Self-Powered Sensor Assembly for Gas Sterilization Monitoring
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Solution Overview
Problem
Current gas sterilization systems lack effective monitoring of sterilant gas concentration and process state variables within the load, relying on microbiological testing which is unreliable and time-consuming, and existing sensors are often tethered to external power sources, posing safety hazards and limiting spatial placement.
Innovation Solution
A sensor assembly comprising a housing with a gas concentration sensor, environmental sensors, an energy storage device, and a controller, designed to operate independently within the sterilization environment for extended periods, providing real-time monitoring of sterilant gas concentration and environmental parameters without external power or connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed within the load to monitor process state variables, then measurement precision is improved, but device complexity increases due to power supply requirements
Solution Approach 1:
The patent combines the sensor, battery, and housing into a single integrated sensor assembly unit. This merging allows the sensor to be placed within the load for accurate monitoring while the integrated battery provides self-contained power, eliminating the need for external power connections and reducing overall system complexity.
Solution Approach 2:
The sensor assembly is designed to be self-powered through an integrated battery that provides continuous power throughout the sterilization cycle. This self-service capability eliminates dependence on external power sources, allowing the sensor to operate autonomously within the load while maintaining measurement precision without adding external complexity.
2Use of energy by moving object
If sensors are tethered to external power sources, then use of energy is improved, but object-generated harmful factors increase due to safety hazards in flammable environments
Solution Approach 1:
The patent extracts the power supply requirement from the external environment by integrating a battery directly into the sensor assembly. This extraction eliminates the need for external power connections and tethers, removing the safety hazards associated with electrical connections in flammable sterilization environments while maintaining continuous energy supply.
Solution Approach 2:
The sensor assembly uses a battery that is designed to last the duration of the sterilization cycle and can be replaced after use. This approach eliminates the need for complex external power infrastructure and reduces safety risks by using a simple, contained power source that can be easily replaced without creating hazardous conditions.
3Device complexity
If sensors are positioned on the perimeter of the sterilization chamber, then device complexity is reduced, but measurement precision deteriorates as it cannot accurately monitor conditions within the load
Solution Approach 1:
The patent segments the monitoring function by placing individual sensor assemblies within specific locations inside the load rather than using a single external monitoring point. This segmentation allows multiple sensors to be distributed throughout the load, providing accurate local measurements while each sensor remains a simple, self-contained unit that is easy to place and operate.
4Reliability
If microbiological testing is used to verify sterility, then reliability is improved, but loss of time increases due to lengthy delays
Solution Approach 1:
The patent performs preliminary monitoring of process state variables (temperature, pressure, sterilant concentration) throughout the sterilization cycle using sensors placed within the load. This preliminary action provides real-time verification that sterilization conditions are met, eliminating the need for post-sterilization microbiological testing and significantly reducing processing time while maintaining reliability.
Solution Approach 2:
The sensor assembly provides continuous feedback on sterilization process parameters during the sterilization cycle. This feedback allows for real-time verification that sterilization conditions are achieved, replacing the delayed feedback from microbiological testing and enabling faster processing while maintaining the same level of reliability through direct process monitoring.
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 sensor assembly ensures accurate and reliable monitoring of sterilization conditions within the load, reducing the need for excess sterilant gas, minimizing hazards, and enhancing processing efficiency by verifying sterility through direct process state variable monitoring.
Implementation Method 1
a gas concentration sensor, at least one environmental sensor, an energy storage device, and a sensor-assembly controller configured to record a set of signals from the gas concentration sensor and the at least one environmental sensor
Implementation Method 2
The sensor assembly includes a housing, a gas concentration sensor, at least one environmental sensor, an energy storage device, and a sensor-assembly controller
Data Source
AI summary
Systems and methods are provided for monitoring a gas sterilization environment. The sensor assembly includes a housing that defines an internal chamber and a sensing volume that is in fluid communication with the gas sterilization environment. A gas concentration sensor and at least one environmental sensor positioned within the internal chamber and operably coupled to the sensing volume. A sensor-assembly controller is configured to execute a set of operations that control the sensors to monitor the gas sterilization environment over a sterilization period of between six hours and 48 hours.