Title of Invention

APPARATUS AND METHOD FOR HUMIDIFYING A STERILIZATION CHAMBER

Abstract An ozone sterilization method, involving humidifying an atmosphere in a sterilization chamber to a target relative humidity prior to injecting ozone as a sterilizing agent, the method comprising the steps of: (a) providing an amount of water in a water reservoir at a temperature Ts at or above a temperature of the chamber atmosphere Tc; (b) reducing a pressure in the chamber to a value below the boiling point of water at the reservoir temperature Ts; (c) bringing the reservoir into fluid communication with the chamber for exposing the water in the reservoir at the temperature Ts to the reduced pressure in the chamber for a preselected exposure time so that water in the reservoir is boiled and to allow resulting water vapour to enter the chamber and disconnecting said fluid communication after said preselected exposure time ; and repeating at least steps (b) and (c) a plurality of times, wherein at least one of the amount of water and the exposure time are controlled such that the relative humidity in the chamber progressively increases with each repetition until the target humidity is reached, and after reaching the target relative humidity, injecting ozone, as a sterilizing agent, into the chamber.
Full Text AN OZONE STERILIZATION METHOD, INVOLVING HUMIDIFYING AN
ATMOSPHERE IN A STERILIZATION CHAMBER
FIELD OF THE INVENTION
The invention relates to a method and apparatus for humidifying an atmosphere in a
sterilization chamber in a sterilization process and in particular to such method and apparatus using
humidified ozone as the sterilant or sterilizing agent.
BACKGROUND OF THE INVENTION
Sterilization is the destruction of any virus, bacteria, fungus or other micro-organism, whether
in a vegetative or in a dormant spore state. Conventional sterilization processes for medical
instruments have involved high temperatures (such as steam and dry heat units) or toxic chemicals
(such as ethylene oxide gas, EtO). Steam sterilization with an autoclave has been the time-honoured
method of sterilization. It is fast and cost effective. However, the autoclave destroys heat-sensitive
instruments. Thus, since more and more heat-sensitive instruments such as arthroscopes and
endoscope are used in medical treatment, other types of sterilization are needed, especially cold
sterilization.
Ethylene oxide may be used to cold sterilize heat-sensitive instruments. However, it has now
been deemed by national health and safety organizations to be carcinogenic and neurotoxic. It also
poses flammability problems and is thus usually used in combination with chlorofluorocarbons
(CFC's) which themselves are now undesirable. Further, sterilization with ethylene oxide takes 14
to 36 hours.
A more efficient, safer, and less expensive sterilization agent is ozone (O3). Ozone, especially
humidified ozone, is a sterilizing gas. Ozone can be easily generated from oxygen, especially
hospital grade oxygen. Oxygen is readily available in the hospital environment, usually
from a wall or ceiling oxygen source, or, if mobility is required, from a portable "J" cylinder
of oxygen. Ozone is widely used in industry as an oxidising agent to bleach paper pulp,
treat drinking water, and sterilize sewage water and food products. The amounts (concentrations)
of ozone required in the sterilization gas for water purification are low, generally less than
40 mg/1 (milligram per litre). However, higher concentrations, combined

with critical humidity levels, are required to make ozone an effective sterilant of micro-
organisms. Those high concentrations of ozone gas have to be combined with critical levels
of humidity. The sterilization efficiency of ozone increases rapidly with increased relative
humidity. A high relative humidity is required for ozone to penetrate the protective shells of
micro-organisms. The presence of water vapour will also accelerate ozone reactions with
organic substances. Sufficient relative humidity further helps the penetration of sterilization
packaging by ozone.
Sterilization with ozone is more efficient and quicker than with EtO and requires few
changes in user habits. Moreover, ozone-based processes are compatible for use with current
packaging, such as sterile pouches and rigid containers.
Ozone sterilization requires substantially no aeration or cooling down of sterilized
instruments which can be used immediately following sterilization. This allows hospitals to
reduce the cost of maintaining expensive medical device inventories. Ozone sterilization
offers several other advantages. It produces no toxic waste, does not require the handling of
dangerous gas cylinders, and poses no threat to the environment or the user's health. Stainless-
steel instruments and heat-sensitive instruments can be treated simultaneously, which for
some users will obviate the need for two separate sterilizers.
U.S. Patent No. 3,719,017 discloses the use of a mixture of ozone gas with a very fine
water mist in a sealed plastic bag container which contains an article to be sterilized. The
method involves repeated evacuation and refilling of the plastic bag with a mixture of ozone
gas and a very fine water mist. The air in the bag is exhausted and replaced with a pressurised
mixture of ozone and water mist. Upon encountering the much lower pressure within the bag,
the water particles from the pressurised mixture explode, forming a water mist. However, this
system cannot generate a sufficiently high water vapour concentration to provide the high
relative humidity required for thorough sterilization (at least 85% relative humidity).
U.S. PatentNo. 5,069,880 describes a device capable of generating a relative humidity
of 85%. In the apparatus the ozone is bubbled through a water bath to increase the water
content of the gas. Although ozone at 85% humidity can kill most micro-organisms, it does
not meet the "worst case scenario" stipulated in North American standards. Moreover, the

device is unable to generate humidity levels higher than 85%. In addition, injecting ozone
while humidifying the chamber increases the contact time of the ozone with the instruments
to be sterilized, which may result in oxidation damage to the instruments.
A minimum relative humidity level of 90% (95% + 5%) is required to meet North
American standards set by agencies such as the Food and Drug Administration and Health
Canada.
Water evaporates at 100°C at atmospheric pressure (1013 mbar or 760 Torr). Thus,
various priorpatents (see Faddis et al., U.S. Patents No. 5,266,275; 5,334,355; and 5,334,622)
teach sterilization systems wherein water is heated to above the boiling point to evaporate the
water for injection into the ozone-containing gas produced by an ozone generator. The steam
is heated to 120°C. Thus, the vapour upon injection into the ozone-containing gas will have
a temperature close to 100°C. However, since the decomposition of ozone increases
exponentially with temperature in the range of 20 to 300°C, injecting the water vapour at a
temperature of about 120°C leads to premature ozone decomposition. As a result, the
effective ozone concentration in the gas produced by the ozone generator is reduced, thereby
requiring significantly increased treatment times and the generation of larger amounts of
ozone gas for each sterilization cycle. Thus, a more efficient and effective sterilization
apparatus is desired for the sterilization of ozone at arelative humidity of above at least 90%.
U.S. Patent Application Serial No.10/005,786 (filed on November 8, 2001 which is
a continuation-in-part application of U.S. Patent Application Serial No. 09/310,695 which was
filed on May 12, 1999 and is now abandoned), which is hereby incorporated by reference,
addresses these problems by applying a vacuum pressure to lower the boiling point of water
below the temperature inside the sterilization chamber. Thus the teachings of this application
provide an effective sterilization process.
As taught in this prior application, it is preferred to repeat the sterilization cycle at
least once to give greater assurance of effective sterilization. Thus, after loading the
sterilization chamber with the articles to be sterilized (such as medical instruments), a
sterilization cycle includes exposing the articles to the humidified ozone sterilant and then
removing the sterilant. Repeating this cycle thus includes exposing the articles again to

humidified ozone sterilant and removing the sterilant.
However, as mentioned above, in order to be sure of sterilization using ozone, the
humidity should be at least 90% (95% ± 5%). Consistently achieving such high humidity
levels has proved difficult. The sterilization chamber is in communication with a source of
water vapour, for example, a water reservoir. As taught in US Patent Application Serial No.
10/005,786 mentioned above, a reduction in pressure will cause water in the reservoir to
evaporate. However, this evaporation leads to cooling of the reservoir. Also, condensation of
water vapour in the chamber tends to heat the chamber.
Any increase in the chamber temperature increases the quantity of water vapour
required to reach the target humidity. Attempts to speed the process involve large thermal
energy inputs, for example excessive heating of the water reservoir. This thermal energy
eventually reaches the chamber and results in a temperature increase in the chamber which
increases the quantity of water vapour needed for a given relative humidity. Thus achieving
a high relative humidity with the consistency and accuracy needed to ensure complete
sterilization is challenging.
SUMMARY OF THE INVENTION
It has now been found that effecting the humidification in a plurality of graduated
steps or stages can provide a consistent and accurate way to reach a particular value of relative
humidity, especially high relative humidity values such as those required for ozone
sterilization.
According to one aspect of the present invention there is provided a method for
humidifying an atmosphere in a sterilization chamber to a target relative humidity, the process
comprising the steps of a) providing an amount of water in a water reservoir at a temperature
Ts at or above a temperature of the chamber atmosphere Tc, b) reducing a pressure in the
chamber to a value below the boiling point of water at the reservoir temperature Ts; c)

bringing the reservoir into fluid communication with the chamber for exposing the water in the
reservoir at the temperature Ts to the reduced pressure in the chamber for a preselected exposure
time so that water in the reservoir is boiled and to allow resulting water vapour to enter the chamber;
and disconnecting said fluid communication after said preselected exposure time; and repeating at
least steps b) and c) a plurality of times, wherein at least one of the amount of water and the exposure
time are controlled such that the relative humidity in the chamber progressively increases with each
repetition until the target humidity is reached.
According to another aspect of the present invention there is provided an ozone sterilization
method for humidifying an atmosphere in a sterilization chamber to a target relative humidity prior to
injecting ozone as a sterilizing agent, the method comprising the steps of: (a) providing an
amount of water in a water reservoir at a temperature Ts at or above a temperature of the chamber
atmosphere Tc; (b) reducing a pressure in the chamber to a value below the boiling point of water
at the reservoir temperature Ts; (c) bringing the reservoir into fluid communication with the
chamber for exposing the water in the reservoir at the temperature Ts to the reduced pressure in the
chamber for a preselected exposure time so that water in the reservoir is boiled and to allow resulting
water vapour to enter the chamber and disconnecting said fluid communication after said preselected
exposure time ;and repeating at least steps (b) and (c) a plurality of times, wherein at least one of the
amount of water and the exposure time are controlled such that the relative humidity in the chamber
progressively increases with each repetition until the target humidity is reached, and after reaching
the target relative humidity, injecting ozone, as a sterilizing agent, into the chamber.
According to another aspect of the present invention there is provided an ozone sterilization
method for humidifying a sterilization chamber to a target relative humidity prior to injecting ozone
as a sterilizing agent, the method comprising a plurality of humidification stages Sx Sn wherein x
is an integer from 1 to n and each x represents an individual stage, each said stage having a
corresponding water vapour pressure hx hn, and hn representing the water vapour pressure
corresponding to the target relative humidity, each said stage Sx comprising the steps of (a) supplying
water vapour from a water vapour source to the sterilization chamber to increase the water vapour

pressure in the sterilization chamber to at least the value hx corresponding to said stage Sx ; (b)
disconnecting the source from the sterilization chamber for a preselected equalization period ; (c)
repeating steps (a) and (b) until said water vapour pressure hn is reached in the sterilization chamber,
and after reaching the target relative humidity, injecting ozone, as a sterilizing agent, into the
chamber.
According to another aspect of the present invention there is provided An apparatus
for sterilization with humidified ozone, the apparatus comprising; a sterilization chamber ; a
reservoir to hold water while in operation, to provide a source of water vapour to humidify the
ozone ; a conduit in fluid communication between the reservoir and the sterilization chamber ; a
valve in the conduit to open and close the conduit; a first heating means to control the temperature of
the chamber ; a second heating means to control the temperature of the reservoir ; a first temperature
sensing means to monitor the temperature of the sterilization chamber ; a second temperature sensing
means to monitor the temperature of the reservoir ;a pressure sensing means to monitor the pressure
in the chamber ; vacuum means to reduce the pressure in the chamber ; an ozone generating means a
processor to control the first and second heating means in response to information from the first and
second temperature sensing means and the pressure sensing means ; wherein the processor is
programmed to effect a humidification of the sterilization chamber in a plurality of stages.

The invention will be described with reference to ozone sterilization process using humidified
ozone. However, it will be understood that the humidification process according to the invention is
applicable to any process which requires accurate humidification.
In a sterilization process, the space to be humidified would be the sterilization chamber.
In the preferred use of the stage-wise humidification in a humidified ozone sterilization
process, the process would normally additionally include other steps such as placing a load of
instruments to be sterilized into a sterilization chamber and injecting ozone into the chamber.
Throughout this description, units of pressure will be variously indicated in mbar.Torr,
atmospheres or ¼ Torr. 1 atmosphere equals 760 Torr or 1013 mbar.
One, or more ventilating cycles can be added to the preferred method for removing the
remaining ozone and humidity from the sterilization chamber.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
The invention will be described in more detail in the following by way of example only and
with reference to the accompanying drawings wherein -
FIG. 1 is a flow diagram of a method in accordance with the invention ;
FIG. 2 is a graph to illustrate the sequence of steps in a method in accordance with the
invention by plotting pressure against time ;
FIG. 3 is a schematic illustration of an apparatus suitable for use with the method of the
invention ; and
FIG. 4 is a graph showing progress of a humidification step according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Preferably the source of water vapour is a reservoir of water in a humidifier chamber or
humidifier unit. The temperature of the water vapour source or the water in the reservoir may be
represented as Ts. The temperature of the space to be humidified or the sterilization

chamber may be represented by Tc. Preferably there is at least one heating means for each of
the sterilization chamber and the reservoir. Such heating means may be referred to as a first
and second heating means. Preferably the reservoir water is at the same temperature as or a
higher temperature than the temperature of the sterilization chamber, that is, Ts ≥ Tc. The
difference in temperatures may be expressed as ∆T (deltaT) so that Ts - Tc = ∆T and thus ∆T
≥ 0. Preferably the temperature difference AT is from 0 to 10°C, more preferably from 0 to
7 °C and particularly from 0 to 3 °C. Maintaining the reservoir water at a higher temperature
encourages evaporation of water vapour and encourages the vapour to flow to the sterilization
chamber and discourages loss of humidity from the sterilization chamber by recondensation
in the reservoir.
The number of stages to be used to complete the humidification, or to achieve the
target relative humidity, is widely variable. A large number of stages could be used. Selection
of the number of stages will depend on the accuracy of the equipment used and a preference
to complete the humidification as quickly as possible without adversely affecting the ability
to accurately obtain the desired relative humidity. Thus, out of convenience, humidification
would preferably be achieved in less than 50 stages, more preferably from 3 to 30, or from 5
to 27.
In a presently preferred embodiment, a processor is programmed with information
corresponding to 27 stages (shown hereafter in Table 1) although the last 10 to 15 stages are
included in case the sterilization chamber temperature Tc increases beyond the preferred
temperature (thus requiring a higher water vapour pressure to achieve the same value of
relative humidity) but they are not always required. Similarly, depending on the
circumstances, it is sometimes possible to achieve up to 60%, or even up to 80% of the target
Relative Humidity in a first stage, so that in the 27 stages (shown hereafter in Table 1), the
first few stages, preferably up to 5 stages (which in a preferred embodiment would correspond
toa water vapour pressure of 112 x 1/4 Torr) may be combined into a first single stage. It is
preferred to reach a water vapour pressure of about 80 x 1/4 Torr in a first stage.
If it is attempted to proceed too quickly or in too few stages, condensation will tend
to occur in the sterilization chamber which will increase the chamber temperature which will

in turn impose a need for a greater amount of water vapour to reach the target relative
humidity. Such an unfavourable sequence can become out of control so that the target relative
humidity cannot be reached. Thus it is preferred to take at least 5 to 10 stages, preferably 10
or more, to reach the target relative humidity.
Even more care should be taken in the later stages to allow the system to stabilize.
Thus it is preferred that at least the last 10 stages, preferably the last 5 stages, particularly the
last 3 stages should be effected in such a way that the increase in water vapour pressure
achieved in the sterilization chamber is in a small increment for each stage, for example from
0.1 to 5 Torr, preferably 0.1 to 3 Torr and particularly from 0.25 to 1 Torr. In a preferred
embodiment the last 10 or more stages are pressure increments of about 0.5 to 1 Torr.
The humidification thus should proceed in graduated stages, preferably in fairly
discrete stages. Thus in a.given stage, after reducing the pressure in the water reservoir (for
example, by evacuating the sterilization chamber and opening a valve to put the reservoir and
sterilization chamber in fluid communication) the boiling point of the water in the reservoir
will be reduced below the actual temperature of the water, thus the water will boil, water
vapour will be formed and can thus travel or flow to the sterilization chamber. The
evaporation will cause the temperature of the water reservoir to drop. It is thus necessary to
heat the reservoir to return the temperature Ts back to or above the chamber temperature Tc.
During this re-heating, it is preferred to close the valve in the conduit joining the chamber to
the reservoir. Thus the reheating becomes a preparation for the next stage. Thus the valve is
closed, disconnecting the reservoir or water vapour source from the chamber for a time
sufficient to adjust either the chamber temperature, or preferably the reservoir temperature,
to return Ts to the preferred value of Tc or above.
In order to better control the stages, it is preferred that there is a temperature sensing
means to monitor the temperature of the water in the reservoir. A temperature sensing means
is also preferred to monitor the chamber temperature.Thus if the chamber temperature sensing
means is referred to as a first temperature sensing means, then the reservoir temperature
sensing means may be referred to as a second temperature sensing means or temperature
sensing device. A suitable device is a Resistance Temperature Dependent sensor (RTD) such

as a class B type sensor commercially available from Omega Temperature. This type of
device has a resolution of 100 degrees, a standard deviation of 0.003 85 and a tolerance of 0.3
degrees which means mat it can measure a temperature to an accuracy of within about ±015
degrees. The temperature sensing means are preferably connected to a processor, computer
or programmable logic controller so that the temperature data can be fed to the processor. The
RTD provides temperature measurements to a processor which can adjust the heating
accordingly, by means of a Proportional Integral Differential (PID) function of the
Programmable Logic Controller (PLC). The heating means are connected so as to be under
control of the processor. Thus by also providing pressure sensing means to monitor the
pressure in the chamber, and connecting this also to the processor, the humidification stages
can be automated. The processor may be programmed with a table of target values of
temperatures, pressures and times, and instructed to proceed with the humidification
according to a pre-programmed sequence in accordance with the table.
As mentioned above, condensation in the chamber will tend to increase the chamber
temperature and will run the risk of losing control of the humidification. Therefore, the
number of stages and the corresponding water vapour pressure values are selected to reduce
the risk of condensation of water vapour in the sterilization chamber, preferably to avoid
substantially any condensation in the chamber.
In the preferred use of the stage-wise humidification in a humidified ozone
sterilization process, the process would normally additionally include other steps such as
placing a load of instruments to be sterilized into a sterilization chamber and injecting ozone
into the chamber.
As can be seen from Figures 1 and 2, the process can be regarded as including six or
seven basic steps, some of which may be repeated in a second sterilization cycle.
Figure 1 is a schematic representation of a sterilization process according to the
invention, showing the steps of the process in sequence. Figure 2 is another representation of
a process according to the invention. Figure 2 illustrates the process by showing the various
steps as a function of the pressure. Thus the vertical axis shows the pressure, with atmospheric
pressure represented at the top end of the vertical axis and zero pressure (or complete vacuum)

at the bottom end of the vertical axis. The horizontal axis represents the sequence of steps in
the process from left to right and thus corresponds to elapsed time, although not necessarily
to any scale, but only for the purpose of illustration.
Since the present invention is mainly concerned with the humidification step, it will
be understood that details of other process steps are in the nature of preferred features which
are not essential to the broadest aspects of the invention.
As shown in Figures 1 and 2, preferably the sterilization is preceded by a conditioning
step, indicated as step 100A. This step may also be referred to as a pre-conditioning step. In
this step, after inserting the articles to be sterilized in a sterilization chamber, the chamber is
sealed.
Generally, it is preferred to effect the sterilization at a target temperature in the range
of from about 25 to 40°C, more preferably from about 30 to 36°C and especially at around
30°C, for example at 30.8°C. The walls of the chamber are preferably maintained at around
this sterilization temperature. Since this is above usual room temperature, it is preferred to
successively fill and empty the chamber, with ambient air, in a succession of pulses. This
pulsing helps stabilize the conditions in the chamber and helps bring any load (instruments
to be sterilized) to the preferred chamber temperature. This is represented by the peaks and
troughs shown in Figure 2 in the left-hand portion of the graph indicated as 100A, which
represents the pre-conditioning step. The peaks represent a pressure of around atmospheric
pressure and thus represent at least partially filling the chamber with ambient air. The troughs
represent reduced pressure or evacuations of the chamber. Room temperature is usually
around 18 to 22° C so to reach a target temperature of, for example, 30 °C, the air must be
heated. The walls of the sterilization chamber are preferably heated. Thus by pulsing a
quantity of air into and out of the chamber, the temperature of the air and the temperature of
the load (any instruments in the chamber for sterilization), approaches the target chamber
temperature of around 30°C. Generally it is preferred that a reduced pressure in the range of
from about 350 to about 450 Torr, more preferably about 250 Torr, is used to evacuate the
chamber in each of the evacuation pulses in this pre-conditioning step. It is preferred that the
ambient air load is pulsed from 7 to 16 times, more preferably ten times. However, the

number of such pulses may be increased or decreased to bring the load of ambient air to a
satisfactory temperature.
Any inert gas may be used as the gas in the pre-conditioning step. The choice of gas
will be governed by costs or by consideration of whether it will interfere with the sterilant in
the subsequent sterilization steps. In later steps, it is preferred to avoid using air since the
nitrogen which it contains may form harmful substances, such as nitrogen oxides as a result
of the powerful oxidizing capacity of ozone. Such nitrogen oxides may then form traces of
nitric acids with any water vapour and may thus damage parts, such as metal parts, of articles
to be sterilized. However, in this pre-conditioning step, air can be used, although oxygen
would be preferred.
The next step is the vacuum step and is indicated as 101 in Figures 1 and 2. In this
step, gaseous contents of the sterilization chamber are evacuated. It is preferred to use a deep
vacuum, generally in the range of from about 5 to 0.5 Torr, more preferably about 2.5 to 0.5
Torr, more particularly, less than 1.25 Torr to remove as much of the gaseous contents as
possible. It is preferred to apply this pressure for a time in the range of from about 30 seconds
to 5 minutes, more preferably about a minute to allow the pressure to stabilize within the
chamber, especially considering that the articles to be sterilized may well include containers
and pouches.
The next step is the humidification step and is indicated as 102 in Figures 1 and 2.
This step is to provide the sterilization chamber with the humidity required for sterilization.
Water from a water reservoir is evaporated and introduced into the chamber as water vapour
until the relative humidity is equal to or above the target value. It is preferred that the relative
humidity during sterilization is at least above 90%, preferably 95% or higher. It is preferred
that after the target humidity is reached, conditions are maintained to stabilize and equilibrate
the conditions throughout the chamber and the articles in the chamber. Preferably conditions
are maintained for a time in the range of from about 10 to 50 minutes, more preferably for at
least 30 minutes.
Relative humidity is a percentage and represents the water vapour present as a
percentage of the theoretical maximum water vapour possible at a given temperature. Thus
a relative humidity of 100% represents the theoretical maximum water vapour pressure at a

given temperature. Since warm air holds more water than cool air, an increase in temperature
requires an increase in water vapour to maintain 100% relative humidification.
The humidification step or humidification phase is a complex process achieved by
graduated steps or increments.
The means of humidification, or humidifier, includes a source of water, preferably
contained as a reservoir, to provide the water vapour for humidification. In one embodiment
the source of water is provided by a cylinder in which there is a known volume of water (in
a process using a 125 liter sterilization chamber, a volume of 500 mls or less is preferred, in
particular, a volume of about 300 mls ± 10 mls) which is sufficient to provide the required
relative humidity under the process conditions.
The water in the water reservoir is preferably heated to a temperature which is equal
to or above the temperature of the sterilization chamber. If the temperature of the water
reservoir is less than the chamber, then as the humidification progresses, a point will be
reached where no more water will evaporate from the reservoir even though the target relative
humidity has not been reached. A lower temperature in the reservoir will thus function as a
"cold spot" which encourages condensation rather than evaporation.
The water reservoir or source, is in fluid communication with the sterilizing chamber
by means of a conduit which may be referred to as a water vapour diffuser. The conduit
preferably includes a valve by which fluid communication between the chamber and the
source can be disconnected in an "off position or re-connected in an "on" position.
Preferably, this conduit, or water vapour diffuser, is also kept at a temperature above the
temperature of the chamber. The temperature of the water vapour diffuser is also preferably
monitored, by a sensor such as an RTD sensor described above, and the measured temperature
information sent to a processor so that appropriate heating adjustments may be made to
maintain a desired temperature. Preferably, the water vapour diffuser is maintained at about
3°C (± 0.5°C) above the temperature of the water source.
Since the water source is also usually kept above the temperature of the chamber
during the humidification step, this means that the water vapour diffuser may often be some
7 or 8°C higher that the chamber.

Before starting the humidification stage, the water source is heated to a temperature
corresponding to the average temperature of the sterilization chamber. As mentioned above,
a preferred sterilization chamber temperature is around 30.8°C.
Just before the HS (humidification step) a vacuum is applied to the sterilization
chamber to reduce the pressure in the chamber, preferably to about 5/4 Torr. At this pressure,
the boiling point of water is -15°C. Thus, if the water source or reservoir is at or above the
preferred chamber temperature of 30.8°C, when the valve in the water vapour diffuser is
opened, the water source will be in fluid communication with the sterilization chamber and
water will evaporate from the reservoir and enter the sterilization chamber.
As mentioned above, in order to consistently and precisely obtain a particular relative
humidification valve, especially the high values of 90% or higher, which are preferred (and
sometimes required) for efficient ozone sterilization, there are many difficulties to overcome.
When the water reservoir, which is at a temperature of , for example, 30.8°C is
exposed to the low pressure of the chamber at for example, 5/4 Torr, by means of opening the
valve, water will immediately evaporate and the resulting water vapour will enter the
sterilization chamber. However, the evaporation has a cooling effect which will also lower the
temperature of the water source.
In practice, at the start of the humidification step, when the valve is opened, although
water vapour enters the sterilization chamber, the quantity of water vapour which enters the
chamber is insufficient to produce a high relative humidity especially the relative humidity
values at or above 90% which are required for ozone sterilization. Further, in practice, the
Sterilization chamber has "cold spots". These are locations within the chamber which are at
a lower temperature than the average chamber temperature or lower that the target
temperature. Such "cold spots" may be provided by components of the load (the medical
instruments to be sterilized) within the Sterilization chamber which may not have reached the
target temperature, or they may be provided by structural limitations of the chamber itself
(such as supporting members to support the configuration of the chamber which members
cannot be directly heated, but only heated indirectly from the other chamber components).
Such "cold spots" may induce some condensation. Any condensation in the chamber will tend

to increase the temperature of the chamber (because of the thermal energy emitted by the
condensation process). Any increase in chamber temperature will increase the water vapour
needed to reach the desired relative humidification. Further, in some systems, the chamber
may not be provided with any cooling means and thus quickly reducing the temperature to the
preferred target temperature value, may not be possible. Further, simply continuing to heat
the water source to obtain the desired water vapour content will tend to exacerbate any
problems such as those caused by condensation on "cold spots".
According to the invention the humidification preferably proceeds in a number of
graduated steps which may be indicated as a series S1, S2, S3 ... Sn in which n indicates the
number of steps. Thus an intermediate step in this series may be represented as Sx in which
x is the number of the step between 1 and n. For each of the steps there is a corresponding
water vapour pressure h, h2 ...hn, which represents a target water vapour pressure value for the
corresponding stage. Thus an intermediate step Sx would have a corresponding water vapour
pressure value hx.
If both the temperature of the chamber and the water vapour pressure in the chamber
are known, then the relative humidity may be calculated. At a temperature of 30.8°C, for
100% relative humidity, the water vapour pressure is 34 Torr.
As mentioned above, it is preferred that the temperature of the water source is kept
above the chamber temperature. This temperature differential (being the difference in
temperature between the water source and the Sterilization chamber) may be represented as
∆T (delta T). Further, it is preferred that the temperature differential is selected according to
each individual humidification stage. Thus, for example, the temperature differential may be
chosen to be higher in the earlier stages and less in the later stages or vice versa. In practice,
a series of suitable temperature differentials dt1, dt2, ...dtn each corresponding to the
humidification stage of the same number, is selected for optimum control of the
humidification. An intermediate stage Sx will thus have an associated ∆T value of ∆TK
Towards the latter stages of the humidification, the temperature difference will preferably
level out to avoid overheating the water and causing the chamber temperature to increase
undesirably.

A preferred humidification step may have many individual stages. The following Table
1 shows 27 possible stages with corresponding pressure and temperature differential values.


In Table 1 above, the left hand column gives the number of the individual
humidification stage, the middle column gives the associated water vapour pressure for that
stage (in the table, the pressure is given in units of ¼ Torr) and the right hand column
indicates the preferred temperature differential for that particular humidification stage, that
is, the difference in temperature between the chamber and the water source (the temperatures
in table 1 are given in units of hundredths of a degree centigrade).
This table of values is programmed into a processor (such as a computer, for example
the PLC), so that the parameters can be controlled automatically in response to the particular
conditions, such as chamber temperature and pressure, as measured by the system
components.
Looking at Table 1 in more detail, at the start of the humidification step the water
source is at approximately the same temperature as the chamber and the chamber has just
been evacuated (at least preferably to a pressure of 5/4 Torr). This represents stage 1 with
corresponding water vapour pressure of 0 and temperature differential (Delta T) of 0. The
valve is then opened and water evaporates from the source to enter the sterilization chamber
as water vapour. The valve is shut and the water source is heated to 75/100 °C above the
chamber temperature. The valve is now opened again. This is now stage 2 of the
humidi fication, and when the pressure in the chamber reaches 80 x ¼ Torr (as shown in Table
1 as the pressure corresponding to stage 2) the valve is closed and the water source is heated
to 125/100 degrees above the chamber temperature and the valve is opened for stage 3 until
the corresponding pressure of 100 x ¼ Torr is reached.
The process is repeated through all the stages until the relative humidity in the
chamber is calculated to be equal or above the target relative humidification.
As mentioned above, for a chamber temperature of 30.8 °C, a relative humidity of
100% is represented by a water vapour pressure of 34 Torr. However, during the process, the
chamber temperature may exceed the preferred temperature, and thus a higher water vapour
pressure will be needed to give the same relative humidity value. The chamber temperature
is regularly monitored and the value is provided to the processor. The processor keeps
repeating the humidification stages from S1 to S2 to S3 etc. until the water vapour pressure

inside the chamber (for the actual chamber temperature) corresponds to the target relative
humidity.
Table 1, which is programmed into the processor, thus has a sufficient number of
humidification steps, with corresponding pressure and temperature information, to ensure that
even when the chamber temperature increases beyond the preferred temperature, the processor
has sufficient information to ensure reaching the target relative humidification.
It is also preferred to run the humidification step for a minimum time to further assist
in ensuring proper humidification.
It is preferred that the target humidity is reached within 10 to 31 minutes. Thus, when
the water vapour pressure set point is reached (which is 34 Torr ± 0.25 Torr for a chamber
temperature of 30.8 °C) a "humidification plateau" is allowed for from 10 minutes to 1 hour,
preferably for at least about 31 minutes. During the humidification plateau, the water vapour
diffuser is kept at 37 °C to avoid any condensation in the diffuser and the valve is kept open
to allow any additional water vapour which may be needed to maintain the target relative
humidification (since, in practice, the chamber temperature may increase during the
humidification plateau).
The minimum humidification time is preferably 50 minutes. If the minimum water
vapour pressure is reached in less than 19 minutes, the "humidification plateau" is extended
beyond the preferred 31 minutes to ensure a total humidification time of at least 50 minutes.
Otherwise, if the minimum water vapour pressure takes longer that 19 minutes to reach, the
"humidification plateau" is still kept for 31 minutes, so the total humidification step will last
longer than the minimum 50 minutes.
The temperature of the sterilization chamber is monitored regularly. The temperature
may be measured by using a device such as the RTD sensor discussed above. It is preferred
to measure the chamber temperature indirectly. Since the mass of the gas in the chamber is
so small, direct measurement would be inaccurate. The chamber temperature is therefore
obtained by averaging measurements of the chamber back wall, top wall and bottom wall.

Where TAV = Average chamber temperature
TR = Temperature of rear wall
TT = Temperature of top wall
and TB = Temperature of bottom wall
The temperature controls are summarized as follows.
While the sterilizer is not in the Humidification phase: the water vapor diffuser
temperature set point is 37°C ±0,5°C; the Humidifier heater set point is: [Average Chamber
Temperature]; and the chamber door heater setpoint is [Average Chamber Temperature].
Duringthe Humidification phase: the Humidifier heater set pointis [Average Chamber
Temperature] + [Delta T]curve; the water vapor diffuser temperature set point is: [TRTDHumidifier]
+ [3°C ±0,5°C]; and the chamber door heater setpoint is [Average Chamber Temperature].
The values for [Delta T] curve. are values obtained from Table 1.
Thus there is what may be referred to as a thermal inertia. That is, thermal energy
added to the system, for example the heat which is applied to the water source, takes time
before it is distributed throughout the whole system, even to the perimeters of the system.
Figure 4 shows the progress of a humidification using graduated steps. The vertical
axis shows the pressure in the Sterilization chamber in units of ¼ Torr. The horizontal axis
shows the time. The targetwatervapourpressure at the preferred chamber temperature of 30.8
°C is about 136 x ¼ Torr (which is 34 Torr). After this pressure has been reached, the valve
is kept open so that the water source and the chamber are in fluid communication during the
"humidification plateau". The target water vapour pressure of 136 x ¼ Torr is shown on the
figure as the water vapour setpoint. After reaching the setpoint, the "humidification plateau"
is maintained for 31 minutes as shown in the figure. It can also be seen from the figure that
in the last 5 to 10 minutes of the humidification plateau, there are virtually no further
increases in pressure, which shows that the conditions in the chamber have stabilized.

After the humidification step, the next step is an ozone injection step which is
represented as step 103 in Figures 1 and 2. Ozone is generated by an ozone generator. It is
preferred to monitor the ozone produced by the generator to ensure that a sufficient quantity
of ozone will be introduced to the sterilization chamber. Thus preferably the ozone generator
is activated before the end of the humidification step so that sufficient ozone is being
generated by the time it is required at the end of the humidification step. For a sterilization
chamber of about 125 Litres, an ozone generation of between 160 and 200 mg/L at normal
temperature and pressure (NTP) from the generator is preferred. Preferably, used ozone and
unrequired ozone is catalytically destroyed (by conversion to oxygen) before expelling it to
the atmosphere to avoid pollution.
A suitable ozone generator produces ozone from oxygen (preferably extra-dry medical
grade oxygen) which is submitted to an electrical field produced inside the generator, suitably
at a high frequency voltage of about 10,000 volts peak to peak. The high voltage permits a
corona discharge in the generator cells to convert the oxygen to ozone. Ozone is heat
sensitive, so it is preferred to keep the ozone generator operation at around 2 to 4°C to
optimise ozone production. When ready, the ozone is introduced into the humidified chamber
until the ozone in the chamber preferably reaches a concentration in the range of about 45 to
100 mg/L NTP, more preferably about 85 mg/L NTP. Coupled with the high humidity, this
concentration is considered to be sufficient to achieve sterilization.
The next step is the humidified ozone exposure step which is indicated as step 104 in
Figures 1 and 2. This step involves maintaining the level of ozone and humidity achieved
from the previous steps for a time sufficient to achieve a satisfactory level of sterilization. A
time period of from 5 minutes to 1 hour may be needed, although 15 minutes is preferred.
This step completes the first sterilization cycle. In the interest of maximising the assurance
of sterilization, it is preferred to repeat the sterilization with at least a second sterilization
cycle, preferably including repeating at least steps 101, 102, 103 and 104.
The next step, is a re-conditioning step which is indicated as step 105 in Figures 1 and
2. The purpose of this step is to remove any condensed water. Preferably all, or substantially
all of the condensed water is removed and preferably all, or substantially all of the water

vapour is removed in this step. It is preferred that the amount of water removed is from about
75% to 100% by weight of all the water in the chamber, more preferably from about 80% to
100%. Thus this step may be regarded as a flushing or purging step to remove condensed
water. It is also preferred that the temperature of the chamber is restabilized to the target
temperature, for example, the preferred temperature of 30.8 °C. The gaseous vehicle used for
this purging or flushing step is preferably a gas which is inert in the context of the sterilization
process. For example, some gases such as nitrogen and other gases, may form undesirable
oxygenated products by contact with ozone and thus are preferably avoided. In this step, since
it follows a previous sterilization cycle which has used ozone, it is preferred to avoid the use
of air because of the high nitrogen content of air. The preferred gas for this step is oxygen,
especially medical grade dry oxygen, which would usually be readily available in an
environment in which the sterilization process of the invention would normally be used, such
as a hospital. The reconditioning step preferably includes, or is preceded by, a vacuum step
to remove humidity and ozone from the chamber. Preferably a vacuum in the range of about
20 down to 5 Ton, more preferably less than 10 Torr, is applied. Gaseous contents removed
from the chamber are passed to a catalyst to convert any ozone to oxygen, for environmental
reasons. It is preferred to maintain the low pressure such as the preferred pressure of 10 Torr
for a period of time, preferably 2 to 3 minutes, to allow gaseous contents within articles in the
chamber (especially articles having pouches and containers) to equilibrate with the rest of the
chamber, to optimise removal. Medical grade oxygen is then introduced to the chamber. It is
preferred that this re-conditioning step include at lease one repetition of the vacuum and
oxygen injection steps to optimise the removal of all condensation.
The removal of condensed water may be referred to as a post-exposure step since it
follows at least a first sterilization cycle and thus an exposure to the humidified ozone
sterilant. However, it may be more appropriate to refer to it as a conditioning or re-
conditioning step (since in preferred processes it may not be the first conditioning step and
is intended to return the conditions within the chamber to conditions at least approximating
those at the start of the sterilization).

When all the sterilization cycles have been completed, a ventilation step is effected,
which is indicated as 107 in Figures 1 and 2. The purpose of this step is to remove ozone and
water vapour before the sterilization chamber is opened and the sterilized articles are
removed.
It will be readily understood by a person skilled in the art that the sequence of some
of the steps may be varied without compromising sterilization. Some steps might be effected
simultaneously although the successive sequence described above is preferred.
An ozone sterilizer apparatus, suitable for use with the method of the invention is
illustrated schematically in FIG. 3. Medical quality oxygen is subjected in an ozone-
generating unit including an ozone generator 22 to an electrical field, which partially converts
the oxygen into ozone. The ozone is then fed into a humidified sterilization chamber 10 where
it sterilises medical devices. The ozone is subsequently reconverted into oxygen using an
ozone converting unit 52. The only residues left at the end of the sterilization cycle are oxygen
and clean water vapour.
The apparatus includes a heated sterilization chamber 10 which can be sealed to
contain a vacuum. This is achieved with an access door 12, which can be selectively opened
for access into the chamber and which seals the chamber in the closed condition. The
apparatus farther includes an ozone generator 22 for supplying ozone-containing gas to the
sterilization chamber, a humidifier arrangement 30 for supplying water vapour to the
sterilization chamber, and a vacuum pump 40 (a suitable pump is a dry scroll vacuum pump
manufactured by Anestiwata). The vacuum pump 40 is used for the application of a sufficient
vacuum to the sterilization chamber 10 to increase the penetration of the sterilizing gas and
to be able to boil water at a temperature below the temperature inside the sterilization
chamber. The vacuum pump 40 in the preferred embodiment is capable of producing a
sufficient vacuum in the sterilization chamber to lower the boiling point of water in the
chamber below the temperature in the chamber. In the preferred apparatus, the vacuum pump
is capable of producing a vacuum of 0.1 mbar. Ozone produced in the ozone-generating unit
22 is destroyed in an ozone converting unit 52 to which ozone-containing gas is fed either
after passage through the sterilization chamber 10 or directly from the ozone-generating unit

22 through valve 29b. The ozone piping circuit includes an ozone converting catalyst (such
as DEST 25, manufacturer TS03). The ozone converting unit 52 is connected in series before
or after the vacuum pump 40 to prevent ozone gas escaping to ambient air. The ozone
decomposing material in the preferred catalyst is carulite. For economic and practical reasons,
it is preferred to use a catalyst to decompose the ozone exhausted from the sterilization
chamber 10. The catalyst destroys ozone on contact and converts it into oxygen with a certain
amount of heat being produced. Catalysts of this type and their manufacture are well known
to the person skilled in the art of ozone generators and need not be described in detail herein.
Furthermore, other means for destroying the ozone contained in the sterilization gas will be
readily apparent to a person skilled in the art. For example, the gas can be heated for a
preselected time to a temperature at which the ozone decomposition is accelerated, for
example, to 300° C.
The humidifier arrangement 30 includes a humidifier chamber 32 (such as HUM 0.5,
manufacturer TS03) sealed from ambient air and connected to the sterilization chamber 10
through a conduit and a vapour intake valve 34. The humidifier chamber 32 is equipped with
a level control to ensure a sufficiently high water level (not shown). Water is directly supplied
to the humidifier chamber 32 from a drinking or purified water supply connection. Water is
supplied to the humidifier chamber 32 by way of a filter 33, a pressure regulator 35, and input
valve 36. The water vapour produced in the humidifier chamber 32 enters the sterilization
chamber 10 by way of a vapour intake valve 34.
The ozone-generating unit includes an ozone generator 22 (such as OZ, model 14a,
manufacturer TSO3) of the corona discharge type, which is cooled to decrease the ozone
decomposition rate, as is well known in the art. To achieve a good lethality rate in an ozone
sterilization process, the ozone supplied in the sterilization chamber should be sufficient to
obtain a concentration of 48 to 96 milligrams per litre, preferably 50 to 90 milligrams per litre.
At these concentrations, the ozone generation is associated with a relatively high energy loss
in the form of heat. Generally, about 95% of the supplied electrical energy is converted into
heat and only 5% is used to produce ozone. Since heat accelerates the inverse transformation
of ozone into oxygen, it must be removed as quickly as possible by cooling the ozone

generator 22. The ozone generator in the apparatus is kept at the relatively low temperature
of 3 to 6°C by either an indirect cooling system with cooling water recirculation, or a direct
cooling system with a refrigeration unit for cooling. The cooling system 60 is preferably kept
at the temperature of 3 to 6°C. In the preferred embodiment, the cooling system is kept at
4°C so that the ozone-containing gas generated by unit 22 is at the ambient temperature of
around 20 to 35°C, preferably 30°C. Thus, the ozone-containing gas entering into the
sterilization chamber for humidification and sterilization is kept at ambient
temperatures of from 20 to 35 °C. This means that ozone decomposition is kept to aminimum
and that the sterilization process is more efficient.
The ozone-generating unit is preferably supplied with medical quality or medical
grade oxygen. The apparatus can be connected to a wall oxygen outlet common in hospitals
or to an oxygen cylinder or to any other source capable of supplying the required quality and
flow. The supply of oxygen to the generator 22 takes place across a filter 23, a pressure
regulator 24, a flow metre 25 and an oxygen shut-off valve 26. The generator is protected
against oxygen over-pressure by a safety pressure switch 27. The ozone-oxygen mixture
generated by the generator 22 is directed to the sterilization chamber 10 by a needle valve 28
and a mixture supply solenoid valve 29a The mixture can also be directly supplied to the
ozone converting unit 52 by way of a bypass solenoid valve 29b. In a preferred embodiment
which includes a sterilization chamber of 125 liters volume, the pressure regulator 24
preferably controls the oxygen input at a flow rate of about 1.5 litres per minute. However,
it will be readily apparent to the skilled person mat other flow rates may be used depending
on the make and model of the ozone generator 22 and the size of the sterilization chamber.
The apparatus in accordance with the invention preferably includes a closed circuit
cooling system using no fresh water.
The vacuum in the sterilization chamber 10 is produced by the vacuum pump 40 and
across the ozone converting unit 52 and the sterilization chamber drainage valve 44.

OPERATION
As mentioned above, the preferred sterilization method includes the following general
steps as illustrated by the flow chart of FIG. 1. The medical instruments to be sterilized are
sealed in sterile packaging containers or pouches such as generally used in the hospital
environment and then placed into the sterilization chamber. The door of the sterilization
chamber is closed and locked and the preconditioning phase is started by applying a vacuum
to the sterilization chamber. Water vapour is admitted into the sterilization chamber to
humidify the chamber contents. A mixture of ozone and oxygen is supplied to the chamber
and the chamber maintained sealed for a preselected treatment period. Before repeating the
sterilization cycle, a re-conditioning step is effected to remove any condensed water. Then the
vacuum application and ozone supply steps are repeated at least once. To remove all
remaining ozone in the sterilization chamber 10 when the sterilization cycle is completed a
ventilation phase begins. After the ventilation phase is complete the door is unlocked and the
sterilized material can be removed from the chamber.
Before the sterilization cycle begins, the humidifier chamber 32 is filled with water
to an adequate level, which is sufficient to satisfy the requirements for the whole sterilization
cycle. This is done by temporarily opening the water-input valve 36. Valve 36 remains closed
for the whole remainder of the sterilization cycle. In the first phase of the sterilization cycle,
intake valve 18, oxygen shut-off valve 26, mixture supply valve 29a, and mixture bypass
valve 29b (optional) are closed and vapour intake valve 34, and chamber drainage valve 44
are opened. The sterilization chamber 10 is evacuated to a vacuum pressure of about 0.1 mbar.
Water vapour inlet valve 34 closes when the absolute pressure in the sterilization chamber
falls below 60 mbar. Once a pressure of about 1,0 mbar is achieved, the chamber drainage
valve 44 closes and the vapour intake valve 34 opens to lower the pressure in the humidifier
chamber 32 to the vacuum pressure in the sterilization chamber. That forces the water in the
humidifier chamber to boil and evaporate and to enter the sterilization chamber 10 as water
vapour. Shortly before the end of the humidification period (usually about 2 to 6 min. before
the end of the humidification period), the ozone generator is activated. The flow of the
oxygen/ozone mixture exiting the ozone generator is controlled by ozone mixture supply

valve 29. The apparatus preferably further includes a needle valve 28 capable of resisting the
vacuum and of adjusting the flow to between 1 and 12 litres per minute. As an optional
feature, the generator can be started at the same time as the humidification period begins. This
is then achieved with shut-off valve 26 and mixture bypass valve 29b. Shut-off valve 26 opens
to let oxygen enter the generator. The ozone-oxygen mixture produced by the generator is
then guided directly into the ozone converting unit 52 through mixture bypass valve 29b and
vacuum pump 40. After a humidification period the oxygen-ozone mixture is guided into the
sterilization chamber by opening the mixture supply valve 29a and closing the mixture bypass
valve 29b. The oxygen-ozone mixture enters the chamber 10 until an ozone concentration of
85 milligrams per litre in the chamber is achieved. The time required for this step is dependent
on the flow rate and concentration of the ozone gas in the mixture (preferably 10% to 12 %
by weight). At this point in time, the mixture supply valve 29a is closed to seal off the
sterilization chamber and to maintain the humidified ozone/oxygen gas mixture in the
chamber under vacuum.
Once the sterilization chamber is filled with the humidified sterilization gas (mixture
of oxygen and ozone gas), the generator 22 is stopped, the oxygen shut-off valve 26 is closed,
and the ozone is maintained in contact with the articles to be sterilized for about 15 minutes,
for a sterilization chamber of a volume of 125 liters (4 cubic feet). At this stage, the
sterilization chamber is still under the effect of a partial vacuum of about 670 mbar. In an
optional second step, the pressure level is raised to about 900 mbar using oxygen as a filling
gas. This pressure level is maintained for about 20 min. After the sterilization period, the
vacuum is reapplied, preferably at a pressure of about 1 0 mbar again. Once the vacuum
reaches 0.1 mbar, the humidification phase is recommenced, followed by the renewed
injection of an oxygen/ozone sterilization gas mixture, followed by the sterilization period.
The cycle of applying a vacuum of about 1.0 mbar, injecting sterilization gas, humidifying
and sterilizing period, can be repeated, and the number of repeat sterilization cycles (mini
cycles) selected to achieve complete sterilization of the instruments. Preferably, between any
two successive sterilization cycles, a re-conditioning step is effected, as described above, to
remove any condensed water from the sterilization chamber. The number of repeat cycles

used in an experimental set-up including a 125 liters (4 cubic foot) chamber was 2 repeat
cycles. This set-up conformed to the Security Assurance Level standards of the FDA (SAL
10 -6).
To remove all remaining ozone and humidity in the sterilization chamber 10 after
complete sterilization (after all successive sterilization cycles) a ventilation phase is engaged.
The ventilation phase begins after the last sterilization cycle. The chamber drainage valve 44
opens and the vacuum is applied down to approximately 13 mbar. Vapour intake valve 34
closes when the pressure reaches 60 mbar to evacuate the remaining ozone in the humidifier.
Once the vacuum pressure of 13 mbar is obtained, drainage valve 44 closes and the intake
valve 21 opens, admitting oxygen into the sterilization chamber 10. Once atmospheric
pressure is reached, intake valve 21 is closed, the sterilization chamber drainage valve 44
opened, and vacuum reapplied until a pressure of 13 mbar is reached. The ventilation cycle
is then repeated twice. Once the atmospheric pressure is reached after the last cycle, the door
mechanism of the sterilization chamber is activated to permit access to the contents of the
sterilization chamber. The ventilation phase has two functions. First, to remove all ozone
residues in the sterilization chamber before opening the access door and, second, to ensure
that the sterilized material is dry, which is achieved by evaporation when the vacuum pressure
is applied.
The ozone-containing gas evacuated from the sterilization chamber 10 is passed over
the ozone decomposing catalyst 52 of the ozone converting unit 50 prior to exhausting the gas
to the atmosphere to ensure a complete decomposition of the ozone in the sterilization gas.
The ozone generator 22 is used during only two portions of the sterilization cycle, the
activation of the generator 22 (with optional valves 29a and 29b) and the evacuation of the
sterilization chamber 10. During the start up phase of the generator 22, the mixture bypass
valve 29b is opened and the ozone is guided across the catalyst. Once the start-up phase of the
generator 22 is complete, the bypass valve 29b closes. During evacuation of the sterilization
chamber 10, the sterilization chamber drainage valve 44 is opened and the ozone containing
sterilization waste gas guided to the catalyst. Once the evacuation of the sterilization chamber
10 is completed, the drainage valve 44 is closed. The circulation of ozone is ensured by the

vacuum pump 40, which operates Airing the whole sterilization cycle including all repeat
cycles. If the ozone decomposing catalyst is located upstream of the vacuum pump this also
ensures that the carulite is kept as dry as possible in order to avoid fouling of the catalytic
material. Since the vacuum pump 40 is running during the whole sterilization process, the
carulite is exposed to reduced pressures, even if it is not used for the decomposition of ozone.
This forces evaporation of water contained in the catalyst, which may have been absorbed
by the carulite during the evacuation of the sterilization chamber. If located downstream of
the vacuum pump, the catalyst is preferably heated to keep the carulite sufficiently dry.
A system, such as the one described above, suitable for use with the method of the
invention is capable of maintaining a relative humidity level of 90%, preferably 95 % +5%
or higher, throughout the sterilization cycle.
The energy needed to evaporate the water during the humidification phase is taken
from many sources. It is taken from the structure of the humidifier unit and the sterilization
chamber and from the material to be sterilized. This contributes to a further cooling of the
chamber, and its contents. In effect, at 20°C, water boils up to an absolute pressure of 23.3
mbar and at 35°C, water boils up to an absolute pressure of 56.3 mbar. The vacuum in the
sterilization chamber is preferably adjusted to a pressure where the boiling temperature of
water is lowered below the temperature in the sterilization chamber. That boiling temperature
may be so low that, depending on the energy available from the surrounding structure and
gases, the water in the humidifier chamber will freeze before it gets vaporized. The humidifier
may also be cooled by the evaporation process to a point where condensation freezes to the
external surface of the humidifier. This can be avoided by heating the external surface of the
humidifier sufficiently to keep the exterior of the humidifier unit and the water inside the
humidifier chamber at room temperature, preferably at or above the temperature of the
sterilization chamber. This is achieved with aheating arrangement (not illustrated) which will
be readily apparent to the person of skill in the art.
The water vapour generated in the humidifier unit increases the relative humidity in
the sterilization chamber. The humidification phase is continued until the relative humidity
of the gas surrounding the medical instruments contained in the packaging pouches and

containers reaches a minimum of 95% ± 5%, preferably 100%. For a sterilization chamber
of an approximate volume of 125 liters, the water vapour admission increases the pressure to
about 53 mbar in the sterilization chamber.
Oxygen/ozone-containing sterilization gas is injected into the humidified sterilization
chamber at ambient temperature. For optimum operation of a sterilizer having a 125 liters
chamber, a system is preferably used which is capable of generating an ozone flow in the
range of about 1 to about 6 litres per minute, more preferably about 1.5 to 2 litres per minute,
containing from about 160 to 200 mg/1 of ozone to obtain at least a total of around 10,000 mg
of ozone for each of the fillings of the sterilization chamber.
Changes and modifications in the specifically described embodiments can be carried
out without departing from the scope of the invention which is intended to be limited only by
the scope of the appended claims.

WE CLAIM :
1. An ozone sterilization method, involving humidifying an atmosphere in a sterilization
chamber to a target relative humidity prior to injecting ozone as a sterilizing agent, the method
comprising the steps of:
(a) providing an amount of water in a water reservoir at a temperature Ts at or above a
temperature of the chamber atmosphere Tc;
(b) reducing a pressure in the chamber to a value below the boiling point of water at the
reservoir temperature Ts;
(c) bringing the reservoir into fluid communication with the chamber for exposing the
water in the reservoir at the temperature Ts to the reduced pressure in the chamber for a preselected
exposure time so that water in the reservoir is boiled and to allow resulting water vapour to enter the
chamber and disconnecting said fluid communication after said preselected exposure time ;
and repeating at least steps (b) and (c) a plurality of times, wherein at least one of the amount
of water and the exposure time are controlled such that the relative humidity in the chamber
progressively increases with each repetition until the target humidity is reached,
and after reaching the target relative humidity, injecting ozone, as a sterilizing agent, into the
chamber.
2. A method as claimed in claim 1, wherein the chamber and the reservoir are in fluid
communication by means of a conduit having a valve to open and close the conduit.
3. A method as claimed in claim 2, wherein after each step (c) the conduit is closed for a time
sufficient to adjust the temperature Ts or Tc of the reservoir or chamber so that Ts is equal to or above
the temperature Tc of the chamber.
4. A method as claimed in any of claims 1 to 3, wherein steps (b) and (c) are repeated from 3 to
30 times.
5. A method as claimed in any of claims 1 to 3, wherein steps (b) and (c) are repeated from 5 to
27 times.

6. A method as claimed in any of claims 1 to 3, wherein steps (b) and (c) are repeated at least
10 times and for each of the last 10 times the water vapour pressure in the chamber is increased by an
amount in the range of from 0.01 to 5 Torr.
7. A method as claimed in any of claims 1 to 3, wherein steps (b) and (c) are repeated at least 5
times and for each of the last 5 times the water vapour pressure in the chamber is increased by an
amount in the range of from 0.01 to 3 Torr.
8. A method as claimed in any of claims 1 to 3, wherein steps (b) and (c) are repeated at least 3
times and for each of the last 3 times the water vapour pressure in the chamber is increased by an
amount in the range of from 0.25 to 1 Torr.

9. A method as claimed in any of claims 1 to 8, wherein the temperature of the water in the
reservoir is maintained from 0 to 10°C above the temperature of the chamber.
10. A method as claimed in any of claims 1 to 8, wherein the temperature of the water in the
reservoir is maintained from 0 to 7°C above the temperature of the chamber.
11. A method as claimed in any of claims 1 to 8, wherein the temperature of the water in the
reservoir is maintained from 0 to 3°C above the temperature of the chamber.
12. A method as claimed in any of claims 1 to 11, wherein the first time steps (b) and (c) are
effected, the relative humidity in the chamber is increased to no more than 80% of the target relative
humidity.
13. A method as claimed in any of claims 1 to 11, wherein the first time steps (b) and (c) are
effected, the relative humidity in the chamber is increased to no more than 60% of the target relative
humidity.
14. A method as claimed in any of claims 1 to 13, wherein the number of times steps (b) and (c)
are repeated and the increase in the relative humidity in the chamber after each step (b) is selected to
avoid substantially any condensation in the chamber.

15. An ozone sterilization method, involving humidifying a sterilization chamber to a target
relative humidity prior to injecting ozone as a sterilizing agent, the method comprising a plurality of
humidification stages Sx Sn, wherein x is an integer from 1 to n and each x represents an
individual stage, each said stage having a corresponding water vapour pressure hx.....hn, and hn
representing the water vapour pressure corresponding to the target relative humidity, each said stage
Sx comprising the steps of:
(a) supplying water vapour from a water vapour source to the sterilization chamber to
increase the water vapour pressure in the sterilization chamber to at least the value hx corresponding
to said stage Sx;
(b) disconnecting the source from the sterilization chamber for a preselected equalization
period ;
(c) repeating steps (a) and (b) until said water vapour pressure h, is reached in the
sterilization chamber,
and after reaching the target relative humidity, injecting ozone, as a sterilizing agent, into the
chamber.
16. A method as claimed in claim 15, wherein the water vapour source is a water reservoir, the
temperature of the water vapour source is Ts, the temperature of the sterilization chamber is Tc, for
each said stage Sx there is a corresponding temperature differential value ∆Tx which is represented by
an equation Ts-Tc = ∆T wherein Ts is the same as, or higher than, Tc so that ATx ≥ 0 and step (b)
comprises disconnecting the source from the sterilization chamber for a time sufficient to adjust Ts or
Tc to achieve the value for ∆Tx.
17. A method as claimed in claim 15 or 16, wherein n is from 3 to 30.
18. A method as claimed in claim 15 or 16, wherein n is from 5 to 27.
19. A method as claimed in any of claims 15 to 18, wherein n is greater than 10 and for each
stage Sx-1 of the last 10 stages, from n-10 to n, each increase in water vapour pressure from the
previous stage Sx-1 to the stage Sx, said increase represented by hx-hx-1, is in the range of from 0.01 to
5 Torr.

20. A method as claimed in any of claims 15 to 18, wherein n is greater than 5 and for each stage
Sx of the last 5 stages, from n-5 to n, each increase in water vapour pressure from the previous stage
Sx-1 to the stage Sx, said increase represented by hx-hx-1, is in the range of from 0.01 to 3 Torr.
21. A method as claimed in any of claims 15 to 18, wherein n is greater than 3 and for each stage
Sx of the last 3 stages, from n-3 to n, each increase in water vapour pressure from the previous stage
Sx-1 to the stage Sx, said increase represented by hx - hx-1, is in the range of from 0.25 to 1 Torr.
22. A method as claimed in any of claims 15 to 21, wherein the value of h1 for the first stage
represents a relative humidity of no more than 80% of the target value.
23. A method as claimed in any of claims 15 to 21, wherein the value of h1 for the first stage
represents a relative humidity of no more than 60% of the target value.
24. A method as claimed in any of claims 15 to 23, wherein the number of stages and the
corresponding water vapour pressure values are selected to avoid substantially any condensation in
said space.
25. An apparatus for sterilization with humidified ozone, the apparatus comprising :
a sterilization chamber ;
a reservoir to hold water while in operation, to provide a source of water vapour to humidify
the ozone ;
a conduit in fluid communication between the reservoir and the sterilization chamber;
a valve in the conduit to open and close the conduit;
a first heating means to control the temperature of the chamber ;
a second heating means to control the temperature of the reservoir ;
a first temperature sensing means to monitor the temperature of the sterilization chamber;
a second temperature sensing means to monitor the temperature of the reservoir ;
a pressure sensing means to monitor the pressure in the chamber ;
vacuum means to reduce the pressure in the chamber;
an ozone generating means

a processor to control the first and second heating means in response to information from the
first and second temperature sensing means and the pressure sensing means ;
wherein the processor is programmed to effect a humidification of the sterilization chamber in
a plurality of stages.
26. An apparatus as claimed in claim 25, wherein said plurality of stages is from 3 to 30.
27. An apparatus as claimed in claim 25, wherein said plurality of stages is from 5 to 26.
28. An apparatus as claimed in any of claims 25 to 27, wherein said plurality of stages is greater
than 10 and the processor is programmed to effect a water vapour pressure increase in each of the last
10 stages in the range of from 0.01 to 5 Torr.
29. An apparatus as claimed in any of claims 25 to 27, wherein said plurality of stages is greater
than 5 and the processor is programmed to effect a water vapour pressure increase in each of the last
5 stages in the range of from 0.01 to 3 Torr.
30. An apparatus as claimed in any of claims 25 to 27, wherein said plurality of stages is greater
than 3 and the processor is programmed to effect a water vapour pressure increase in each of the last
3 stages in the range of from 0.25 to 1 Torr.
31. An apparatus as claimed in any of claims 25 to 30, wherein the processor is programmed to
maintain the temperature of the reservoir at or above the temperature of the chamber.
32. An apparatus as claimed in any of claims 25 to 31, wherein the processor is programmed to
maintain the temperature of the reservoir from 0 to 7°C above the temperature of the chamber.
33. An apparatus as claimed in any of claims 25 to 31, wherein the processor is programmed to
maintain the temperature of the reservoir from 0 to 3°C above the temperature of the chamber.

An ozone sterilization method, involving humidifying an atmosphere in a sterilization
chamber to a target relative humidity prior to injecting ozone as a sterilizing agent, the method
comprising the steps of:
(a) providing an amount of water in a water reservoir at a temperature Ts at or above a
temperature of the chamber atmosphere Tc;
(b) reducing a pressure in the chamber to a value below the boiling point of water at the
reservoir temperature Ts;
(c) bringing the reservoir into fluid communication with the chamber for exposing the
water in the reservoir at the temperature Ts to the reduced pressure in the chamber for a preselected
exposure time so that water in the reservoir is boiled and to allow resulting water vapour to enter the
chamber and disconnecting said fluid communication after said preselected exposure time ;
and repeating at least steps (b) and (c) a plurality of times, wherein at least one of the amount
of water and the exposure time are controlled such that the relative humidity in the chamber
progressively increases with each repetition until the target humidity is reached,
and after reaching the target relative humidity, injecting ozone, as a sterilizing agent, into the
chamber.

Documents:

2098-KOLNP-2005-CORRESPONDENCE.pdf

2098-KOLNP-2005-FORM 27.pdf

2098-KOLNP-2005-FORM-27.pdf

2098-kolnp-2005-granted-abstract.pdf

2098-kolnp-2005-granted-assignment.pdf

2098-kolnp-2005-granted-correspondence.pdf

2098-kolnp-2005-granted-description (complete).pdf

2098-kolnp-2005-granted-drawings.pdf

2098-kolnp-2005-granted-examination report.pdf

2098-kolnp-2005-granted-form 1.pdf

2098-kolnp-2005-granted-form 13.pdf

2098-kolnp-2005-granted-form 18.pdf

2098-kolnp-2005-granted-form 3.pdf

2098-kolnp-2005-granted-form 5.pdf

2098-kolnp-2005-granted-gpa.pdf

2098-kolnp-2005-granted-reply to examination report.pdf

2098-kolnp-2005-granted-specification.pdf


Patent Number 230122
Indian Patent Application Number 2098/KOLNP/2005
PG Journal Number 09/2009
Publication Date 27-Feb-2009
Grant Date 25-Feb-2009
Date of Filing 24-Oct-2005
Name of Patentee TSO3 INC.
Applicant Address 2505 RUE DALTON, SAINTE-FOY, QUEBEC G1P 3S5
Inventors:
# Inventor's Name Inventor's Address
1 CHAMPAGNE REAL 621 AVENUE ROYALE 2, BEAUPORT, QUEBEC G1E 1Y6
PCT International Classification Number F24F 6/00
PCT International Application Number PCT/CA2004/001636
PCT International Filing date 2004-09-07
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2,443,044 2003-09-26 Canada