Patent Document

[0001]     THIS IS A NON-PROVISIONAL PATENT APPLICATION CLAIMING THE FILING DATE OF JAN. 18, 2005 OF PROVISIONAL PATENT APPLICATION SER. NO. 60/644,904. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The invention relates and pertains to systems and methods for accomplishing cleaning, disinfection, sterilization, and decontamination.  
         [0004]     2. Description of the Prior Art  
         [0005]     As used herein, the term “cleaning” means and refers to removal of what is normally referred to as “dirt” or “soiling,” i.e., visible foreign matter such as dust, grime, dried blood, dirt and the like from objects which are required to be free of same.  
         [0006]     The term “disinfection” means and refers to removal and killing of organisms with varying amounts of resistance less than that of spores or protozoan cysts.  
         [0007]     “Sterilization” means and refers to removing and killing spores such as  bacillus subtilis.    
         [0008]     “Decontamination” means and refers to the removal and/or disabling of toxic materials such as chemicals (including those used in chemical warfare), radiation, and the like.  
         [0009]     “Sterilant” means and refers to a sterilizing agent, and is occasionally specifically employed herein to refer to fluid used in sterilization to contact spores and remove or kill same.  
         [0010]     Existing systems and methods for accomplishing cleaning, disinfection, sterilization, and/or decontamination are applicable to some but not all of the foregoing activities and have, within such constraints, varying degrees of effectiveness, scope, convenience and expeditiousness.  
         [0011]     Applications include medical, commercial, industrial and military among others, including weapons of mass destruction and span the range from microscopic to vehicles to buildings and further include human beings as well as objects.  
         [0012]     Existing methods and apparatus applying oxidants and peroxidants for the above stated purposes are required to employ relatively high concentration of oxidants and peroxidants—as high as 35% or more of hydrogen peroxide, a powerful and commonly-used peroxidant—in order to accomplish the purpose. The corrosiveness of H 2 O 2  in relatively high concentrations causes destruction and/or deterioration of particular materials to which they are applied as, for example, electronics, avionics, steel, requiring the peroxide solution and residue to be flushed away. For small and/or hard-to-access mechanisms such as typewriters, computers, certain types of weapons, avionics, electronics, and the like, such flushing is not wholly effective and as a result such mechanisms must be eventually discarded due to corrosion.  
         [0013]     Particular examples include devices depicted and described in U.S. Pat. No. 4,414,037 (Friedheim); U.S. Pat. No. 4,282,903 (Powell); U.S. Pat. No. 5,290,511 (Newman); U.S. Pat. No. 4,263,258 (Kalasek); U.S. Pat. No. 4,169,123 (Moore); U.S. Pat. No. 5,580,530 (Kowatsch); U.S. Pat. No. 6,036,918 (Kowanko); U.S. Pat. No. 5,508,009 (Rickloff); U.S. Pat. No. 5,344,622 (Faddis); U.S. Pat. No. 4,909,999 (Cummings); U.S. Pat. No. 4,282,179 (Gunther).  
         [0014]     The foregoing existing apparatus and methods exhibit shortfalls and deficiencies including bulkiness, unsuitability for expeditious use and for reaching difficult-to-access portions of objects to be cleaned, disinfected, sterilized and decontaminated generally requiring an autoclave or cleaning chamber. In U.S. Pat. No. 4,414,037, a number of these problems are addressed; however, sterilization is not readily accomplished, nor is decontamination.  
         [0015]     Consequently, there has been a felt and unfulfilled need for a general system and method for expeditious and convenient cleaning, disinfecting, sterilizing, and decontaminating for the generality of objects, including those which may be difficult to access, corrodible, small, or fragile, and may include human beings and other living things.  
       SUMMARY OF THE INVENTION  
       [0016]     A system and method for cleaning, disinfection, sterilization, and decontamination includes means for generating and emanating superheated vapor including at least one sterilant. In particular embodiments, an anti-corrosion agent is also employed. The liquid from which the superheated vapor is generated comprises solution of sterilant, as well as anti-corrosion means in particular embodiments.  
         [0017]     A method for cleaning, disinfecting, sterilizing, and decontaminating includes the steps of generating superheated vapor under pressure, providing at least one sterilant therein, and directing the superheated vapor under pressure toward the object to be cleaned, disinfected, sterilized, and decontaminated and may include the step of providing an anti-corrosion reagent in connection with said superheated vapor.  
         [0018]     A method for cleaning, disinfecting, sterilizing, and decontaminating may be employed in accordance with the invention including the steps of directing superheated vapor containing a steriliant toward an object in such a manner as to subject substantially all of the object to the vapor flow, such step involving in a particular embodiment, providing a tortuous path as, for example, a serpentine path upon or adjacent to the object. Said system and method provide for selectively varying and adjusting the concentration of sterilant, the temperature of the superheated vapor at its source, the distance of the source of superheated vapor from the object, the temperature of the superheated vapor at the object, the pressure of the superheated vapor stream to achieve the desired result, among other parameters. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1 . depicts a system for cleaning, disinfecting, sterilizing and decontamination, in accordance with the invention;  
         [0020]      FIG. 2 . is a section through the line  2 - 2  of  FIG. 1 ;  
         [0021]      FIG. 3 . depicts in fragmentary form a portion of an object to be cleaned showing a path thereon of superheated vapor applied thereto in accordance with the invention.  
         [0022]      FIG. 4 . is a depiction, somewhat simplified and schematic, of a lumen in an enclosure or needle;  
         [0023]      FIG. 5  is a schematic diagram relating to a particular mode of operation in accordance with the invention;  
         [0024]      FIG. 6  is a schematic diagram of operation in accordance with the invention in conjunction with a conveyor;  
         [0025]      FIG. 7  is a view, somewhat schematic, of a superheated vapor generator multi-unit system employed in accordance with the invention; and  
         [0026]      FIG. 8  is a schematic diagram of a control of the superheated vapor generator system of  FIG. 7 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]     U.S. Pat. No. 4,034,037 (the &#39;037 patent) and U.S. Pat. No. 5,471,556 (the &#39;556 patent), U.S. Pat. No. 6,006,009 (the &#39;009 patent), all issued to an inventor herein, Max Friedheim, are incorporated by reference herein and as appropriate the disclosures thereof will be employed in connection with the description and discussion herein of corresponding parts.  
         [0028]     As depicted in  FIG. 1 , a system  10  for accomplishing cleaning, disinfection, sterilization, and decontamination in accordance with the invention comprises a base forming the bottom of housing  14 , which together with base  12  forms a container for a portion of system  10 . The top and sides of housing  14  are fastened to base  12  by conventional means such as screws and are removable to permit access to the interior of system  10   
         [0029]     Controls of the system  10  are disposed upon a portion of housing  14  comprising a control panel  16 . A power switch  18  is conveniently disposed on panel  16  and comprises a bi-polar arrangement of conventional type, controlling drawing of power from an external source i.e. whether the system  10  is “On” or “Off” as is more fully described hereinbelow. Said control is in accordance with circuitry and electronics disclosed in detail in the &#39;009 patent.  
         [0030]     Disposed upon control panel  16  adjoining power switch  18  is a removable line fuse holder  20 . A white power light  22  is disposed on control panel  16  and as described in more detail hereinbelow functions to indicate power in the system  10 .  
         [0031]     Also disposed on the control panel  16  is a manual vapor heating switch  24  which participates in controlling the generation of superheated vapor as described herein. An amber vapor generator light  26  is disposed on the control panel  16  adjacent power indicator  22 . Light  26  as described hereinbelow is an indicator of the operation of electronic controls of a vapor generator (described in more detail below and in the &#39;009 patent) in the system  10 .  
         [0032]     A footswitch electric receptacle  28  is disposed in a lower part of panel  16  and accommodates a foot switch (not shown) for controlling superheated vapor production.  
         [0033]     A power line  30  is accommodated in a fitting  32  attached to the panel  16  around a slot  34  for passage therethrough of power line  30 .  
         [0034]     An amber heating chamber light  36  is positioned on panel  16  adjacent power light  22  and is electrically connected as described hereinbelow to remain on while a heating element described below is drawing current. A liquid pick-up tube inlet  38  is defined in control panel  13  to receive a liquid pick-up tube  40 .  
         [0035]     At the top of housing  14  is disposed a carrying handle  42  secured by fasteners  44  to housing  14 . In a rear panel  46  of housing  14 , an aperture  48  is defined; secured on both sides of aperture  48  is a gasket-type fitting  50 . Aperture  48  and gasket  50  accommodate and receive a vapor exit pipe connector  52 . A quick disconnect connector member  54  is disposed at an outer end of pipe  52  and connectable to a vapor control member or wand  56 . The wand  56  contains a grip handle  58  in which is disposed a vapor control switch operable by a vapor control push button  60 . A tube  62  extends outwardly from the control member handle  58 . A vapor control power connector  64  connects between the vapor control  60  and into a socket  64  and is mounted in rear panel  46 .  
         [0036]     Pick-up tube  40  is depicted as connected to a reservoir  65  through a port  67 . Reservoir  65  is depicted in simplified, schematic form only and may be of appropriate shape and size among other parameters, in particular applications of the invention.  
         [0037]     Contained in reservoir  65  is liquid for input into system  10  for vaporization into superheated vapor. The nature and function of said liquid is discussed more fully hereinbelow.  
         [0038]     Turning now to  FIG. 2 , a support plate  66  is fastened to base  12 , which in turn rests upon feet  68 .  
         [0039]     A mounting plate  70  is fastened to support  66 . Fastened to mounting plate  70  is a pump  72 . Pump  72  includes a cylinder  74  receiving a piston  76  which reciprocates within cylinder  74 . Piston  74  is pivotably and connected to a rod  78  with a pivoting member  80  at the opposite end of the rod from the pivotable connection between the rod  78  and the piston  76 . A substantially square cam  82  is pivotably attached to pivot member  80  and pivots and is rotatable on a shaft  84  mounted and pivotably journalled in plate  70 . In particular applications, cam  82  is at least ⅞ inch square. This configuration of the cam  82  has been found to add leverage beyond that achieved by the device in the &#39;037 patent and to eliminate possible vapor-lock in the fluid line as fluid enters the vaporization chamber, in addition to providing more efficient prevention of back pressure of steam build-up within the vaporization chamber. This is of moment in system  10  due to the substantial heat generated in a smaller area than in the device of the &#39;037 patent.  
         [0040]     An electric motor  86  is mounted upon mounting plate  70  and rotates shaft  84 . Electric motor  86  is Class B wired to withstand heat generated in system  10 . Cam  82  is rotated by shaft  84 , which in turn rotates on a sleeve in pivot member  80 . An inlet fitting  88  accommodates inflow of liquid from inlet port  38  through inlet conduit  40 . A first check valve  90  is connected to inlet fitting  88  and is shown in detail in  FIG. 2 . Check valve  90  not only blocks backflow and prevents intake of solids into the apparatus but also affects by particular parameters the liquid content of superheated vapor produced by system  10 .  
         [0041]     An elbow fitting  92  is connected to check valve  90  and accommodates flow of liquid therethrough to a T-fitting  94 . T-fitting  94  is connected to the fluid intake inlet  88 . Connected to T-fitting  94  is a second check valve  100  which in turn is connected to an elbow fitting  96 . Check valve  100 , is identical to and is described in detail hereinbelow in conjunction with the description of check valve  90 .  
         [0042]     From fitting  96  fluid passes through a fitting  104  which is connectable to a tube  106 , depicted as coiled for economy of space utilization. Tube  106  leads into a superheated vapor generator  120 . A sleeve  107  is secured to tube  106  at its point of entry into generator  120 . Sleeve  107  is preferably composed of aluminum and is welded to tube  106 . Sleeve  107  preferably extends substantially ¾″ above the top surface of generator  120  and is secured to generator  120  at an exterior weld  109  and an interior weld  111 .  
         [0043]     A male connector  110  is fastened to screw  112  mounted in panel  16  and connected to vapor switch  24 . A bracket  114  fastened to plate  12  provides support and mounting for the vapor generator  108 .  
         [0044]     Electric gear motor  86  is secured by fasteners  115  to mounting bracket  70 . Electric gear motor  86  is of conventional type and in a preferred embodiment provides 366 RPM at 115 volts. Motor  86  drives pump  72  by means of cam  82  joumalled on shaft  84  which in turn is driven by motor  86 . A pair of buffer members  113  upon motor  106  are in contact with bracket  70  for the purpose of minimizing the effect of vibration upon the structure.  
         [0045]     Vapor generator  120  comprises metal castings in two parts welded together at  122  defining a vaporization chamber (not shown)  6 . Generator  120  is detachably positioned within housing  14  and is secured thereto at bracket  114  as noted hereinabove, and rests on washers  124  between plate  66  and bracket  114 . A vaporization chamber  126  is defined centrally within generator  120 . The bottom section is longer to allow room for a heating element  132  described below. As depicted, chamber  126  is substantially spherical; however, other configurations may be employed in accordance with the invention. In the depicted spherical configuration, the periphery of chamber  126  is referred to on occasion as a wall. In other configurations in accordance with the invention such periphery may comprise more than one wall.  
         [0046]     A more fully described and discussed in the &#39;037 and &#39;556 patent, walls of chamber  126  may be of varied surfaces (etched as in the &#39;037 patent; cut in ridges and grooves as in the &#39;556 patent), among other configurations.  
         [0047]     As disclosed in full detail in the &#39;556 patent, disposed in generator  120  is a heating element for heating to the desired temperature for generating superheated vapor. Control of temperature and heat generation as well as the frequency and duration of flows of superheated vapor in system  10  is as described in the &#39;009 patent, through a system of electronics and controls whose purpose is to achieve selected operating temperatures, to prevent overheating and to provide a desired level frequency and duration of flows of superheated vapor.  
         [0048]     As described in fuller detail in the &#39;009 patent and as shown and depicted in  FIG. 7, 8 , a plurality of superheated vapor generators  10   a - 10   d  are controlled by a logic box  122  of conventional type including circuitry regulating input of liquid and heating of generators  120 .  
         [0049]     Vapor control member or wand  56  in detail is as described and depicted I the &#39;556 patent. Wand  56  comprises a conduit member  57 , a handle member  58 , and a tube  62  as previously discussed.  
         [0050]     Handle  58  includes a central bore  188 . An insulator sheath  190  is disposed around handle  58 . Insulation sheath  190  may comprise rubber or other conventional material.  
         [0051]     Switch  60  controls the operation of wand  56 . Switch  60  is of conventional type, for example a single-pole spring-operated mechanism. Conduit member  57  is fastened to tube  62  by fitting (not shown). Tube  62  is received in an aperture  200  at the outer end of handle  58  and may be fabricated of brass or other durable non-corrosible material.  
         [0052]     The electrical circuitry for system  10  is as described and depicted in the &#39;556 patent and the &#39;009 patent. Power switch  18  controls the on/off condition of the entire system. Switch  24  is a manual vapor generator switch which as noted above is mounted on control panel  16 . A switch (not shown) in wand  56  is actuated by push button  60  and like switch  24  controls vapor generation but is contained in the wand  56  for ease of operation of the device, these switches controlling the on/off condition of pump motor  72 .  
         [0053]     Red light  26  is connected to the system thermostats in order to notify the operator of a change in condition in the system, as described in the &#39;556 patent.  
         [0054]     As more fully described in the &#39;556 patent, white light  22  is illuminated when power switch  18  is closed (i.e. when the power switch is turned on). Amber light  36  is on when heating element in generator  120  is drawing current and remains on so long as the heating element draws current. When light  36  goes out, this indicates that generator  120  has reached its operating temperature.  
         [0055]     System  10  is connected by hose  40  to liquid reservoir  65 . The liquid contained in reservoir  65  may be any of a broad range related to the purposes for which system  10  is to be used. In a typical cleaning context in which the system is employed to loosen and dissolve dirt as on machinery or circuit boards or in corners of a room, 100% undiluted water, distilled or deionized, may be employed. Additives such as detergents or disinfectants may be employed provided that they are stable at the operating temperatures of the system. The proportions of additives and water may be varied depending on the application. The solution may contain vaporizers, emulsifiers, degreasers, oxidants, alkalis, deodorizers, antiseptics, germicides, sterilants, corrosion inhibitors, or the like. In addition, the liquid may comprise humidifiers, fresheners, and other reagents which the user may wish to impart to the air or to a surface or object.  
         [0056]     In accordance with the invention, in a preferred embodiment, reservoir  65  contains an aqueous solution of substantially 8% Hydrogen Peroxide (H 2 O 2 ). Reservoir  65  may also contain a corrosion—inhibiting agent marketed in connection with the trademark ARMA-SOL®.  
         [0057]     Particular applications of the system include cleaning, disinfection, sterilization, and decontamination of equipment, circuit boards and/or surfaces and spaces such as rooms in connection with maintenance or janitorial work. Wand  56  provides the capability for precise direction of the vapor flow even to small objectives and in particular allows impingement of the vapor into small, confined, or relatively inaccessible objects or spaces. Apparatus in accordance with the invention provides a general purpose cleaning capability with particular applicability to remote or relatively inaccessible areas, objects and small parts.  
         [0058]     The invention may be employed in connection with burnishing or cleaning of small parts such as time-piece apparatus, in connection with metal plating, printing and photo-engraving, lapidary and stone cutting activity, manufacture and/or repair of electronic components, removal of such things as wallpaper, labels and the like, in connection with dry-cleaning, sanitizing and sterilizing of eating implements, in connection with optical and optometric laboratory and office work, with jewelry, dental and medical offices and operating theatres, miniature instrument manufacture and repair, and biological and analytic laboratories, among many other applications. Use of apparatus in accordance with the invention is particularly advantageous in that its flexibility permits cleaning of small parts to be accomplished with a minimum of disassembly.  
         [0059]     A particularly useful application of the invention is in connection with the cleaning and maintenance of military equipment, including weapons and related items. This has become timely in view of the current concern with possibility of chemical or biological warfare attacks as well as emphasis on repair and maintenance as opposed to acquisition of new items.  
         [0060]     System  10  preferably operates at substantially 1500 watts at 120 or 240 volts. When the power switch  18  is turned to the ON position, white signal light  20  and amber signal light  36  are illuminated. As indicated, illumination of light  22  indicates that power is being provided to the system and light  36  indicates that the heating cartridge  132  of the vapor generator  120  is drawing current. When vaporization chamber  124  reaches the desired temperature of 500° degrees. F., indicator light  136  goes out under the influence of electronic circuitry. This informs the operator that superheated steam or other superheated vapor is available.  
         [0061]     As noted any one of switches  24 ,  38 ,  192  can be actuated to cause the issuance of superheated vapor from tube  62 . When the machine “warms up”, a period of 6 minutes is normally sufficient for the chamber  126  to reach operating temperature for generation of superheated vapor.  
         [0062]     As depicted in  FIGS. 7, 8 , and as fully disclosed in the &#39;009 patent incorporated by reference herein, the invention may employ a plurality of vapor generator systems in order to adjust the frequency, duration and size—among other parameters—of flow of superheated vapor. The description of such multi-unit superheated vapor generators will be brief herein in view of the &#39;009 patent.  
         [0063]     As depicted in  FIGS. 7, 8 , a superheated vapor generator system  310  in accordance with the invention comprises a plurality, in the depicted embodiment four, of superheated vapor generators  312   a ,  312   b ,  312   c , and  312   d . Vapor generators  312   a - 312   d  are coupled to an output manifold collector assembly  314  by a conduit system  316 .  
         [0064]     Superheated vapor generators  312   a - 312   d , and each of them, are in accordance with the superheated vapor generators described and claimed in U.S. Pat. No. 4,414,037 or U.S. Pat. No. 5,471,556 to the inventor herein, as is discussed in further detail hereinbelow. Manifold system conduit sections  318  connects the output of superheated vapor generator  312   a  to manifold  314 ; conduit section  320  connects vapor generator  312   b  to manifold  314 ; conduit section  322  connects vapor generator  312   c  to manifold  314 , and conduit section  324  connects vapor generator  312   d  to manifold  314 . Check valves  318 ′,  320 ′,  322 ′, and  324 ′, are positioned in conduit sections  318 ,  326 ,  322 , and  324 , respectively, to prevent backflow of superheated vapor generated from the superheated vapor generators  312   a - 312   d.    
         [0065]     Intake conduits  326 ,  328 ,  330 ,  332  connect generators  312   a ,  312   b ,  312   c ,  312   d , respectively, to a source of liquid (not shown) for use in vaporization by the generators.  
         [0066]     Connected to manifold  314  is an output conduit  334  for issuance of superheated vapor generated by vapor generators  312   a - 312   d  and collected in manifold  314 . In particular applications, output  334  constitutes a hose, a pipe, and the like, or may constitute a nozzle connectable to a vapor controller of the type described and claimed in the &#39;556 patent.  
         [0067]     Referring to  FIG. 8 , depicted therein is a control system  336  for vapor generator systems in accordance with the invention. Controller  336  comprises a logic “smart box” of conventional type having an offperiod control switch  338  and an on period control switch  340 . Controller  336  is electrically connected to vapor generators  312   a ,  312   b ,  312   c ,  312   d , in parallel wiring. The setting of switch  338  determines the time interval during which each generator  312  is “off” per cycle and switch  340  determines the time interval which generators  312  are “on” as described in further detail in the &#39;009 patent.  
         [0068]     An indicator light (not shown) indicates in the same manner as shown in connection with  FIGS. 1-5  that the power is on and is part of the system circuitry shown in the &#39;009 patent.  
         [0069]     In operation, timer controller  336  is set for: the desired intervals of operation (that is, pumping of liquid to the generator for vaporization providing superheated vapor output from the generator) for each generator  312   a - 312   d ; for the desired sequence of operation of the respective generators; and for the period of time between the activation of a particular generator in one cycle and its activation in the next cycle. This is accomplished by adjustment of switches  38 ,  40  as fully disclosed in the &#39;009 patent.  
         [0070]     A power switch  396  connected to a source of external power (not shown) is turned to the “on” position. At this point, the first generator in the selected sequence,  312   a , is caused to produce superheated vapor by activation of a pump (not shown) supplying liquid to generator  312   a  in the same manner as shown in connection with  FIGS. 1-5 . In a typical cycle, generator  312   a  will produce output superheated steam for four (4) seconds and will be set to repeat this operation twelve (12) seconds after cessation of emission of steam or sixteen (16) seconds after commencement of output of steam.  
         [0071]     In the 12 seconds of downtime for generator  312   a , generators  312   b ,  312   c ,  312   d  are performing the identical operation described for generator  312   a ; concurrently for at least a part of its downtime, generator  312   a  is in a “recovery phase” in which its temperature, reduced by the heat loss from vaporization of water producing steam in its active phase, is raised once again to operating temperature, at which point generator  312   a  is ready to produce additional steam in the next cycle. Of course, this series of events is identical for each generator  312   a - 312   d.    
         [0072]     Superheated vapor produced by the invention is supplied to manifold collector  314  via output conduits  318 , 320 , 322 , 324  for generators  312   a ,  312   b ,  312   c ,  312   d , respectively.  
         [0073]     The amount of downtime, length of time on, pressure and volume of output vapor, are parameters of the system  310 . For example, if additional steam per unit time is desired, the operating cycle may be shortened or additional generator units may be added; such addition of units may be in “parallel” with existing arrangement of generators to operate concurrently in the existing sequence, thereby maintaining timing of the existing cycle, or in series, whereby the cycle will be lengthened.  
         [0074]     In the foregoing manner, generation of superheated vapor can be accomplished under precise control for numerous applications where a substantially continuous flow of output vapor is desired as, for example, in operation of a steam-powered engine or generator for cleaning, disinfection, sterilization and decontamination of large, multiple or difficult-access objects.  
         [0075]     In operation the operator directs the tube  62  toward the object which is to receive superheated vapor, which issues from tube  62 . The superheated vapor such as steam, is “dry” i.e. having a high proportion of gas as opposed to content of fluid droplets. This has a favorable effect in that the amount of liquid included in the vapor is so small that the residue does not interfere with further cleaning and does not require a cleanup, the amount of fluid residue being so small that it can normally be readily removed by a cloth or paper towel. In many instances, the liquid residue rapidly completely evaporates (either naturally due to the small amount of liquid in the superheated vapor in the first instance and the elevated temperature of the surface or induced by application of a drying flow)—without use of toweling. This is particularly advantageous in the treatment of avionics and electronics which are subject to corrosion from liquid water but cannot be readily dried with a towel.  
         [0076]     In a particular application for cleaning, disinfection, sterilization and decontamination of sensitive avionics or electronics the end of tube  62  is initially positioned sufficiently closely to the surface/area to be treated such that the velocity, temperature and concentration of sterilant are higher in the impact region of the flow of superheated vapor. Thereafter, tube  62  is moved away from the treated surface such that velocity, temperature and concentration of sterilant are reduced. This may be performed in connection with inclusion of cooler air into the vapor flow which can be employed to assist in evaporation of condensed liquid form the treated surface as well as to cool said surface. Pooling of liquid is virtually eliminated. The material removed by a towel in the form of a residue is easily disposed of, particularly in cases where any removed contaminants are non-hazardous or non-toxic.  
         [0077]     Performance testing has evidenced that with a substantially 8% aqueous solution of H 2 O 2  cleaning of standard soiling (geobacilillus steamthermophilus spore contaminated dried blood) effectiveness of cleaning was 99.9% with use of superheated vapor for thirty (30) seconds.  
         [0078]     With regard to disinfection, use of the invention with superheated steam, with or without a disinfectant, resulted in complete success with 60-second treatment time.  
         [0079]     Concerning spore reduction it has been established, using  Bactillus Subtlis  at 60 seconds treatment time, that among other successful results; (1) average disinfection effectiveness with 8% aqueous solution of H 2 O 2  was 99.9994% and for superheated steam alone was 99.9983%; and (2) H 2 O 2  reduced the number of residual spores by a factor of three (3) compared to superheated steam alone.  
         [0080]     With respect to sterilization, using spores of geobacillus steamthermophilus (spores used to test autoclaves and recommended for H 2 O 2 ) two treatments with 8% H 2 O 2  were successful in producing complete sterility. One treatment comprised a 60-second cleaning with H 2 O 2 , followed by sealing in a bag with H 2 O 2 , and boiling for 30 minutes. Further testing established that with 90-second exposure and an 8% aqueous solution of H 2 O 2  plus ARMA-SOL®, complete sterility was achieved without risking corrosion.  
         [0081]     Another test comprised a 180-second cleaning followed by bagging and leaving 12-14 hours with no further heating. This contrasts with existing methods where substantially higher concentrations of H 2 O 2  are used. Other concentrations of H 2 O 2  in other media may be employed in accordance with the invention.  
         [0082]     In accordance with the invention, solutions may be employed including NH 3 OH, oxygenated water, ozonified water, and peroxides including H 2 O 2  (HOOH), alkyl hydrogen peroxide (R—OO—H), dialkyl hydrogen peroxide (R—O—O—R′), peroxy acids (RCO—O—O—H), peroxy esters (R—CO—OOR′) and diacyl peroxides (R—CO—O—O—CO—R′) where “R” and “R′” are defined as alkyl groups of the general formula C nH2 n+1 where n is from 1 to 50.  
         [0083]     Concerning decontamination, the H 2 O 2  functioning as an oxidant and hydrolyzing agent has the effect upon use in accordance with the invention of negating common contaminants through oxidation and hydrolysis. In a military context, this includes nerve gases, mustard gas and Lewisite. The hydrolyzing and oxidizing action of H 2 O 2  is substantially enhanced due to the elevated temperature of the superheated vapor in which it is disseminated, in accordance with the invention.  
         [0084]     By use of the invention, the operator gains the capability of precisely directing relatively dry vapor to the object targeted. The operator can control the amount of heat transferred to any target by varying the distance between the end of the tube  62  and the object of the heat, decreasing the distance and increasing the heat applied, increasing the distance and decreasing the heat applied. The invention produces a jet of superheated vapor of a temperature of approximately 300° degree. F. at the nozzle and for a short distance. It has been found that approximately 2-3 inches from the nozzle the vapor has cooled sufficiently that human flesh will not be burned by it.  
         [0085]     Superheated vapor issues at approximately 190 PSI. As a result of this, the superheated vapor impinges upon, and into such relatively hard-to-reach spaces as portholes, crevices, and the like. Application of heat causes contaminants to soften, liquify, and generally decompose or disengage from the surfaces on which they are disposed. This applies to such normally hard-to-clean substances as grease, oil, grime, paste, glue, and carbon. A burst of superheated vapor, such as steam in a cleaning context, lasting 5-10 seconds, is sufficient for many cleaning purposes. In the preferred embodiment, the burst of superheated vapor produced by the system  10  will last approximately 15-30 seconds. For removal of tenacious contaminants, heat applied by the invention initiates cleaning. Then a cleaner or emulsifier may be applied in conventional fashion at which point a further burst of superheated vapor from the invention completes removal of the contaminant. For larger surfaces where a substantial and/or continuous vapor flow is required, this may be achieved by use of the multiple unit system disclosed in connection with  FIG. 7, 8 , herein and further disclosed in the &#39;009 patent.  
         [0086]     Actuation of one of the switches  24 ,  38 , or  192  activates electric motor  86  which in turns drives pump  72 . The configuration of the pump  72  and in particular the cam  82  is such as to inhibit vapor lock in the fluid line which might be caused by the heat in the system. In addition, the cam arrangement enables a more effective combating of back pressure of the vapor as it builds up within the generator  120 . This allows steam to exit tube  62  in a burst with greater force at times even than the rated 120 PSI and for a longer vapor flow, with the back pressure under control.  
         [0087]     As a result of the action of pump  72 , liquid is drawn into the system  10  through conduit  40 . The liquid proceeds through conduit  40  and into pipe  88 . Check valve  90  inhibits any tendency to back flow. The liquid then passes through T-fitting  94  and through second check valve  100 . The liquid then passes into the superheated vapor generator  120  and into chamber  126  and very rapidly vaporizes to form superheated vapor.  
         [0088]     Turning to  FIG. 4 , an instrunent  250  is to be treated. The instrument  250  has a lumen  251 , with a length  252 , substantially longer than a diameter  253  and is filled with two contaminant plugs  254 ,  255 . Superheated vapor  256  enters through a port  257  accessed by a nozzle  258  from which superheated vapor issues. The pressure of the superheated vapor penetrates and heats contaminant plugs  254 ,  255  thus causing particles of debris  259  to be blown off the end of contaminant plug  255 . Contaminant plugs  254 ,  255  are soil which may be of various types and contain water which vaporizes and exerts pressure; they frequently also contain fats which liquefy and thus reduce adherence. Examples of such lumens would be endoscopes whose dimension  251  is 24 to 36 inches and dimension  253  is 2 to 5 mm and needles whose dimension  251  is 1-4 inches and dimension  253  is 0.2 to 0.7 mm. The port location and type can vary providing a substantially leakproof seal is obtained. Lumen  251  may be curved or straight.  
         [0089]     As shown in  FIG. 3 , a method in accordance with the invention facilitates contact between superheated vapor jet and an item  260  to be cleaned, disinfected, sterilized or decontaminated. Item  260 , is traversed with the jet of vapor in a serpentine pattern  261 . This pattern can then be repeated as needed.  
         [0090]     In accordance with a further aspect of the invention  FIG. 5  shows a method of automating the treatment of an item  270  to be treated (i.e., cleaned/disinfected/sterilized/decontaminated). A detailed disclosure and discussion of the system depicted schematically herein is contained in co-pending provisional patent application Ser. No. 60/612,316 filed Sep. 22, 2004, hereby incorporated by reference herein. A system  269  includes, a manifold  273  of nozzles  274   a - f , (depicted for specificity as six in number) producing a plurality (six in the depicted example) of jets  275   a - f.    
         [0091]     Item  270  is picked up by grippers  272   a,b , attached to a robotic arm  271  and moved through the ring of jets  275   a - f . The opposite end of item  270  is gripped by grippers  276   a,b  on a receiving robotic arm  277  at which point grippers  272   a,b  release and arm  271  picks up the next item to be treated. Arm  277  pulls item  270  through jets  275   a - f , and places the item aside. The cycle may now be repeated. Pursuant to the invention it is feasible to program the robotic arm to undertake a variety of actions to improve the treatment of the item in various ways without departing from the invention. For example where a hinged device is to be treated the program may provide extra time for the hinged area or rotate the item to position it approximately. Such treatment programs are within the purview of one having normal skill in the art of robotics by following the above method. The selection of the treatment program to be run for a given item may be manual or automatic using an automatic recognition method, such as bar codes, radio frequency identity devices or machine vision systems and may be accomplished in various ways in accordance with the invention.  
         [0092]      FIG. 6  depicts a cross sectional drawing of a system  279  and method to continuously treat items  280 ,  284 ,  286 . System  279  includes mechanical conveyors  281 ,  285  and three nozzles,  282   a ,  282   b ,  282   c . Nozzle  282   a  produces a jet  283   a  which cleans the top surface and sides of item  280 . Item  284  is shown at the next step of the process where it flips as it transitions from the conveyor  281  to conveyor  285  which is treated by jet  283   b  from nozzle  282   b  to prevent recontamination of the previously treated side.  
         [0093]     In a further step nozzle  282   c  produces a jet  283   c  which cleans the top surface and sides of item  286 . In carrying out the invention it is possible to combine elements of the above figures in many ways without departing from the invention. Alternative methods of implementing the nozzles in this figure are a manifold of multiple jets similar to that shown in  FIG. 5  or a programmed arm for moving the nozzles in a predetermined path. Further conveyors and additional nozzles may be employed to provide different vapors at each nozzle. While steam is the lowest cost vapor, other combinations of vapors can have specific uses. Ammonia can be used to neutralize acidic surfaces. Hydrogen peroxide and other organic peroxides, peroxy acids and peroxy esters are strong oxidizing agents and effective disinfectants.  
         [0094]     Accordingly, an organic peryoxyacid step may be followed by an ammonia neutralization step followed by a clean and dry which kills substantially everything including small hidden bacteria spores. By extending the time of exposure to the jet the organisms are exposed to progressively high temperatures and any protective coatings of other organisms, bioslime and contaminants are removed.  
         [0095]     As described hereinabove, there have been therefore been provided systems and methods for cleaning disinfection, sterilization and decontamination. Though a preferred embodiment has been described and depicted herein, the scope of the invention is defined by the appended claims to be filed pursuant to law, interpreted in light of the specification and drawings.

Technology Category: 1