Abstract:
The present invention provides a spray arm assembly comprised of a tubular member rotatable about a fixed axis. The tubular member has an internal passage and a central axis extending a length of the tubular member. A nozzle assembly is attachable to an end of the tubular member and fluidly communicates with the internal passage of the tubular member. The nozzle assembly is comprised of an insert attachable to the tubular member in a predetermined position. A nozzle body has an aperture therein defining a spray orifice. The nozzle body is mountable to the insert in one of a plurality of positions wherein the spray orifice has an orientation based upon a position of the nozzle body relative to the insert. A fastening means is provided for fastening the insert and the nozzle body together in one of the plurality of positions.

Description:
FIELD OF THE INVENTION 
     The present invention relates to microbial deactivation of medical, dental, pharmaceutical, veterinary or mortuary instruments and devices, and more particularly to a spray arm for use in a washer decontamination system. 
     BACKGROUND OF THE INVENTION 
     Medical, dental, pharmaceutical, veterinary or mortuary instruments and devices that are exposed to blood or other body fluids require thorough cleaning and microbial deactivation between each use. Washer decontamination systems are now widely used to clean and deactivate instruments and devices that cannot withstand the high temperatures of a steam sterilization system. Washer decontamination systems typically operate by exposing the medical devices and/or instruments to a washing solution and/or heated water for thermal disinfection. 
     In such systems, the instruments or devices to be cleaned are typically placed within a rack that is dimensioned to be received into a chamber within the washer decontamination system. During a deactivation cycle, a circulation system circulates a liquid disinfectant to nozzles located in the chamber. The nozzles spray the liquid disinfectant onto the items disposed in the chamber thereby microbially deactivating them. Following the deactivation cycle, a rinse solution, typically water, is circulated to the nozzles. The nozzles spray the rinse solution on the items in the chamber to remove traces of the liquid disinfectant and any particulate that may have accumulated on the instruments or devices during the deactivation cycle. 
     In some systems, rotatable spray arms having nozzles formed therein, are disposed in the chamber to provide better coverage. In some applications, it is desirable to be able to adjust the direction of a spray nozzle or to be able to vary the speed of rotation of a rotatable spray arm. 
     The present invention provides an improved nozzle assembly wherein the direction of coverage of a nozzle can be adjusted and the speed of a rotational spray arm can be varied. 
     SUMMARY OF THE INVENTION 
     In accordance with one embodiment of the present invention, there is provided a spray arm assembly comprised of a tubular member rotatable about a fixed axis. The tubular member has an internal passage and a central axis extending a length of the tubular member. A nozzle assembly is attachable to an end of the tubular member and fluidly communicates with the internal passage of the tubular member. The nozzle assembly is comprised of an insert attachable to the tubular member in a predetermined position. A nozzle body has an aperture therein defining a spray orifice. The nozzle body is mountable to the insert in one of a plurality of positions wherein the spray orifice has an orientation based upon a position of the nozzle body relative to the insert. A fastening means is provided for fastening the insert and the nozzle member together in one of the plurality of positions. 
     In accordance with another embodiment of the present invention, there is provided a nozzle assembly comprised of an insert attachable to a tubular member. A nozzle body has an aperture therein. The aperture directs a spray of fluid in a predetermined direction relative to the nozzle body. The nozzle body is mountable to the insert in one of a plurality of positions wherein a direction of fluid exiting from the nozzle body through the aperture is adjustable relative to the tubular member. A fastening means is provided for fastening the insert and the nozzle member together in one of the plurality of mounting positions. 
     One advantage of the present invention is a nozzle assembly for use in a washer. 
     Another advantage of the present invention is a nozzle assembly for use on a spray arm. 
     Another advantage of the present invention is a nozzle assembly for use on a rotatable spray arm. 
     Yet another advantage of the present invention is nozzle assembly as described above, that can be repositioned relative to a spray arm. 
     Another advantage of the present invention is a spray arm assembly as described above, wherein the rotational speed of the spray arm can be modified based on the position of a nozzle relative to the spray arm. 
     Yet another advantage of the present invention is a spray arm assembly as described above, including a sensor element that allows for monitoring of the position of the spray arm. 
     Another advantage of the present invention is a spray arm assembly, as described above, wherein the nozzle assembly is removable from the spray arm assembly to facilitate the cleaning of an interior of the spray arm assembly. 
     Yet another advantage of the present invention is a spray arm assembly, as described above, wherein the nozzle assembly is removable from the spray arm assembly without removing the spray arm assembly from the washer. 
     These and other advantages will become apparent from the following description of one embodiment taken together with the accompanying drawings and the appended claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may take physical form in certain parts and arrangement of parts, one embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein: 
         FIG. 1  is a schematic view of a washer decontamination system, 
         FIG. 2  is an enlarged view of one end of a spray arm showing a preferred embodiment of the present invention; 
         FIG. 3  is a cross sectional view taken along lines  3 - 3  in  FIG. 2 ; 
         FIG. 4  is a cross section view taken along lines  4 - 4  in  FIG. 2 ; 
         FIG. 5  is an isomeric view of one end of the spray arm shown in  FIG. 2 ; 
         FIG. 6  is a cross sectional view of one end of the spray arm shown in  FIG. 2 ; and 
         FIG. 7  is an exploded view of one end of the spray arm shown in  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings wherein the showings are for the purpose of illustrating one embodiment of the invention only, and not for the purpose of limiting same.  FIG. 1  shows a schematic view of a washer  10 . In the embodiment shown, washer  10  is a washer decontamination system wherein medical instruments and/or devices may be deactivated. However, as will be appreciated from a reading of the specification, the present invention may find advantageous application in other types of washers and other apparatus wherein a fluid is sprayed. 
     Washer  10  is generally comprised of a housing  22  that defines a chamber  24 . Housing  22  is formed to include a sloped sump  26  that is disposed at the bottom of chamber  24 . Sump  26  is provided to receive washing or rinsing fluids, as will be described in greater detail below. 
     A circulation conduit  32  fluidly connects sump  26  to first and second branch conduits  34   a ,  34   b  having upper and lower spray arm assembly  50 A,  50 B attached thereto. First branch conduit  34   a  extends through a side wall of housing  22  and has an end disposed in an upper portion of chamber  24  with upper spray arm assembly  50 A attached thereto. Second branch conduit  34   b  extends through the side wall of housing  22  and has an end disposed in a lower portion of chamber  24  with lower spray arm assembly  50 B attached thereto. A pump  36  is provided within circulation conduit  32  for pumping fluids from sump  26  to spray arm assemblies  50 A,  50 B. A motor  38 , schematically illustrated in the drawing, drives pump  36 . 
     Washer  10  is dimensioned to contain one or more racks  42 . Rack  42  is dimensioned to hold an instrument and/or device to be washed. Rack  42  is disposed between the upper and lower spray arms  50 A,  50 B, as shown in  FIG. 1 . 
     Upper and lower monitoring elements  44 A,  44 B are spaced away from the side walls of housing  22  at locations relative to spray arm assemblies  50 A,  50 B, respectively, as seen in  FIG. 1 . Upper and lower monitoring elements  44 A,  44 B are located outside of chamber  24  to isolate elements  44 A,  44 B from moisture in chamber  24 . Upper and lower monitoring elements  44 A,  44 B are operable to sense spray arm assemblies  50 A,  50 B, respectively, during an operation of washer  10 , as shall be described in greater detail below. 
     A controller  56  is operable to control motor  38  and receive signals from sensing elements  44 A,  44 B. In this respect, controller  56  controls the flow of fluid through circulation conduit  32  and monitors the position of spray arm assemblies  50 A,  50 B. 
     Spray arm assemblies  50 A,  50 B are essentially identical and as such only upper spray arm assembly  50 A will be described in detail. Spray arm assembly  50 A is comprised of a central hub  52  with arm assemblies  60 A,  60 B extending therefrom, as shown in  FIG. 1 . Central hub  52  defines an internal cavity (not shown) that is in fluid communication with first branch conduit  34   a . Central hub  52  is mounted to an end of first branch conduit  34   a  to rotate about a fixed axis ‘X.’ In this respect, spray arm assembly  50 A rotates about fixed axis ‘X.’ In the embodiment shown, spray arm assembly  50 A includes two arm assemblies  60 A,  60 B extending from central hub  52 . It is also contemplated that more than two, equally-spaced arm assemblies may extend from central hub  52 . A retaining clip  54  attaches each arm assembly  60 A,  60 B to central hub  52 , as shown in  FIG. 1 . 
     In the embodiment shown, arm assemblies  60 A,  60 B are essentially identical. Accordingly, only one arm assembly  60 A will be described in detail. Arm assembly  60 A, as best seen in  FIG. 2 , is generally comprised of an elongated tubular member  62  having a central axis ‘Y.’ Tubular member  62  defines an internal passage  64  that extends a length of tubular member  62 . A series of spaced-apart spray nozzles  68  extend through a wall of tubular member  62  at discrete locations along tubular member  62 . In the embodiment shown, tubular member  62  is a cylindrical tube and spray nozzles  68  are generally deformed openings. Spray nozzles  68  are formed by first drilling cylindrical holes  67  in the wall of tubular member  62 . Opposing sides of tubular member  62  are then deformed to define axially-extending grooves  66   a ,  66   b  that extend a length of tubular member  62 . Holes  67  become conical-shaped when grooves  66   a ,  66   b  are formed in tubular member  62 , as seen in  FIG. 4 . The conical-shaped holes  67  define spray nozzles  68  that have a distinct spray pattern. Channels  69  are formed in the inner wall of tubular member  62  when grooves  66   a ,  66   b  are formed therein. 
     A pair of holes  72   a ,  72   b  extend through the wall of tubular member  62  near the outward most end of tubular member  62 . Holes  72   a ,  72   b  are aligned along a common axis, as best seen in  FIG. 7 . A counter bore  62   a  extends partially into the outward most end of tubular member  62 . Counter bore  62   a  is dimensioned to receive a nozzle assembly  70 . 
     Nozzle assembly  70  is attached to the distal end of each arm assembly  60 A,  60 B. Broadly stated, nozzle assembly  70  is comprised of an insert  74 , a nozzle member  96  and a sensing element  122 . 
     Insert  74  is dimensioned to be disposed in the distal end of tubular member  62 , as best seen in  FIGS. 6 and 7 . Insert  74  is generally cylindrical in shape with an outer surface  74   a , a first end  74   b  and a second end  74   c . An axially-aligned cylindrical recess  76  extends inwardly into first end  74   b  of insert  74 . A hole  78  extends axially through second end  74   c  of insert  74  to communicate with recess  76 . A series of arcuate slots  82  surround hole  78 , as best seen in  FIG. 7 . Slots  82  communicate with recess  76 , as best seen in  FIG. 6 . An annular groove  84  is formed in outer surface  74   a  of insert  74  near first end  74   b . Groove  84  is dimensioned to accept a conventional o-ring  86  therein. A flange  88  extends outwardly from surface  74   a  of insert  74  near second end  74   c . A conical surface  74   d  extends from flange  88  to surface  74   a . A first series and a second series of surface projections  92  extend from the axially-facing surface of flange  88 . Projections  92  are designed to matingly engage surface projections  106  of nozzle member  96 , as shall be described in greater detail below. In the embodiment shown, surface projections  92  are triangular projections that extend radially outward from the axis of insert  74 . Hole  94   a , best seen in  FIG. 7 , and hole  94   b  (not shown) are formed in insert  74  and extend radially into recess  76 . Holes  94   a ,  94   b  are aligned along a common axis. 
     Nozzle member  96  is designed to matingly engage insert  74 . Nozzle member  96  is generally cylindrical in shape and has an outer surface  96   a , a first end  96   b  and a second end  96   c . A cavity  98  is formed in first end  96   b  of nozzle member  96 . Cavity  98  is generally conical in shape. A cylindrical recess  102  is formed in second end  96   c  of nozzle member  96 . A cylindrical and flat circular surface define recess  102 . A conventional o-ring  118  is disposed in recess  102 . A hole  104  extends axially through nozzle member  96  and communicates with cavity  98  and recess  102 . Surface projections  106  are formed on an outward facing surface of nozzle member  96 . Projections  106  are dimensioned to matingly engage projections  92  on insert  74 , as shall be described in detail below. In the embodiment shown, projections  106  are triangular projections that extend radially inward from an edge of one end of nozzle member  96  to a chamfered surface of cavity  98 . 
     Outer surface  96   a  of nozzle member  96  includes a first ribbed section  108   a  and a second ribbed section  108   b . In the embodiment shown, first and second ribbed sections  108   a ,  108   b  are a series of triangular shaped projections that extend axially along surface  96   a  of nozzle member  96 . First ribbed section  108   a  and second ribbed section  108   b  are disposed on opposite sides of nozzle member  96 . A side of nozzle member  96  is cutaway to form a notch  112 . In the embodiment shown, notch  112  is formed in surface  96   a  between first ribbed section  108   a  and second ribbed section  108   b . Notch  112  defines two surfaces that are at angles relative to each other. A rectangular channel  114  is formed in the surfaces defined by notch  112  and extends from first end  96   b  to second end  96   c . An orifice  116  extends through a side wall of nozzle member  96  along an axis ‘Z,’ best seen in  FIG. 6 , to communicate with cavity  98 . 
     A sensor element  122  is provided to mount to one end of nozzle member  96 . Sensor element  122  is generally cylindrical in shape and has a first end  122   a  and second end  122   b . A hole  126  extends axially through sensor element  122 . A recess  124  is formed in an end surface of sensor element  122 . Recess  124  defines two flat side surfaces  124   a  and two curved surfaces  124   b  disposed therebetween and a flat surface  124   c . Sensor element  122  and upper and lower monitoring elements  44 A,  44 B are dimensioned relative to each other, as shall be described in greater detail below. 
     Opening  126  and recess  124  are dimensioned to receive a plug  128 . Plug  128  is generally cylindrical in shape and includes a flange  132  extending outwardly from one end. An outer surface of flange  132  includes two flat outer surfaces  132   a  disposed between two curved outer surfaces  132   b . A threaded bore  134  extends axially into plug  128  from another end of plug  128 . Flat outer surfaces  132   a  and curved surfaces  132   b  are dimensioned to engage flat side surfaces  124   a  and curved surfaces  124   b  of sensor element  122 , respectively. In one embodiment, plug  128  is made of a polymeric material. 
     Insert  74 , nozzle member  96 , and sensor element  122  are attached together by a conventionally known fastener  136 . As shown in  FIGS. 6 and 7 , fastener  136  is dimensioned to have a length such that a head of fastener  136  is disposed in recess  76  of insert  74 . A threaded end of fastener  136  extends through hole  78  of insert  74 , through cavity  98  and hole  104  of nozzle member  96 , and into threaded bore  134  of plug  128 . In this respect, when fastener  136  is threaded into plug  128 , a bottom surface of the slotted head of fastener  136  contacts a wall of recess  76  of insert  74 . In a similar manner, an end surface of flange  132  of plug  128  contacts flat surface  124   c  of recess  124  in sensor element  122 . As a result, fastener  136  and plug  128  apply an axial force to insert  74 , nozzle member  96  and sensor element  122  to be secured together. O-ring  118  is disposed between sensor element  122  and nozzle member  96  and is dimensioned to create a fluid tight seal therebetween. 
     As stated above, projections  92  on insert  74  are dimensioned to engage projections  106  on nozzle member  96 . In this respect, nozzle member  96  can be fixed in one of a plurality of positions relative to insert  74 . Once nozzle member  96  is placed in the desired orientation, fastener  136  and plug  128  are tightened, as described above. Axis ‘Z’ of orifice  116  is fixed relative to nozzle member  96 . In this respect, axis ‘Z’ of orifice  116  is also fixed in one of a plurality of positions relative to insert  74 . A length of fastener  136  is dimensioned to allow plug  128  to be partially threaded off of fastener  136 , i.e., loosened, such that nozzle member  96  can rotate with respect to insert  74 , while still keeping nozzle member  96  restrained between insert  74  and sensor element  122 . In this respect, an orientation of nozzle member  96  and orifice  116  can be varied without completely disassembling nozzle assembly  70 . 
     As best seen in  FIG. 6 , nozzle assembly  70  is dimensioned to be received into counter-bore  62   a  of tubular member  62 . Insert  74  of nozzle assembly  70  may be placed into tubular member  62  in one orientation. As stated above, nozzle member  96  and orifice  116  of nozzle assembly  70  may be placed in one of a plurality of positions relative to insert  74 . In this respect, an orientation of nozzle member  96  and orifice  116  may be in one of a plurality of positions, relative to tubular member  62 . 
     A retaining clip  138  is provided to attach nozzle assembly  70  to arm assembly  60 A,  60 B. Retaining clip  138  is generally a rod-shaped element with a straight end and a curved end. The straight end of retaining clip  138  has an outer diameter and the curved end is formed as shall be described in greater detail below. Retaining clip  138  is dimensioned to retain insert  74  within tubular member  62  by extending through holes  72   a ,  72   b  of tubular member  62  and through holes  94   a ,  94   b  of insert  74 . Nozzle assembly  70  is placed into tubular member  62  such that holes  72   a ,  72   b ,  94   a ,  94   b  align. Holes  72   a ,  72   b ,  94   a ,  94   b  are all dimensioned to receive retaining clip  138  therein. The curve end of retaining clip  138  is dimensioned to rest on the outer surface of tubular member  62 , as best shown in  FIG. 5 . Retaining clip  138  is therefore prevented from separating from tubular member  62 . O-ring  86  is placed between an inner surface of tubular member  62  and insert  74 . O-ring  86  is dimensioned to form a fluid tight seal between tubular member  62  and insert  74 . In this respect, internal passage  64  is in fluid communication with cavity  76  in insert  74 , oblong hole  82  in insert  74 , first cavity  98  in nozzle member  96  and orifice  116  in nozzle member  96 . 
     In the embodiment shown, nozzle member  96  is repositionable about axis ‘Y’ of tubular member  62  to position nozzle member  96  in one of a plurality of positions. As best seen in  FIG. 6 , axis ‘Z’ of orifice  116  is fixed relative to nozzle member  96  at a predetermined angle relative to axis ‘Y’ of tubular member  62 . Therefore, axis ‘Z’ of orifice  116  is also repositionable about axis ‘Y’ of tubular member  62  to fix orifice  116  in one of a plurality of positions relative to axis ‘Y’ of tubular member  62 . 
     The aforementioned embodiment of the invention shall now be further described with relation to the operation of washer  10 . During a decontamination cycle in washer  10 , water fills sump  26  from a source of water (not shown). Once filled to a desired level, controller  56  energizes pump  36  to cause fluid to circulate along circulation conduit  32 , through first and second branch conduits  34   a ,  34   b , through upper and lower spray arm assemblies  50 A,  50 B and back to chamber  24 . In this respect, fluid flows through the cavity disposed in central hub  52 , through internal passage  64  in tubular member  62 , and exits through spray nozzle  68  in the wall of tubular member  62 . Fluid exiting spray nozzles  68  creates sprays of water that impact the devices and/or instruments disposed in rack  42 . Channels  69  in tubular member  62  define paths wherein fluid may flow toward the outward most end of tubular member  62 . 
     A portion of the fluid that flows within internal passage  64  also passes through cavity  76  and holes  82  in insert  74 , through cavity  98  and orifice  116  in nozzle member  96 . Upon exiting orifice  116 , the fluid creates a jet of high velocity water. The jet of water exiting orifice  116  creates a force that causes spray arm assemblies  50 A,  50 B to rotate about fixed axis ‘X.’ As stated above, nozzle member  96  is repositionable relative to insert  74  and tubular member  62  in one of a plurality of positions. In this respect, axis ‘Z’ of orifice  116  is repositionable to one of a plurality of positions relative to fixed axis ‘X’ about which spray arm assemblies  50 A,  50 B rotate. For each position of axis ‘Z’ of orifice  116 , relative to fixed axis ‘X,’ there is a tangential component of force that causes upper and lower spray arm assemblies  50 A,  50 B to rotate. By varying the angle of axis ‘Z’ relative to axis ‘X,’ the speed of rotation of upper and lower spray arm assemblies  50 A,  50 B is also varied. In this respect, the present invention provides a structure wherein the orientation of an orifice  116  relative to an axis of rotation of a spray arm assembly  50 A,  50 B can be change to achieve a desired rate of rotation. 
     The rotation of spray arm assemblies  50 A,  50 B causes sensor element  122  to move along a predetermined path. Upper and lower monitoring elements  44 A,  44 B and sensor element  122  are dimensioned such that a portion of the predetermined path of sensor element  122  is within a predetermined distance from upper and lower monitoring elements  44 A,  44 B. In the embodiment shown, the path along which sensor element  122  moves is circular. In this embodiment, a portion of the circular path is within about 3 inches from upper and lower monitoring elements  44 A,  44 B. Upper and lower monitoring elements  44 A,  44 B are operable to sense when sensor element  122  passes within the predetermined distance from monitoring elements  44 A,  44 B. In this respect, upper and lower monitoring elements  44 A,  44 B are operable to provide a signal to the system controller  56  corresponding to the presence or absence of sensor element  122  next to upper and lower monitoring elements  44 A,  44 B. In one embodiment, the system controller  56  uses a signal from upper and lower monitoring elements  44 A,  44 B to determine a rate of rotation of upper and lower spray arm assemblies  50 A,  50 B, respectively. 
     The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purposes of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is contemplated that racks  52  include one or more of the spray arm assemblies described above. The spray arm assemblies are connectable to a fluid inlet port (not shown) when racks  52  are disposed in chamber  24 . The spray arm assemblies in racks  52  include the aforementioned nozzle assembly  70  that enable the spray arm assemblies to be detected by monitoring elements disposed outside of chamber  24 , as described above. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.