Electron Beam Transfer Chamber for Aseptic Surface Decontamination

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Solution Overview

Problem

Existing sterilization systems face challenges in achieving complete decontamination of container surfaces with efficient productivity, minimal equipment complexity, and maintaining a clear boundary between sterile and non-sterile areas, while also ensuring reliable protection against recontamination and effective airflow separation.

Innovation Solution

A production system with a process chamber containing at least two electron beam sources, where objects are passed between these sources for external decontamination, with controlled airflow and radiation characteristics to maintain aseptic conditions and ensure a stable sterile boundary, using movable radiation-shielding doors and airflow elements to manage object transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single electron beam source is used for sterilization, then equipment complexity is reduced, but the ability to maintain a clear sterile boundary and ensure complete surface decontamination deteriorates

Engineering Contradiction:

Improveequipment complexityVSAvoidsterile boundary clarity

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The single electron beam source is segmented into two separate electron beam sources positioned on opposite sides of the process chamber. This segmentation allows each source to independently illuminate its respective side, creating a clear sterile boundary at the chamber entrance while maintaining complete surface decontamination capability through coordinated operation of both sources.

Inventive Principle:

Principle #1Segmentation

2Reliability

If sequential rotational and translational movements are used to treat container surfaces, then complete surface sterilization is achieved, but productivity decreases due to multiple sequential stages

Engineering Contradiction:

Improvesurface sterilization completenessVSAvoidprocessing throughput

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system eliminates sequential rotational and translational movements by using two electron beam sources positioned on opposite sides of the process chamber. Objects move continuously through the chamber in a single pass, with both electron sources operating simultaneously to illuminate all surfaces, achieving complete sterilization without the productivity loss associated with multiple sequential stages.

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If the electron cloud is structured into sequential stages for container treatment, then surface decontamination is achieved, but the ability to overlay laminar flow for airflow separation deteriorates

Engineering Contradiction:

Improvesurface decontaminationVSAvoidairflow separation capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The process chamber is segmented into distinct functional zones: a first region receiving electrons from the first electron beam source, a second region receiving electrons from the second electron beam source, and a third region where treated objects exit. This spatial segmentation allows laminar flow to be overlaid in the third region for effective airflow separation between sterile and non-sterile areas, while both electron sources maintain their decontamination function in their respective regions.

Inventive Principle:

Principle #1Segmentation

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

The system achieves complete decontamination of object surfaces with high productivity, minimal equipment requirements, and maintains a clear sterile boundary, ensuring aseptic conditions throughout the process.

Implementation Method 1

At least two electron beam sources (E1, E2) are installed in the process chamber (5), between which the respective object (O1-Ox) is passed for external decontamination

Methodology Applied

Scientific EffectElectron beam irradiation: Electron Beam

Implementation Method 2

the at least two electron beam sources are only switched on for a specific period of time to externally irradiate the individual object passed between them

Methodology Applied

Scientific EffectElectron radiation: Radiation

Implementation Method 3

Continuous airflow within the process chamber maintains a sterile boundary in the area of effect of the irradiation zone formed by the electron beam sources

Methodology Applied

Scientific EffectLaminar flow: Laminar Flow

Data Source

PatentEP4663209A1Method for serially transferring objects through a process chamber for further processing in a containment under aseptic conditions and production system therefor

Publication Date: 2025.12.17 SKAN STEIN AG

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Figure 5~6

AI summary

The inventive method with a production plant (1) designed for this purpose is intended for the serial transfer of objects (O1-Ox) through a process chamber (5) for further processing in a containment (6) under aseptic conditions. A staging area (2) is located upstream of the process chamber (5), from which the respective object (O1-Ox) is loaded into the process chamber (5) for decontaminating its surface. The staging area (2), the process chamber (5), and the adjoining containment (6) form a production plant (1) erected in a room (A). At least two electron beam sources (E1, E2) are installed in the process chamber (5), between which the respective object (O1-Ox) is passed to achieve its external decontamination. The objects (O1-Ox) have, for example, the external shape of trough-shaped tubs or trays, and the articles stored therein are, for example,pharmaceutical phials, vials, syringes or cartridges.