Isolator Parallel Leak Test and Sterilization Heating
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Solution Overview
Problem
In isolators, the sterilizing process is lengthy, leading to inefficiencies in work efficiency, and there are challenges in controlling the discharge of sterilizing substances, which can result in exposure risks and prolonged processing times due to inconsistent gas concentration monitoring.
Innovation Solution
The isolator design includes a sterilizing substance supply unit independent from the gas flow channel in terms of heat and pressure, with a controller that manages the heating of the heater during a leak test and adjusts pressure to enable parallel leak testing and sterilization, and a concentration measurement unit to control the discharge amount based on measured concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sterilizing process is performed sequentially (leak test first, then sterilization), then the sterilization can be performed safely, but the total processing time is prolonged
Solution Approach 1:
The heater is started in advance during the leak test phase to pre-heat the sterilizing substance. This preliminary action allows the heater to reach operating temperature before sterilization begins, eliminating the need for sequential processing and reducing total process time while maintaining safety through independent pressure control during leak testing
Solution Approach 2:
The system divides the sterilizing substance supply into independent pressure control (for leak testing) and heating control (for sterilization). This segmentation allows simultaneous execution of leak tests and heater preparation without interference, enabling parallel processing that reduces overall time while maintaining the reliability of sequential safety checks
2Productivity
If the heater is operated at high temperature to rapidly vaporize sterilizing substance, then sterilization efficiency is improved, but the risk of sterilizing substance leakage increases
Solution Approach 1:
The system separates pressure control and heating control into independent systems. The pressure control unit maintains safe pressure levels for vaporization, while the heating unit operates at high temperature for efficient sterilization. This segmentation allows high-temperature operation without proportionally increasing pressure and leakage risk
Solution Approach 2:
The system uses concentration measurement units to monitor sterilizing substance levels and provides feedback to the control unit. This feedback mechanism allows the system to adjust heating and pressure parameters in real-time, maintaining high sterilization efficiency while preventing excessive vaporization that could lead to leakage
3Reliability
If the discharge amount of sterilizing substance is increased to ensure thorough sterilization, then sterilization quality is improved, but the exposure risk to workers increases
Solution Approach 1:
Concentration measurement units monitor the sterilizing substance concentration in real-time and provide feedback to the control unit. This allows the system to discharge the minimum necessary amount to achieve target sterilization levels, preventing excessive discharge that would increase worker exposure risk while maintaining thorough sterilization quality
Solution Approach 2:
The system dynamically adjusts discharge parameters (flow rate, duration, timing) based on real-time concentration measurements and process stage. This parameter optimization ensures sufficient sterilization is achieved with the lowest possible discharge amounts, reducing worker exposure risk while maintaining sterilization effectiveness
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
This approach shortens the sterilizing process time, reduces the discharge of sterilizing substances into the air, and enhances worker safety by optimizing the timing for starting subsequent work and maintaining safe gas concentrations.
Implementation Method 1
liquid hydrogen peroxide is vaporized by being hit with dried, hot air
Implementation Method 2
a heater for heating a sterilizing substance to be vaporized
Data Source
AI summary
An isolator includes a work chamber, a sterilizing substance supply unit, a gas flow channel pressure adjustment unit, a work chamber barometer, and a controller. The controller is configured to control execution of a gas flow channel leak test for checking a gas leak in a gas flow channel based on a detection result by the work chamber barometer after making the gas flow channel pressure adjustment unit increase or decrease the pressure in the gas flow channel, and is configured to control supply of the sterilizing substance by the sterilizing substance supply unit. The controller performs heating of a heater, which accompanies the supply of the sterilizing substance, in parallel with the gas flow channel leak test.