Reprocessing apparatus and a method of reprocessing a load in a reprocessing apparatus
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Solution Overview
Problem
Conventional reprocessors for surgical instruments and medical equipment face challenges in ensuring consistent quality and efficiency due to manual processes, which introduce variability, and suffer from cross-contamination and biofilm buildup, especially in complex instruments with internal channels, leading to inadequate disinfection and sterilization.
Innovation Solution
A non-recirculating fluid-based reprocessing system with simultaneous filling, processing, and draining, using a buffer tank for fresh process fluid, dedicated fluid distribution devices, and ultrasonic cleaning to ensure thorough cleaning and disinfection without reintroducing contaminants, optimizing chemical concentrations for internal and external cleaning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning processes are used, then flexibility and adaptability are maintained, but quality consistency and efficiency deteriorate due to human variability
Solution Approach 1:
The system enables self-service through automated fluid distribution devices that automatically deliver cleaning fluids to internal channels without manual intervention. The irrigation pumps and fluid delivery systems operate autonomously to flush and clean instrument lumens, eliminating the need for manual cleaning while ensuring consistent quality outcomes.
Solution Approach 2:
Manual mechanical cleaning actions are replaced by automated fluid dynamics systems. The patent employs pressurized fluid delivery through irrigation pumps and distribution devices to substitute human hand-based cleaning mechanisms, achieving both automation and reliability.
2Loss of substance
If recirculating fluid systems are used, then water and chemical consumption is reduced, but cross-contamination and biofilm buildup increase due to reintroduction of contaminants
Solution Approach 1:
The harmful function of recirculating contaminated fluid is eliminated by extracting the recirculation loop from the system. The patent employs a non-recirculating design where fluids are delivered through internal channels and then discharged, preventing reintroduction of contaminants to the load while still achieving efficient resource utilization through targeted delivery.
Solution Approach 2:
The fluid delivery system is segmented into dedicated pathways for clean fluid delivery and contaminated fluid discharge. Internal connection lines and irrigation pumps create separate zones that prevent mixing of clean and contaminated fluids, eliminating cross-contamination while maintaining efficient fluid usage.
3Reliability
If separate filling and draining stages are implemented, then thorough cleaning is achieved, but processing time increases due to sequential operations
Solution Approach 1:
The patent merges filling, processing, and draining operations into a simultaneous continuous process. Fluid distribution devices deliver cleaning fluids while draining systems concurrently remove contaminants, eliminating sequential transitions and reducing total processing time while maintaining cleaning effectiveness through continuous fluid flow.
Solution Approach 2:
The system maintains continuous useful action by ensuring uninterrupted fluid delivery and removal throughout the cleaning process. Irrigation pumps and fluid distribution devices operate continuously without idle transition periods, keeping the cleaning action constant and eliminating time losses associated with stage transitions.
4Reliability
If conventional fluid distribution methods are used, then system complexity is minimized, but cleaning efficacy deteriorates due to inadequate delivery to internal channels
Solution Approach 1:
The patent introduces intermediary components including irrigation pumps and internal connection lines that act as mediators between the fluid source and instrument internal channels. These intermediaries enable effective delivery of cleaning fluids to difficult-to-reach areas while managing system complexity through modular, integrated design.
Solution Approach 2:
The system employs hydraulic principles through pressurized fluid delivery via irrigation pumps and distribution devices. This hydraulic approach enables effective penetration of cleaning fluids into internal instrument channels, achieving superior cleaning efficacy through fluid pressure and flow dynamics rather than complex mechanical mechanisms.
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 significantly reduces cross-contamination, enhances cleaning efficacy, and shortens processing time by eliminating the need for separate filling and draining stages, ensuring thorough disinfection and sterilization of both external and internal surfaces of complex instruments.
Implementation Method 1
Ultrasonic transducers may be mounted outside and/or inside of the reprocessing chamber on walls, doors and other elements of the chamber that get submerged or partially submerged by the cleaning fluid or anywhere on the outside of the chamber walls or doors below the process fluid water line. The ultrasonic transducers generate ultrasonic waves in the process fluid that cause cavitation in the volume of the process fluid and produce shockwaves during cavitation bubble collapse that remove contamination from surfaces in direct contact with the process fluid within which cavitation was induced.
Implementation Method 2
Heating is typically performed within the sump of the reprocessing chamber. At the end of each stage—prewash, main wash, rinse al used process fluid is discharged from the chamber.
Implementation Method 3
disinfection is typically achieved by rinsing the load with fluid (usually water) at elevated temperature (60° C. to 100° C.)
Data Source
AI summary
A reprocessing apparatus for washing and cleaning a load comprising a reprocessing chamber, a buffer tank, a buffer tank valve and recirculation valve, fluid distribution devices and plurality of pumps, at least one ultrasonic transducer and a drainage system characterised by said buffer tank is supplied with fresh water and process chemical where buffer tank holds fresh process fluid that is pumped to at least one fluid distribution device and directly into the load, the drainage system for discharging process fluids and recirculation loop for pumping said fluid back the reprocessing chamber, and a method of reprocessing a load in a reprocessing apparatus characterised by that fresh water is mixed with process chemicals externally to said chamber in the buffer tank and delivered to said chamber through fluid distribution devices and internal connecting lines while simultaneously washing the load internally and externally and discharging the fluid from the reprocessing chamber.