Direct fluid injection implant cleaning system and method

Abstract

The present disclosure discusses systems and methods for cleaning implants. The system includes an implant support that includes a plurality of nozzles that direct a cleaning fluid toward an interior surface of the implants.

Description

DIRECT FLUID INJECTION IMPLANT CLEANING SYSTEM AND METHODCross-Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 667,395 entitled "DIRECT FLUID INJECTION IMPLANT CLEANING SYSTEM AND METHOD" filed July 3, 2024, which is incorporated herein by reference in its entirety.Field of the Technology

[0002] The present technology relates to an implant cleaning system and methods. Specifically, the present technology relates to the cleaning of dental implants.Background

[0003] Dental implants are used for mounting a dental prothesis onto bone. For example, dental implants can be used for the attachment of artificial teeth. In some examples, a dental implant is anchored within the bone and a mounting part is used to mount a dental prothesis onto the implant. The dental prothesis is typically screwed or cemented into the dental implant.

[0004] The dental implant is typically made using a milling process to create the dental implant out of a solid material. The milling process uses a series of cutting tools attached to a rotating spindle to remove portions of the solid material. The milling creates debris, such as dust, during the process of removing the implant material which adheres to the surfaces of the dental implant. This debris must be removed from the implant prior to use.

[0005] Automation of the milling process allows dental implants to be rapidly created. The rapid production of dental implants can create a backlog of dental implants that require rigorous cleaning before the dental implant can be used. It is therefore desirable to have a process capable of thoroughly cleaning a plurality of dental implants prior to use.Summary

[0006] The present technology uses a cleaning system to simultaneously clean a plurality of implants. An implant support is used in the cleaning system to simultaneously hold a plurality of implants. Each implant is positioned over a nozzle. A cover is positioned overthe implants at a fixed distance. The distance is preselected such that a clearance is created between the implant and the cover. During use, the implant can be pushed by the cleaning fluid against the cover, allowing fluid to wash the interior surface of the implant. The cleaning fluid leaves the interior of the implant through a gap created between the nozzle and the implant.

[0007] In an embodiment, an implant support for use in a cleaning system includes a body and a plurality of nozzles disposed in the body. Each of the plurality of nozzles comprises an inlet and an outlet. Each of the plurality of nozzles is disposed in the body such that the outlet of each of the plurality of nozzles extends away from the body. For example, each of the plurality of nozzles can be disposed in a cavity formed in the body. The outlet of each of the plurality nozzles can extend above the cavity. The plurality of nozzles can be disposed within the body in an array configuration.

[0008] The implant support includes one or more conduits dispersed within the body. Each of the plurality of nozzles is disposed in the body such that the inlet of each of the plurality of nozzles is coupled to one or more of the conduits. The one or more conduits can include a central conduit extending through the body. The inlet of each of the plurality of nozzles can be fluidically coupled to the central conduit.

[0009] The implant support includes an inlet port coupled to the one or more conduits. During use, a cleaning fluid enters the one or more conduits dispersed within the body via the inlet port.

[0010] The implant support includes a cover comprising a plurality of openings extending into the cover. Each of the plurality of openings in the cover can be conical shaped. In an embodiment, the plurality of openings in the cover comprise a conical upper portion and a cylindrical lower portion. The cover is positioned over the nozzles such that the plurality of openings in the cover are substantially aligned with the plurality of nozzles. The cover is positioned at a fixed distance above the nozzles such that when an implant is placed on the nozzle, an end of the implant extends partially into the opening. A gap is present between the end of the implant and a bottom surface of the opening.

[0011] The implant support can also include a spacer positioned between the body and the cover, wherein the spacer maintains the cover at the fixed distance above the nozzles.

[0012] The body of the implant support comprises a front surface and a back surface opposite to the front surface. The plurality of nozzles can be disposed within the front surface of the body and the back surface of the body.

[0013] The implant support can also include a fastener system connected to the body and extending through the cover. The fastener system is used to secure the cover to the body.

[0014] In an embodiment, an implant support, as described above, is placed in a cleaning system and a plurality of implants attached to the implant support are simultaneously cleaned. A cleaning system includes: a frame support structure; a fluid injection tank coupled to the frame support structure; and a fluid manifold coupled to the frame support structure and to an inlet port of each of the one or more implant supports. The fluid injection tank is configured to hold a cleaning fluid.

[0015] The frame support structure is formed as an open framework having sides that allow a fluid to pass through the frame support structure to contact the one or more implant supports during use.

[0016] The cleaning system can also include a vacuum source coupled to the fluid injection tank, wherein the vacuum source applies a vacuum to the fluid injection tank to pull a cleaning fluid into the fluid injection tank. The cleaning system can also include a control system comprising a controller and one or more valves. The controller provides control signals to the one or more valves, during use, to control the application of a vacuum to the fluid injection tank.

[0017] The cleaning system also includes an air inlet coupled to the fluid injection tank. The cleaning system can also include a control system comprising a controller and one or more valves. The controller provides control signals to one or more valves, during use, to control the flow of air into the fluid injection tank.

[0018] A cleaning system as described above, can be used to clean a plurality of implants. In one embodiment, a plurality of implants are placed on one or more implant supports, as described herein. The one or more implant supports are placed in a cleaning system, as described herein. The cleaning system is placed in a cleaning fluid tank comprising a cleaning fluid. The cleaning system is positioned in the cleaning fluid such that one or more implant supports are submerged in the cleaning fluid. Once placed in the cleaning tank, at least a portion of the cleaning fluid from the cleaning fluid tank is transferred to the fluid injection tank. The interior surfaces of the implants are cleaned by directing the cleaningfluid from the fluid injection tank through the fluid manifold into the one or more implant supports. The cleaning fluid is ejected from the plurality of nozzles attached to the implant support to apply the cleaning fluid to an interior surface of the implant.

[0019] One or more types of cleaning solutions can be used to clean the implants. In one embodiment, the cleaning solution comprises an aqueous solution of a surfactant. Another cleaning solution that can be used comprises an aqueous solution of an acid-based detergent. Purified water can also be used to clean the implants.

[0020] In one embodiment, multiple cleaning fluid tanks are used in sequence to clean the implants. Each of the multiple cleaning fluid tanks can include the same or a different cleaning fluid. In one embodiment, at least one cleaning fluid tank has a cleaning fluid comprising an aqueous solution of a surfactant. At least one cleaning fluid tank has a cleaning fluid comprising an aqueous solution of an acid-based detergent. At least one cleaning fluid tank has purified water.

[0021] The method of cleaning the implants also includes drying the implants. The implants can be dried by placing the cleaning system in a drying tank. The drying tank heats the air surrounding the cleaning system. The implants can also be dried by directing heated air into the implant supports.Brief Description of the Drawings

[0022] The technology will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0023] FIG. 1A depicts an example of an implant.

[0024] FIG. IB depicts a cross-sectional view of the implant of FIG. 1 A.

[0025] FIG. 2 depicts an implant having an implant extension.

[0026] FIG. 3 depicts a cleaning system.

[0027] FIG. 4 depicts a projection view of an implant support.

[0028] FIG. 5 depicts a side view of an implant support.

[0029] FIG. 6 depicts a cross-sectional side view of an implant support.

[0030] FIG. 7 depicts an expanded view of the cross-sectional view of FIG 6.

[0031] FIG. 8 depicts different configurations of nozzles.

[0032] FIG. 9 depicts a side view of an implant support having an implant positioned over a nozzle.

[0033] FIG. 10 depicts an expanded view of the implant and cover depicted in FIG. 9.

[0034] FIG. 11 a cross section view of an opening formed in the cover.

[0035] FIG. 12 depicts a flow chart of a cleaning process.

[0036] FIG. 13 depicts a cleaning system placed in a cleaning fluid tank.

[0037] FIG. 14 depicts a schematic diagram of the pneumatic and fluid components of the cleaning system.Detailed Description

[0038] A typical dental implant used for mounting a dental prothesis within a subject’s mouth is depicted in FIGS. 1A and IB. A dental implant 100 in terms of the present invention is intended to mean the anchor part of a multipart implant system (e.g., a two-part, a three-part, etc.). The dental implant 100 is the part of a multipart implant system that becomes integrated with the bone. The dental implant is sunk into the bone up to about 1.5-3 mm above the bone ridge at mucosal level.

[0039] Dental implant 100 has an outer surface 110 which is the surface that is in contact with the bone, as shown in FIG. 1A. Outer surface 110 can have threading to allow the implant to be screwed into the bone. Dental implant 100 also has an interior surface 120 which is configured to receive a dental prothesis (e.g., an artificial tooth), as shown in FIG. IB. Interior surface 120 can also have threading which is complementary to a threaded bolt which is attached to the dental prothesis. Exemplary dental implants are described in U.S. Patent No. 11,331,167 which is incorporated herein by reference.

[0040] Implants that are placed into bone tissues of a subject, such as dental implant 100, are commonly manufactured using computer-controlled manufacturing processes. One such process is Computer Numerical Control (CNC) machining. In a CNC machining process a pre-programmed controller provides instructions to control various manufacturing tools to create the implant from a provided starting material. Implants can be made from solid rods of metal or polymers which are subjected to milling, grinding, drilling, and routing operations toprecisely form the desired implant. These operations produce debris in the form of dust and particles which can adhere to the surfaces of the implant. Additionally, the process is typically run in the presence of oil which serves as a coolant and a lubricant during the milling process. After the milling process is completed, the implant is contaminated with oil and debris that must be removed before the implant can be used. Removal of oil and debris from interior surfaces of an implant can be particularly difficult.

[0041] Depicted in FIG. 2 is an implant 200 having an implant extension 250. The implant extension 250 is formed in one piece with the implant. An axial constriction 255 is formed at the interface between the implant 200 and the implant extension 250. The implant extension is used during the manufacturing process to transport the implant, after machining, without touching the implant. This allows the implant to be mechanically moved to other processing stations without inadvertently damaging the implant. When the manufacturing processing is complete, the implant extension can be broken off from the implant at the axial constriction 255. Exemplary implants having an implant extension are dental implants as described in U.S. Patent No. 11,857,390, which is incorporated herein by reference.

[0042] FIG. 3 depicts a cleaning system 300 that can be used to simultaneously clean a plurality of implants. The cleaning system includes a frame support structure 305, one or more implant supports 350, a fluid injection tank 310, and a fluid manifold 320. The cleaning system also includes a vacuum pressure gauge 330, an air inlet connector 335, an air inlet pressure gauge 340 and a programmable logic controller (PLC) 345. The cleaning system further includes a fluid inlet conduit 315 and a fluid outlet conduit 325. Fluid outlet conduit 325 couples the fluid injection tank 310 to the fluid manifold 320.

[0043] The cleaning system includes a frame support structure 305. The frame support structure 305 forms a framework to which the various components of the cleaning system are attached. The frame support structure is formed as an open framework such that the sides are generally open. During use, fluids can pass through the open sides of the framework contacting the implants disposed therein.

[0044] FIG. 4 depicts a projection view of an implant support 350. Implant support 350 includes a body 355, a plurality of nozzles 360 disposed in the body, a cover 365, and an inlet port 370. FIG. 5 depicts a side view of the implant support 350 with a plurality of implants positioned over the nozzles. The body includes a front surface 362 and a back surface 364,opposite to the front surface. In some embodiments, nozzles are disposed within the front surface of the body and the back surface of the body as shown in FIG. 5.

[0045] The plurality of nozzles 360 can be disposed in an array configuration. The implant support can include any number of nozzles. The number of nozzles disposed in the body is only limited by the size of the body and the spacing required between each nozzle. The spacing between the nozzles is determined, in part, by the size of the implant. When an implant is placed on the nozzle it should not be touching, or capable of touching, implants on adjacent nozzles. In the implant support 350, depicted in FIG. 4, the front surface of the implant includes two hundred forty nozzles arrayed in a 20 X 12 array. The back surface also includes two hundred forty nozzles, which are also in the same 20 X 12 array configuration. Therefore a total of four hundred eighty nozzles, in the depicted embodiment, are disposed on the body of the implant support.

[0046] Referring to FIG. 3, up to four implant supports 350 can be present in the depicted cleaning system, with each implant support holding four hundred eighty nozzles. The total number of nozzles, and therefore, the total number of implants that can be simultaneously cleaned using the cleaning system 300 is one thousand nine hundred twenty. While only four implant supports are shown in cleaning system 300, it should be understood that more, or less, implant supports 350 can be present in the cleaning system, by altering the frame support structure 305.

[0047] Disposed over the nozzles, on both the front surface and the back surface of the body is a cover 365. Cover 365 includes a plurality of openings 390 extending into the cover. When positioned over the nozzles, the plurality of openings in the cover are substantially aligned with the plurality of nozzles.

[0048] Cover 365 is coupled to the body through a fastener system 375 which extends through the cover and into the body. The fastener system also can include a spacer 380 positioned between the body and the cover. The spacer maintains the cover at a fixed distance above the nozzles. In one embodiment, depicted in FIG. 6, the fastener system comprises a threaded rod 377 and a connector (e.g., a nut) 379. In the depicted embodiment, threaded rod 377 extends from the body, through the spacer 380, and through the cover 365. Connector 379 is attached to the threaded rod to secure the cover to the spacer, creating a gap between the implant and the cover. As shown in FIG. 4, the implant support can include at least four fastener systems 375 to secure the cover to the body. As shown in FIG. 5, eachsurface (front and back surfaces) of the body can have a cover and fastening system as described.

[0049] Cover 365 is positioned at a fixed distance above the nozzles. As shown in FIG. 5, when an implant is placed on the nozzle, an end of the implant extends partially into the opening. The cover 365 is placed at a preselected fixed distance such that a gap is present between the end of the implant and a bottom surface of the opening 390, as shown in more detail in FIG. 10. Cover 365 is held at a fixed distance, in one embodiment, by spacer 380.

[0050] Implant support 350 includes an inlet port 370 and one or more conduits 372 dispersed within the body (depicted in FIGS. 6 and 7). FIGS. 4 and 5 depict an embodiment of an inlet port 370 positioned at a side of the implant support. Referring to FIG. 3, inlet port 370 (not shown) couples to fluid manifold 320 through a connection port 322 on the fluid manifold. In an embodiment, implant support 350 is placed on a rail 307 of the frame support structure 305 and the inlet port 370 is connected to the connection port 322. Fluids for cleaning and drying the implant, particularly the interior surface of the implant, can be passed into the implant support through from the fluid manifold through the connection port and the inlet port.

[0051] FIG. 6 depicts a cross-sectional side view of implant support 350. FIG. 7 depicts an expanded view of the cross-sectional view of FIG 6, showing an implant positioned on a nozzle. As depicted in FIGS. 6 and 7, implant support 350 includes one or more conduits 376 dispersed within the body 355 and a plurality of nozzles 360. In one embodiment, the conduits dispersed in the body include a central conduit 374 and one or more branch conduits 372. Nozzles 360 are positioned such that each of the nozzles is coupled to one or more conduits carrying the cleaning fluid. For example, each nozzle can be coupled to a branch conduit 376 which connects to central conduit 374. During use, fluid flows into the implant support through the inlet port 370 and enters the central conduit 374. The fluid then travels from the central conduit to the branch conduits 376. The cleaning fluid enters the nozzles 360 through the nozzle inlets and is sprayed out of the nozzle for cleaning or drying of the implant. While the use of branch conduits is depicted in the particular embodiments described herein, it should be understood that branch conduits are not required. In an alternate embodiment, not depicted, the implant body only includes a central conduit and the nozzles are positioned such that the inlets of the nozzles are positioned in the central conduit or are positioned such that the inlet opening is disposed along the wall of the central conduit.

[0052] Nozzles 360 are disposed in the body of the implant support. The nozzles can be positioned in a cavity 357 formed in the body of the support member. The nozzles can be positioned such that such that the outlet of each of the plurality of nozzles extends away from the body of the implant support. The nozzles 360 can be configured with a shelf 361 that contacts the bottom 359 of the cavity. The nozzle inlet extends through the bottom 359 of the cavity where it is connected to a branch conduit 376. An O-ring or washer 378 can be positioned between the nozzle and the cavity to prevent fluid from leaking through the cavity.

[0053] Nozzles 360 can have a shape and / or size which is complementary with a shape and / or size of the interior surface of an implant. Nozzles 360 have an outlet 367, an inlet 368 and a nozzle shelf 361. (See, for example, FIG. 8.) As discussed above, the nozzle shelf contacts the bottom of the cavity, and the inlet connects to an internal conduit (e.g., a branch conduit) in the body of an implant support. FIG. 8 shows different configurations of nozzles. In some embodiments, nozzle outlets have an external diameter of 2 mm to 4 mm. Nozzle outlets can also have an exterior shape that is the complement of the interior surface of the implant. Using a nozzle with a complementary shape will minimize the gap between the nozzle and the implant. This allows cleaning to be performed efficiently, with minimal cleaning fluid needed.

[0054] Cleaning fluid, exiting the nozzles is sprayed against the interior surface of the implant. The cleaning fluid removes debris and oil from the interior surface of the implant. In an embodiment, the implant is not secured to the nozzle. By leaving the implant unsecured to the nozzle a number of advantages can be realized. One advantage is that the implants are easily placed on the nozzle. This allows the implant support to be quickly loaded with implants. Another advantage is the implant can “float” over the nozzle while fluid is being sprayed from the nozzle. As shown in FIG. 7, the movement of the implant away from the nozzle, as a result of the pressure of the fluid ejected from the nozzle, creates an opening between the nozzle and the implant that allows the fluid to exit the interior of the implant. As the fluid exits the interior of the implant, debris and oil is carried away by the fluid.

[0055] “Floating” of the implants over the nozzles during the cleaning process is achieved through designed gaps and clearances formed between the implants, the nozzles, and the cover. FIGS. 9 and 10 depict a side view of an implant support having an implant 200 positioned over a nozzle. FIG. 10 depicts an expanded view of the implant and cover depicted in FIG. 9. The implant 200 includes an implant extension 250 which extends into the opening 390 formed in cover 365. When the cover is secured to the body of the implantsupport, a gap 394 exists between the implant extension 250 and the bottom 392 of the opening. This gap allows the implant to travel outward, away from the body, when fluid is directed at the interior surface of the implant, as indicated by the arrows (FIG. 9). Contact of the implant extension with the bottom 392 of the opening will stop the outward movement of the implant.

[0056] Additionally, as shown in FIGS. 9 and 10, the region between the cover 365 and the body 255 of the implant support is open. The implant support does not include any walls or panels allowing the flow of a cleaning or drying fluid over the outer surface of the implants. As will be discussed in reference to FIGS. 13 and 14, the cleaning system 300 is placed into a cleaning or drying tank during the cleaning process. The open frame support structure 305 and the open region between the implant support body and cover, allow fluid in the cleaning or drying tank to wash over the outer surface of the implants.

[0057] FIG. 11 depicts a cross section view of an opening formed in the cover. Opening 390 in the cover has a generally conical upper portion 396 and a cylindrical lower section 398. A conical shape at the upper portion of the opening allows the cover to be more easily and quickly placed over the implants. Because the implants are loosely positioned over the nozzles, the implants may not be precisely aligned with the openings as the cover is placed on the implant support. The conical opening allows the implants to be angled or off center while the cover is placed on the implant support. As the cover descends on the implants, the conical opening guides the implant (or implant extension) into the cylindrical lower section of the opening. The cylindrical lower section has a diameter that is larger than the diameter of the end of the implant (e.g., the implant extension). This creates additional gaps around the sides of the implant extension, as shown in FIG. 11, which assists with alignment of the implant within the opening.

[0058] As discussed above, the cover is positioned at a fixed distance above the nozzles such that when an implant is placed on the nozzle an end of the implant (e.g., the implant extension) partially extends into the lower section 398 of the opening. A gap 394 is present between the implant end and a bottom surface of the lower section of the opening, as well as the sides on the implant extension. The gap allows the implant to float above the nozzle during cleaning. Movement of the implant away from the nozzle is inhibited by contact of the implant with the bottom surface of the opening.

[0059] A conduit 397 extends through the cover from the lower section 398 of the opening to the top side (side opposite the upper portion of the opening) of the cover. The conduit 397 has a diameter that is smaller than the diameter of the end of the implant (e.g., the implant extension). During use, conduit 397 in the cover allows fluid to flow around the end of the implant. This allows the entire outside of the implant to be cleaned.

[0060] The cleaning system can be used to simultaneously clean a plurality of implants. A flow chart of the cleaning process is presented in FIG. 12. In the first step, implants are loaded onto the implant support. A plurality of implants are loaded onto the implant support by placing the implant over the nozzles. Once the implants are placed on the nozzles, the cover plate is positioned over the implants and lowered onto the spacers. The cover is carefully positioned over the implants so that the implant extension from each of the implants enters the openings in the cover (See FIG. 4). Once properly positioned, the cover is fastened to the implant support using the fastening system. The implant support is then turned over and the procedure is repeated on the opposing side. The fully loaded implant support is shown in FIG 5.

[0061] Once one or more implant supports are loaded with implants, the implant supports are attached to the cleaning system. Each implant support is placed on a rail 307. The inlet port 370 is connected to the connection port 322 on the fluid manifold. The inlet port and connection port may be complementary parts of a quick connect / disconnect fluid connector.

[0062] The cleaning system is then passed through a series of cleaning tanks to clean the implants. The process steps in each tank are generally the same. The process begins by placing the cleaning system in a cleaning fluid tank 400, as depicted in FIG. 13. The control system is activated, and a series of processing steps are automatically performed to clean the implants with the cleaning fluid present in the cleaning tank. The control system includes a controller (e.g., a programmable logic controller) and one or more valves. The controller provides control signals to the one or more valves to control the flow of fluid through the cleaning system.

[0063] Once activated, the controller will initiate the cleaning process. In the first step of the cleaning process, cleaning fluid is drawn from the cleaning fluid tank into the fluid injection tank. In one embodiment, the cleaning system is connected to a vacuum source. Alternatively, the cleaning system can include a vacuum pump. The cleaning fluid is drawn into the fluid injection tank by applying a vacuum to the fluid injection tank. The controllerprovides control signals to one or more valves to control the application of a vacuum to the fluid injection tank. Once the pressure in the fluid injection tank is reduced, a valve to the fluid inlet conduit 315 is opened creating a fluid path between the cleaning fluid in the cleaning tank and the fluid injection tank. The reduced pressure in the fluid injection tank draws the cleaning fluid into the fluid injection tank. The connection between the fluid injection tank and the cleaning fluid is closed when a sufficient amount of cleaning fluid is drawn into the fluid injection tank, or when the fluid injection tank is substantially full.

[0064] The next step in the cleaning process is to expel the cleaning fluid from the fluid injection tank to the implant supports through the fluid manifold. The controller provides control signals to one or more valves to control the flow of cleaning fluid into the fluid manifold. In one embodiment, the fluid injection tank is pressurized by sending pressurized air into the fluid injection tank. The increased air pressure in the tank forces the fluid through the fluid outlet conduit into the manifold at elevated pressure. The cleaning fluid passes into the fluid manifold and is distributed to each of the implant supports.

[0065] The cleaning fluid enters each of the implant supports through the input port. Once the cleaning fluid enter the implant support, the fluid passes through the central conduit and is distributed to each of the nozzles. The fluid then passes into each of the nozzles and is expelled into the interior of the implants. The expelled fluid from the nozzles washes the interior surface of the implants as shown in FIG. 7. As the fluid exits the interior of the implant, the fluid can create turbulence in the fluid surrounding the implants, providing cleaning to the outer surface of the implant. The fluid, after exiting the implant, will pass through the implant support and collect in the cleaning fluid tank. At the completion of the cleaning cycle, the cleaning system is moved to the next cleaning tank, or to a drying tank.

[0066] A schematic diagram of the pneumatic and fluid components is shown in FIG. 14. As discussed above, the cleaning system uses a combination of compressed gas (e.g., air) and a vacuum to control the flow of fluids. In this embodiment, the cleaning system includes a compressed air source, a vacuum generator, Valve 1, and Valve 2. The cleaning system also includes: an air pressure regulator; a vacuum pressure regulator for regulating the vacuum pressure; an air gauge, a vacuum gauge, an exhaust, and one way flow valves. The arrows in the diagram show the flow of fluids through the system.

[0067] During the first cycle of the cleaning process, the cleaning system is placed into a cleaning tank filled with a cleaning fluid. The level of the cleaning fluid in the cleaning tankis indicated by the “water level” line in FIG. 14. To prepare for cleaning the internal features of the implant, the pneumatic and fluid components are operated in State 1. In State 1, the vacuum generator is operated to create a vacuum in the vacuum pressure regulator. The vacuum pressure regulator is configured to control the vacuum pressure applied to the fluid injection tank (320). The vacuum applied to the fluid injection tank (310) creates a vacuum in the fluid inlet conduit (315, See FIG. 3) which extends into the cleaning fluid in the cleaning tank. A one-way valve is positioned along the fluid inlet conduit to prevent backflow of the cleaning fluid. The applied vacuum draws cleaning fluid from the cleaning tank into the fluid injection tank. During this stage valve 1 is closed and valve 2 is open. By maintaining valve 2 in an open position, air can flow past the vacuum generator, along with the air expelled by the vacuum generator.

[0068] In the second cycle of the cleaning process, the cleaning fluid is ejected from the nozzles to clean the interior surfaces of the implant. During the second cycle of the cleaning process the pneumatic and fluid components are operated in State 2. In State 2, compressed air is flowed through into the air pressure regulator. In the air pressure regulator, the compressed air, which is at a pressure of 90 psi is reduced to a pressure of about 40 psi. The regulated compressed air is directed through the vacuum generator, which is not operating, into the fluid injection tank (310). The increased air pressure forces the cleaning fluid out of the fluid injection tank through the fluid outlet conduit (325, See FIG. 3) into the manifold (320). The pressurized fluid entering the manifold is distributed to the implant support (350, See FIG. 3) as previously discussed. A one-way valve is positioned along the fluid outlet conduit to prevent backflow of the cleaning fluid. During this stage valve 1 is closed and valve 2 is closed, forcing the compressed air into the fluid injection tank.

[0069] In the third cycle of the cleaning process, the air is ejected from the nozzles to dry the interior surfaces of the implant during the drying cycle. At the beginning of the third cycle, the cleaning system is removed from a cleaning tank and placed in a drying tank. During the drying process the pneumatic and fluid components are operated in State 3. In State 3, compressed air is redirected to an air outlet tube that is coupled to the manifold (320). The unregulated, compressed air is passed directly into the manifold where the air is distributed to the implant supports. The compressed air entering the implant supports is distributed to each of the nozzles, where the air contacts the interior of the implants to assist with drying. During this stage valve 1 is open and valve 2 is closed, forcing the compressed air into the manifold.

[0070] Operation of the pneumatic and fluid components can be controlled by a programmable logic controller (PLC). The PLC can have code executing thereof, which, when executed, causes the PLC to initiate the cleaning method described herein by providing control signals to the various components of the cleaning system. For example, the PLC can automatically switch the valves to an open or close position and turn on or off the vacuum generator.

[0071] In some embodiments, the PLC can store the data in memory. In some embodiments, the PLC includes a non-transitory computer readable medium that includes code stored for executing the cleaning method process steps described herein.

[0072] Cleaning of an implant can be accomplished through a series of cleaning steps. In one embodiment, five cleaning cycles and three drying cycles are used to clean an implant.

[0073] The first cleaning cycle, Wash #1, is performed using a cleaning fluid comprising an aqueous solution of a surfactant. Wash #1 can be performed at a pH ranging from 1.5 to 7.0, depending on the surfactant in the aqueous solution. Wash #1 can be performed at an operating temperature of 20 °C to 80 °C. The implant is exposed to the cleaning solution for a time of 60 seconds to 240 seconds in Wash #1. Exemplary cleaning compositions and conditions for Wash #1 are: KKS Ultraschall cleaning solutions or Surtec cleaning solutions, pH 2.5, temperature 70 °C, and exposure time in the tank of 200 seconds.

[0074] The second cleaning cycle, Wash #2, is performed using a cleaning fluid comprising an aqueous solution of a surfactant. Wash #2 can be performed at a pH ranging from 1.5 to 7.0, depending on the surfactant in the aqueous solution. Wash #2 can be performed at an operating temperature of 20 °C to 80 °C. The implant is exposed to the cleaning solution for a time of 60 seconds to 240 seconds in Wash #2. Exemplary cleaning compositions and conditions for Wash #2 are: KKS Ultraschall cleaning solutions or Surtec cleaning solutions, pH 2.5, temperature 70 °C, and exposure time in the tank of 200 seconds.

[0075] The third cleaning cycle, Wash #3, is performed using a cleaning fluid comprising an aqueous solution of an acid-based detergent. For example, the cleaning fluid for Wash #3 can be a citric acid-based detergent. Wash #3 can be performed at a pH ranging from 1.5 to 7.0. Wash #3 can be performed at an operating temperature of 20 °C to 80 °C. The implant is exposed to the cleaning solution for a time of 60 seconds to 240 seconds in Wash #3. Exemplary cleaning compositions and conditions for Wash #3 are: HAMO Acid Rinse, pH 3.5, at a temperature of 25 °C, and exposure time in the tank of 200 seconds.

[0076] After the implants are exposed to the three chemical cleaning fluids, the implant is washed two times with purified water (Rinse #1 and Rinse #2). The purifies water removes chemical residues (e.g., surfactants and acid-based detergents) from the implant that may be present from the previous cleaning steps. The purified water rinse is performed at an operating temperature of 20 °C to 80 °C.

[0077] After the cleaning and rinsing steps are completed, the implants are dried using one or more dryers. On one embodiment, the implant can be dried three times (Dryer #1, Dryer #2, and Dryer #3). Implants are dried by transferring the cleaning system to a drying tank. The drying tank heats the air surrounding the cleaning system to a temperature of 80 °C to 120 °C. In addition, compressed dry air is heated to a temperature of 80 °C to 140 °C and passed into the fluid manifold. The fluid manifold distributes the heated air to each of the implant supports to dry the interior surface of the implant. The cleaning system is exposed to the heating conditions for 360 seconds to 1000 seconds. In an exemplary drying procedure the implants are exposed to a surrounding atmosphere of 80 °C; the heated compressed dry air is heated to 123 °C; and the drying time is 660 seconds. In some embodiments, only one dryer is used for the drying process.

[0078] After the cleaning and drying cycles are completed, the cleaning system is removed from the final drying tank. The implant supports are then removed from the cleaning system. The cover on the implant support is unfastened from the body and the implants are removed and stored for use.

[0079] Specific systems and methods for cleaning implants have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the disclosure. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a nonexclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

Claims

CLAIMSWhat is claimed is:

1. An implant support for use in a cleaning system, the implant support comprising: a body; a plurality of nozzles partially disposed in the body, each of the plurality of nozzles comprising an inlet and an outlet, wherein each of the plurality of nozzles is disposed in the body such that the outlet of each of the plurality of nozzles extends away from the body; one or more conduits dispersed within the body, wherein each of the plurality of nozzles is disposed in the body such that the inlet of each of the plurality of nozzles is coupled to one or more of the conduits; an inlet port coupled to the one or more conduits, wherein, during use, a cleaning fluid enters the one or more conduits dispersed within the body via the inlet port; and a cover comprising a plurality of openings extending into the cover, wherein the cover is positioned over the nozzles such that the plurality of openings in the cover are substantially aligned with the plurality of nozzles; wherein the cover is positioned at a fixed distance above the nozzles such that when an implant is placed on the nozzle, an end of the implant extends partially into the opening, and wherein a gap is present between the end of the implant and a bottom surface of the opening.

2. The implant support of claim 1, further comprising a spacer positioned between the body and the cover, wherein the spacer maintains the cover at the fixed distance above the nozzles.

3. The implant support of claim 1 or 2, wherein the plurality of nozzles are disposed within the body in an array configuration.

4. The implant support of any one of claims 1-3, wherein the body comprises a front surface and a back surface opposite to the front surface, wherein the plurality of nozzles are disposed within the front surface of the body and the back surface of the body.

5. The implant support of any one of claims 1-4, wherein the one or more conduits comprise a central conduit extending through the body, wherein the inlet of each of the plurality of nozzles is fluidically coupled to the central conduit.

6. The implant support of any one of claims 1-5, further comprising a fastener system connected to the body and extending through the cover, wherein the fastener system secures the cover to the body.

7. The implant support of any one of claims 1-6, wherein each of the plurality of nozzles is disposed in a cavity formed in the body, wherein the outlet of each of the plurality nozzles extends above the cavity.

8. The implant support of any one of claims 1-7, wherein each of the plurality of openings in the cover is conical shaped.

9. The implant support of any one of claims 1-8, wherein each of the plurality of openings in the cover comprise a conical upper portion and a cylindrical lower portion.

10. A cleaning system comprising: a frame support structure; a fluid injection tank coupled to the frame support structure, wherein the fluid injection tank is configured to hold a cleaning fluid; one or more implant supports, as described in any one of claims 1-9, coupled to the frame support structure; and a fluid manifold coupled to the frame support structure and to the inlet port of each of the one or more implant supports.

11. The system of claim 10, wherein the frame support structure is formed as an open framework having sides that allow a fluid to pass through the frame support structure to contact the one or more implant supports during use.

12. The system of claim 10 or 11, further comprising a vacuum source coupled to the fluid injection tank, wherein the vacuum source applies a vacuum to the fluid injection tank to pull a cleaning fluid into the fluid injection tank.

13. The system of claim 12, further comprising a control system comprising a controller and one or more valves, wherein the controller provides control signals to the one or more valves, during use, to control the application of a vacuum to the fluid injection tank.

14. The system of any one of claims 10-13, further comprising an air inlet coupled to the fluid injection tank.

15. The system of claim 14, further comprising a control system comprising a controller and one or more valves, wherein the controller provides control signals to one or more valves, during use, to control the flow of air into the fluid injection tank.

16. A method of cleaning an implant comprising: placing a plurality of implants on one or more implant supports as described in any one of claims 1-9; placing the one or more implant supports in a cleaning system as described in any one of claims 10-15; placing the cleaning system in a cleaning fluid tank comprising a cleaning fluid, wherein the one or more implant supports are submerged in the cleaning fluid; transferring at least a portion of the cleaning fluid from the cleaning fluid tank to the fluid injection tank; and directing the cleaning fluid from the fluid injection tank through the fluid manifold into the one or more implant supports, wherein the cleaning fluid is ejected from the plurality of nozzles attached to the implant support to apply the cleaning fluid to an interior surface of the implant.

17. The method of claim 16, wherein the cleaning fluid comprises an aqueous solution of a surfactant.

18. The method of claim 16, wherein the cleaning fluid comprises an aqueous solution of an acid-based detergent.

19. The method of claim 16, wherein the cleaning fluid comprises purified water.

20. The method of any one of claims 16-19, wherein multiple cleaning fluid tanks are used in sequence to clean the implants.

21. The method of claim 20, wherein the multiple cleaning fluid tanks comprise: at least one cleaning fluid tank having a cleaning fluid comprising an aqueous solution of a surfactant; at least one cleaning fluid tank having a cleaning fluid comprising an aqueous solution of an acid-based detergent; and at least one cleaning fluid tank has purified water.

22. The method of any one of claims 16-21, further comprising placing the cleaning system in a drying tank, wherein the drying tank heats the air surrounding the cleaning system.

23. The method of claim 22, further comprising directing heated air into the implant supports.

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