization chamber is positioned between the pre-conditioning chamber and the post-conditioning chamber; 2. The continuous element decontamination and sterilization system of claim 1, wherein the conveyor system is operatively connected between the pre-conditioning chamber, the sterilization chamber, the post-conditioning chamber, and the plurality of transition chambers, and the conveyor system moves the containers between the pre-conditioning chamber, the sterilization chamber, the post-conditioning chamber, and the plurality of transition chambers.

3. at least one working mesh; the plurality of work ports comprising at least one work input port and at least one work output port; the work input port is positioned offset from the work output port across from any one of the work chambers, the any one of the work chambers being from the plurality of work chambers; 10. The continuous element decontamination and sterilization system of claim 1, wherein the working mesh is attached over the working exhaust port.

4. at least one transition mesh; the plurality of transition ports comprising at least one transition input port and at least one transition output port; the transition input port is positioned offset from the transition output port across from any transition chamber, the any transition chamber being from the plurality of transition chambers; 10. The continuous element decontamination and sterilization system of claim 1, wherein the transition mesh is mounted over the transition exhaust port.

5. Equipped with multiple migration measurement systems, 10. The continuous element decontamination and sterilization system of claim 1, wherein each of said plurality of transition measurement systems is incorporated into a corresponding transition chamber, said corresponding transition chamber being from said plurality of transition chambers.

6. Equipped with multiple work measurement systems, 2. The continuous element decontamination and sterilization system of claim 1, wherein each of said plurality of work measurement systems is incorporated into a corresponding work chamber, said corresponding work chamber being from said plurality of work chambers.

7. a plurality of insulating liners; 2. The continuous element decontamination and sterilization system of claim 1, wherein each of said plurality of transition chambers and each of said plurality of working chambers is lined by a corresponding liner from said plurality of insulating liners.

8. a plurality of linear actuators; each of the plurality of linear actuators is integrated into a sidewall of a corresponding transition chamber, the corresponding transition chamber being from the plurality of transition chambers; 2. The sequential element decontamination and sterilization system of claim 1, wherein the container is operatively coupled to the linear actuator of the corresponding transition chamber, the linear actuator providing sufficient force to overcome a pressure differential between the preceding chamber and an adjacent working chamber from the plurality of working chambers.

9. the conveyor system includes a loading section, an unloading section, a processing section, and a feedback section; the stowage section is positioned adjacent to a first leading chamber, the first leading chamber being from the plurality of transition chambers; the unloader is positioned adjacent to a last subsequent chamber, the last subsequent chamber being from the plurality of transition chambers; The processing unit is connected between the loading unit and the unloading unit, the processing section traverses through the plurality of transition chambers and the plurality of working chambers; the feedback unit is connected between the loading unit and the unloading unit; 10. The continuous element decontamination and sterilization system of claim 1, wherein the feedback section is positioned offset from the treatment section.

10. A programmable controller is provided, 10. The continuous element decontamination and sterilization system of claim 1, wherein the programmable controller is communicatively coupled to the plurality of transition chambers, the conveyor system, and the plurality of working chambers.

11. A continuous element decontamination and sterilization system, comprising: a plurality of transition chambers; a plurality of working chambers; a plurality of migration ports; Multiple working ports; at least one conveyor system; at least one container; each of the plurality of working chambers is connected between a leading chamber and a trailing chamber, the leading chamber and the trailing chamber being from the plurality of transition chambers; any plurality of transition ports are integrated into the plurality of transition chambers, and any plurality of transition ports are from the plurality of transition ports; any plurality of working ports are integrated into the plurality of working chambers, and any plurality of working ports are from the plurality of working ports; the conveyor system is operatively connected between the plurality of working chambers and the plurality of transition chambers, the conveyor system moving the container between the plurality of working chambers and the plurality of transition chambers; Equipped with an access door, the container comprising a first end cap, a second end cap, a permeable sidewall, a first gasket, and a second gasket; the first end cap is connected adjacent to a first end of the permeable side wall; the second end cap is connected adjacent a second end of the permeable side wall opposite the first end cap and across from the permeable side wall; the first gasket is connected around the first end cap; the second gasket is connected around the second end cap; A continuous element decontamination and sterilization system, wherein the access door is integrated into the container.

12. The plurality of working chambers comprises at least one pre-conditioning chamber, at least one sterilization chamber, and at least one post-conditioning chamber; the pre-conditioning chamber, the sterilization chamber, the post-conditioning chamber, and the plurality of transition chambers are connected in series; the sterilization chamber is positioned between the pre-conditioning chamber and the post-conditioning chamber; 12. The continuous element decontamination and sterilization system of claim 11, wherein the conveyor system is operatively connected between the pre-conditioning chamber, the sterilization chamber, the post-conditioning chamber, and the plurality of transition chambers, and the conveyor system moves the containers between the pre-conditioning chamber, the sterilization chamber, the post-conditioning chamber, and the plurality of transition chambers.

13. A method of manufacturing a semiconductor device, comprising: the plurality of work ports comprising at least one work input port and at least one work output port; the work input port is positioned offset from the work output port across from any one of the work chambers, the any one of the work chambers being from the plurality of work chambers; 12. The continuous element decontamination and sterilization system of claim 11, wherein the working mesh is attached over the working exhaust port.

14. A method for manufacturing a semiconductor device, comprising: the plurality of transition ports comprising at least one transition input port and at least one transition output port; the transition input port is positioned offset from the transition output port across from any transition chamber, the any transition chamber being from the plurality of transition chambers; 12. The continuous element decontamination and sterilization system of claim 11, wherein the transition mesh is mounted over the transition exhaust port.

15. A plurality of transition measurement systems, 12. The continuous element decontamination and sterilization system of claim 11, wherein each of said plurality of transition measurement systems is incorporated into a corresponding transition chamber, said corresponding transition chamber being from said plurality of transition chambers.

16. A plurality of work measurement systems are provided, 12. The continuous element decontamination and sterilization system of claim 11, wherein each of said plurality of work measurement systems is incorporated into a corresponding work chamber, said corresponding work chamber being from said plurality of work chambers.

17. A plurality of insulating liners, 12. The continuous element decontamination and sterilization system of claim 11, wherein each of said plurality of transition chambers and each of said plurality of working chambers is lined by a corresponding liner from said plurality of insulating liners.

18. A plurality of linear actuators, each of the plurality of linear actuators is integrated into a sidewall of a corresponding transition chamber, the corresponding transition chamber being from the plurality of transition chambers; 12. The sequential element decontamination and sterilization system of claim 11, wherein the container is operatively coupled to the linear actuator of the corresponding transition chamber, the linear actuator providing sufficient force to overcome a pressure differential between the preceding chamber and an adjacent working chamber from the plurality of working chambers.

19. The conveyor system comprises a loading section, an unloading section, a processing section, and a feedback section; the stowage section is positioned adjacent to a first leading chamber, the first leading chamber being from the plurality of transition chambers; the unloader is positioned adjacent to a last subsequent chamber, the last subsequent chamber being from the plurality of transition chambers; The processing unit is connected between the loading unit and the unloading unit, the processing section traverses through the plurality of transition chambers and the plurality of working chambers; the feedback unit is connected between the loading unit and the unloading unit; 12. The continuous element decontamination and sterilization system of claim 11, wherein the feedback section is positioned offset from the treatment section.

20. A programmable controller, 12. The continuous element decontamination and sterilization system of claim 11, wherein the programmable controller is communicatively coupled to the plurality of transition chambers, the conveyor system, and the plurality of working chambers.

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