Modular decontamination system

• US 7,700,056 B2
• Filed: 08/10/2006
• Issued: 04/20/2010
• Est. Priority Date: 08/10/2006
• Status: Active Grant

• Current Assignee: American Sterilizer Company (Steris Corporation)
• Original Assignee: American Sterilizer Company (Steris Corporation)
• Inventors: Logue, Leslie M., Bruskevith, Ryan A., Hill, Aaron L.
• Primary Examiner(s): CONLEY, SEAN EVERETT
• Application Number:
  US11/463,608
• Publication Number:
  US 20080038166A1
• Time in Patent Office: 1,349 Days
• Field of Search: 422/292, 422/3, 422/28, 422/37, 422/105, 422/10, 422/298
• US Class Current: 422/292
• CPC Class Codes: A61L 2/208 Hydrogen peroxide
• CPC Class Codes: A61L 2/22 Phase substances, e.g. smokes, aerosols or sprayed or atomised substances
• CPC Class Codes: A61L 2/24 Apparatus using programmed or automatic operation
• CPC Class Codes: A61L 2202/14 Means for controlling sterilisation processes, data processing, presentation and storage means, e.g. sensors, controllers, programs
• CPC Class Codes: A61L 2202/25 Rooms in buildings, passenger compartments
• CPC Class Codes: A61L 2209/111 Sensor means, e.g. motion, brightness, scent, contaminant sensors
• CPC Class Codes: A61L 2209/133 Replaceable cartridges, refills
• CPC Class Codes: A61L 2209/134 Distributing means, e.g. baffles, valves, manifolds, nozzles
• CPC Class Codes: A61L 2209/211 Use of hydrogen peroxide, liquid and vaporous
• CPC Class Codes: A61L 9/14 using sprayed or atomised substances including air-liquid contact processes
• CPC Class Codes: A61L 9/145 air-liquid contact processes, e.g. scrubbing

Abstract

A decontamination system having modular components to efficiently decontaminate enclosures of various dimensions. The decontamination system includes a main unit comprising a controller, a supply of liquid decontaminant, a vaporizer for vaporizing the liquid decontaminant to generate a vaporized decontaminant, and a destroyer for breaking down hydrogen peroxide into water and oxygen. An embodiment of the present invention includes a detachable dryer and a detachable external blower that are in fluid communication with the main unit. An optional external destroyer and an optional external dryer may be controlled by the controller of the main unit to respectively increase the destroying and drying capacity of the decontamination system.

Claims

1. A vapor decontamination system for decontaminating a region, said system comprising:

(a) a main unit including;

a reservoir for providing an aqueous solution of hydrogen peroxide,

a vaporizer for generating vaporized hydrogen peroxide from the aqueous solution of hydrogen peroxide,

at least one humidity sensor providing a first signal indicative of moisture in the region,

a temperature sensor providing a second signal indicative of the temperature in the region,

at least one concentration sensor providing a third signal indicative of the concentration of the decontaminant in the region,

a first destroyer for breaking down said vaporized hydrogen peroxide,

a first input port,

first and second output ports,

a controller for controlling operation of the vapor decontamination system,

input means for inputting into the controller one of;

(a) a first concentration level and a first exposure time associated therewith, or (b) a first concentration level and a D-value indicative of a desired reduction of bioburden, wherein a first exposure time associated with the first concentration level is determined according to the D-value,

said controller communicating with said vaporizer to control the rate at which vaporized hydrogen peroxide is injected into the region, and receiving the first, second, and third signal, wherein said controller is programmed to;

inject the vaporized hydrogen peroxide into the region at an injection rate for obtaining the first concentration level of vaporized decontaminant in the region,

monitor actual concentration of the vaporized hydrogen peroxide in the region,

determine dew point concentration of the vaporized hydrogen peroxide in the region,

determine whether the actual concentration of the vaporized hydrogen peroxide in the region is at least a predetermined amount below the dew point concentration of the vaporized hydrogen peroxide in the region, and

decrease the actual concentration of the vaporized hydrogen peroxide if the actual concentration of the vaporized hydrogen peroxide in the region is not at least the predetermined amount below the dew point concentration of the vaporized hydrogen peroxide in the region;

(b) a first dryer detachable from said main unit, said first dryer including;

an inlet port fluidly connectable with said first output port, and

an outlet port fluidly connectable with said first input port; and

(c) a mobile blower unit detachable from the main unit, the blower unit fluidly connectable with the second output port of the main unit, and controlled by the controller of the main unit.

2. A vapor decontamination system as defined in claim 1, wherein said system further comprises:

external power switching means having a plurality of switchable electrical outlets controllable by said controller.

3. A vapor decontamination system as defined in claim 2, wherein at least one of a second destroyer and a second dryer are electrically connected to the external power switching means for supplying power thereto.

4. A vapor decontamination system as defined in claim 1, wherein said controller records operating parameters associated with control of the vapor decontamination system during a first decontamination cycle and repeats the operating parameters for a subsequent decontamination cycle.

5. A vapor decontamination system as defined in claim 1, wherein said system further comprises a dryer regeneration unit, said dryer regeneration unit fluidly connectable with said first dryer.

6. A vapor decontamination system according to claim 1, wherein said vapor decontamination system further comprises:

a second dryer external to said main unit, said second dryer activated by said controller of said main unit;

wherein said main unit, said first dryer, said blower unit, and said second dryer each include a housing supported by wheels to facilitate transportation thereof.

7. A vapor decontamination system according to claim 1, wherein said main unit includes a leak detection means for detecting the presence of the aqueous solution of hydrogen peroxide in a collecting region of said main unit.

8. A vapor decontamination system according to claim 7, wherein said leak detection means includes at least one of the following:

a float switch or a conductivity sensor.

9. A vapor decontamination system according to claim 1, wherein said first dryer includes a removable insulating blanket.

10. A vapor decontamination system according to claim 1, wherein said system further comprises:

a first removable memory device for storing sensor calibration data; and

a second removable memory device for storing a copy of the sensor calibration data stored in said first removable memory device.

11. A vapor decontamination system according to claim 10, wherein said second removable memory device stores encrypted data associated with a decontamination cycle.

12. A vapor decontamination system according to claim 10, wherein said first removable memory device is a flash memory device.

13. A vapor decontamination system according to claim 10, wherein said second removable memory device is a USB memory device.

14. A vapor decontamination system according to claim 1, wherein said controller includes a network adapter for remote operation of said controller via a wired or wireless network.

15. A vapor decontamination system according to claim 1, wherein said system further comprises:

an H₂O₂ alarm sensor for detecting leakage of H₂O₂ outside said region during a decontamination cycle.

16. A vapor decontamination system according to claim 1, wherein said controller is further programmed to:

initiate a first timer when the actual concentration of the vaporized decontaminant in the region reaches the first concentration level, wherein the first timer indicates the total time that the actual concentration of the vaporized decontaminant in the region is at or above the first concentration level; and

initiate a second timer when the actual concentration of the vaporized decontaminant in the region reaches a second concentration level, wherein a second exposure time is associated with the second concentration level, the second timer indicating the total time that the actual concentration of the vaporized decontaminant in the region is at or above the second concentration level;

determine a first time value indicative of the amount of time needed to complete a successful decontamination cycle at the first concentration level;

determine a second time value indicative of the amount of time needed to complete a successful decontamination cycle at the second concentration level; and

inject vaporized decontaminant into the region at an injection rate for obtaining one of said first and second concentration levels based upon a comparison of the first and second time values.

17. A vapor decontamination system for decontaminating a region, said system comprising:

(a) a main unit including;

a reservoir for providing an aqueous solution of hydrogen peroxide,

a vaporizer for generating vaporized hydrogen peroxide from the aqueous solution of hydrogen peroxide,

at least one humidity sensor providing a first signal indicative of moisture in the region,

a temperature sensor providing a second signal indicative of the temperature in the region,

at least one concentration sensor providing a third signal indicative of the concentration of the decontaminant in the region,

a first destroyer for breaking down said vaporized hydrogen peroxide,

a first input port,

first and second output ports,

a controller for controlling operation of the vapor decontamination system,

input means for inputting into the controller one of;

(a) a first concentration level and a first exposure time associated therewith, or (b) a first concentration level and a D-value indicative of a desired reduction of bioburden, wherein a first exposure time associated with the first concentration level is determined according to the D-value,

said controller communicating with said vaporizer to control the rate at which vaporized hydrogen peroxide is injected into the region, and receiving the first, second, and third signal, wherein said controller is programmed to;

inject the vaporized hydrogen peroxide into the region at an injection rate for obtaining the first concentration level of vaporized decontaminant in the region,

monitor the actual concentration of the vaporized hydrogen peroxide in the region,

determine the dew point concentration of the vaporized hydrogen peroxide in the region,

determine whether the actual concentration of the vaporized hydrogen peroxide in the region is at least a predetermined amount below the dew point concentration of the vaporized hydrogen peroxide in the region, and

decrease the actual concentration of the vaporized hydrogen peroxide if the actual concentration of the vaporized hydrogen peroxide in the region is not at least the predetermined amount below the dew point concentration of the vaporized hydrogen peroxide in the region;

(b) a first dryer detachable from said main unit, said first dryer including;

an inlet port fluidly connectable with said first output port, and

an outlet port fluidly connectable with said first input port; and

(c) a mobile second destroyer external to the main unit, said second destroyer activated by the controller of the main unit.

18. A vapor decontamination system according to claim 17, wherein said controller is further programmed to:

initiate a first timer when the actual concentration of the vaporized decontaminant in the region reaches the first concentration level, wherein the first timer indicates the total time that the actual concentration of the vaporized decontaminant in the region is at or above the first concentration level; and

initiate a second timer when the actual concentration of the vaporized decontaminant in the region reaches a second concentration level, wherein a second exposure time is associated with the second concentration level, the second timer indicating the total time that the actual concentration of the vaporized decontaminant in the region is at or above the second concentration level;

determine a first time value indicative of the amount of time needed to complete a successful decontamination cycle at the first concentration level;

determine a second time value indicative of the amount of time needed to complete a successful decontamination cycle at the second concentration level; and

inject vaporized decontaminant into the region at an injection rate for obtaining one of said first and second concentration levels based upon a comparison of the first and second time values.

19. A vapor decontamination system for decontaminating a region, said system comprising:

(a) a main unit including;

a reservoir for providing an aqueous solution of hydrogen peroxide,

a vaporizer for generating vaporized hydrogen peroxide from the aqueous solution of hydrogen peroxide,

at least one humidity sensor providing a first signal indicative of moisture in the region,

a temperature sensor providing a second signal indicative of the temperature in the region,

at least one concentration sensor providing a third signal indicative of the concentration of the decontaminant in the region,

a first destroyer for breaking down said vaporized hydrogen peroxide,

a first input port,

first and second output ports,

a controller for controlling operation of the vapor decontamination system,

input means for inputting into the controller one of;

(a) a first concentration level and a first exposure time associated therewith, or (b) a first concentration level and a D-value indicative of a desired reduction of bioburden, wherein a first exposure time associated with the first concentration level is determined according to the D-value,

said controller communicating with said vaporizer to control the rate at which vaporized hydrogen peroxide is injected into the region, and receiving the first, second, and third signal, wherein said controller is programmed to;

inject the vaporized hydrogen peroxide into the region at an injection rate for obtaining the first concentration level of vaporized decontaminant in the region,

monitor the actual concentration of the vaporized hydrogen peroxide in the region,

determine the dew point concentration of the vaporized hydrogen peroxide in the region,

determine whether the actual concentration of the vaporized hydrogen peroxide in the region is at least a predetermined amount below the dew point concentration of the vaporized hydrogen peroxide in the region, and

decrease the actual concentration of the vaporized hydrogen peroxide if the actual concentration of the vaporized hydrogen peroxide in the region is not at least the predetermined amount below the dew point concentration of the vaporized hydrogen peroxide in the region;

(b) a first dryer detachable from said main unit, said first dryer including;

an inlet port fluidly connectable with said first output port, and

an outlet port fluidly connectable with said first input port; and

(c) a mobile second dryer external to the main unit, said second dryer activated by the controller of the main unit.

20. A vapor decontamination system according to claim 19, wherein said controller is further programmed to:

initiate a first timer when the actual concentration of the vaporized decontaminant in the region reaches the first concentration level, wherein the first timer indicates the total time that the actual concentration of the vaporized decontaminant in the region is at or above the first concentration level; and

initiate a second timer when the actual concentration of the vaporized decontaminant in the region reaches a second concentration level, wherein a second exposure time is associated with the second concentration level, the second timer indicating the total time that the actual concentration of the vaporized decontaminant in the region is at or above the second concentration level;

determine a first time value indicative of the amount of time needed to complete a successful decontamination cycle at the first concentration level;

determine a second time value indicative of the amount of time needed to complete a successful decontamination cycle at the second concentration level; and

inject vaporized decontaminant into the region at an injection rate for obtaining one of said first and second concentration levels based upon a comparison of the first and second time values.