Continuous Element Sterilization Using Transition Chambers
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Solution Overview
Problem
Existing sterilization systems face inefficiencies due to batch processing, variability in sterilization processes based on load weight, high resource consumption, and limitations in continuous or semi-continuous processing, leading to increased costs and ecological impact.
Innovation Solution
A system comprising operation and transition chambers with a continuous conveyor, allowing for continuous processing through preconditioning, sterilization, and postconditioning stages, maintaining stable conditions in each chamber to minimize downtime and resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch sterilization method is used, then equipment capacity is utilized, but productivity is reduced and idle time increases
Solution Approach 1:
The patent implements continuous sterilization where elements are constantly moved through the sterilization chamber on a conveyor system, eliminating idle time between batches. The conveyor continuously feeds elements through the sterilization zone, maintaining uninterrupted processing and maximizing equipment utilization without requiring chamber emptying or reconfiguration between batches.
Solution Approach 2:
The sterilization system is divided into discrete functional zones (pre-sterilization, sterilization, post-sterilization) that operate simultaneously. Elements move through segmented sections of the conveyor system, allowing different stages of processing to occur in parallel, thereby increasing overall throughput while maintaining controlled conditions in each zone.
2Productivity
If chamber capacity is increased to improve economics, then resource consumption increases, but processing efficiency decreases
Solution Approach 1:
The patent applies different sterilization conditions to different zones along the conveyor path. Elements receive targeted treatment in specific sections (e.g., vapor injection in the sterilization zone, drying in the post-sterilization zone) rather than subjecting the entire chamber to maximum energy input simultaneously. This localized approach maintains effective sterilization while reducing overall energy consumption.
Solution Approach 2:
The continuous conveyor system maintains constant element flow through the sterilization chamber, eliminating the energy-intensive cycles of heating, cooling, and venting required by batch systems. The steady-state operation allows energy input to be optimized for continuous processing rather than periodic batch cycles, significantly reducing total energy consumption while increasing throughput.
3Reliability
If load weight variability is accommodated, then process stability improves, but device complexity increases
Solution Approach 1:
The conveyor system is designed with adjustable speed control and positioning mechanisms that adapt to varying load weights. The system dynamically adjusts conveyance parameters to maintain optimal sterilization conditions regardless of element weight or density variations, ensuring consistent process outcomes without requiring complex manual intervention or reconfiguration.
Solution Approach 2:
The system incorporates sensors and automated control mechanisms that self-adjust to accommodate different load characteristics. The conveyor automatically detects and adapts to varying element weights and dimensions, maintaining stable sterilization parameters without requiring external calibration or complex operator intervention, thereby achieving process reliability with minimal added complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous sterilization with reduced energy and resource consumption, faster turnaround times, and improved process stability, overcoming load weight variability and space constraints.
Implementation Method 1
A conveyor system traverses through each of the plurality of operation chambers and each of the plurality of transition chambers
Implementation Method 2
The preferred embodiment for the present invention is demonstrated with a steam sterilizer or autoclave
Implementation Method 3
The internal condition of each of the operation chambers and each of the transition chambers varies to perform a specific processing stage
Data Source
AI summary
A continuous element decontamination and sterilization system has a set of transition chambers and operation chambers, a set of ports, a conveyor system, and a container. The sterilization system uses the chambers to form a modular system where each of the operation chambers is sandwiched between a preceding transition chamber and a subsequent transition chamber. The transition chambers serve as preprocessing or post processing devices that condition the container before entering an operation chamber. In this way, the conditions within the operation chamber do not fluctuate when the container is moved into it by the conveyor system. The conveyor system moves the container through the transition chambers and the operation chambers and enables a user to reload the container to be passed through the chambers for subsequent sterilization operations. The ports are integrated into the chambers so fluids and cleaning agents can be pumped into and extracted from the chambers.