NOVEL APPARATUS AND METHODS TO IMPROVE INFECTION CONTROL IN FACILITIES

Abstract

An Apparatus that generates onsite three antimicrobial solutions by electrolyzing a dilute brine solution. At least one of the generated solutions can be used to dissolve protein, emulsify oils and fats making it an effective general purpose cleaner. A second solution can be used as a non-corrosive, fast active general purpose sanitizer and a third solution can be used as a high level disinfectant, capable of killing all microorganism, including MRSA (methicillin resistant staphylococcus aureaus), C. diff (clostridium difficle), VRE (vancomycin resistant enterococci) and acinetobactor baumannii. The onsite generated antimicrobial solutions reduce the occurrence of infectious diseases in hospitals, other human or animal health care settings, cruise-ships, hotels and other facilities whereas there is a higher risk of spreading infectious diseases.

Description

RELATED APPLICATIONS

The present invention is related to U.S. patent application Ser. No. 13/718,677, filed Dec. 18, 2012, and entitled “APPARATUS AND METHOD FOR GENERATING A STABILIZED SANITIZING SOLUTION”; U.S. patent application Ser. No. 13/718,721, filed Dec. 18, 2012, and entitled “MESH ELECTRODE ELECTROLYSIS APPARATUS AND METHOD FOR GENERATING A SANITIZING SOLUTION”; and U.S. patent application Ser. No. 13/324,714, filed Dec. 13, 2011, entitled “DUAL DIAPHRAGM ELECTROLYSIS CELL ASSEMBLY AND METHOD FOR GENERATING A CLEANING SOLUTION WITHOUT ANY SALT RESIDUES AND SIMULTANEOUSLY GENERATING A SANITIZING SOLUTION HAVING A PREDETERMINED LEVEL OF AVAILABLE FREE CHLORINE AND pH”; the contents of the above referenced applications are incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to the onsite generating of antimicrobial solutions and methods and procedures to apply the generated antimicrobial solutions to minimize the risk of spreading infections, especially in hospitals and human or animal health care facilities.

BACKGROUND OF THE INVENTION

There is an epidemic of healthcare acquired infections within hospitals, out-patient surgical centers, nursing homes and medical clinics. The number of hospital acquired infections alone is staggering. About 1 in every 15 patients gets an infection while hospitalized and up to 98,000 Americans die from these infections each year. That makes infections the most common complication in hospital care and one of the nation's top causes of death. In California, an estimated 200,000 patients develop hospital infections each year, resulting in 12,000 deaths.

The problem is much larger than official statistics because the numbers fail to account for millions of patients treated in outpatient surgery centers, community clinics, nursing homes and other care facilities. About six and one half percent of patients admitted to U.S. hospitals. Nearly 5,500 daily or two million annually get sick from a hospital-acquired infection. This adds 19 days of hospitalization and $43,000 in costs totaling more than $45 billion a year to U.S. medical bills.

Under the new Affordable Healthcare Law consumers will be able to learn hospital infection rates. Hospital Infection rate information will be posted on a Department Health and Human Services website called Hospital Compare. This new reporting a requirement applies to hospitals that participate in Medicare and Medicaid programs which are virtually every hospital in the country. Beginning in October 2012, Medicare payments to hospitals will be tied to how well they protect patients from these infections. Hospitals with infection rates exceeding national averages will lose 1 percent of their Medicare funding, starting in 2015. This is a huge dollar amount considering the federal government spent $563 billion last year on 49 million recipients and Medicare spending is expected to grow to $970 billion by 2021.

Hospital Cleaning is the removal of all dust, oil, and organic materials such as blood, secretions, excretions and microorganisms. Cleaning reduces or eliminates the populations of potential pathogenic organisms. It is accomplished with water, detergents and mechanical action. Hospital disinfection is the inactivation of disease producing organisms. Disinfection does not destroy high levels of bacterial spores. Disinfectants are used on inanimate objects. Disinfection usually involves chemicals, heat or ultraviolet light. Levels of chemical disinfection vary with the type of product used.

Terminal Room cleaning is performed by the Environmental Services Staff. The cleaning includes emptying trash and removing any loose items, changing bed linen, wiping the mattress with a disinfectant, washing walls with detergent, cleaning bathroom sink and toilet with a disinfectant, wiping all bed rails, tables, light switches, door handles, telephone, call buttons, privacy curtain and other “high touch” items with a disinfectant then mop the floor with a detergent cleaner and disinfectant. Once the Environmental Staff completes the terminal room cleaning, the Environmental Service Supervisor inspects the room. The Supervisor will look for any visible dirt, blood, secretions, etc. They will also use a bio-luminescence meter to measure bacterial contamination. If the Environmental Service Supervisor rejects a room, the entire room is re-cleaned and disinfected.

In the U.S. the average time from patient discharge to another patient occupying the same room is 27 minutes. The work required (as noted above) by the Environmental Service Staff to terminally clean the discharged patient room in the 27-minute timeframe is almost impossible. This creates extreme pressure and stress on the Environmental Service Staff resulting in poor cleaning and very high job turnover. Other factors contributing to poor cleaning and high turnover is the use of toxic and corrosive detergents and disinfectants. To improve cleaning performance, stronger and more toxic chemicals are required. However, these chemicals slow down cleaning time. The Staff must be more careful in handling these chemicals, adding a rinse step and allow time for the room to dry and “air out”.

Using stronger and more toxic cleaning and disinfecting chemicals does not always provide the level of disinfecting required by hospital guidelines. The overprescribed use of antibiotics has created “super-bugs”. These “super-bugs” can develop a resistance to disinfectants. There are sixteen hospital identified “super-bugs”. A few of these are MRSA (methicillin resistant staphylococcus aureaus), C. diff (clostridium difficle), VRE (vancomycin resistant enterococci) and acinetobactor baumannii.

To reduce the human factor in terminal room cleaning and eliminate the chemical resistance of “super-bugs” new technologies have been developed and are currently marketed. One new technology is called VHP (vaporize hydrogen peroxide). VHP meets and exceeds hospital guidelines for environmental surface disinfection. The guideline for hospital cleaning was developed by HICPAC (Hospital Infection Control Procedures Advisory Committee). This committee is Infection Control doctors and researchers within the medical community specializing in Non-Critical Environmental surface disinfection. The level of surface disinfection for terminal room cleaning is called 6-log reduction. 6-log cleanliness is basically a sterile surface. VHP provides 6-log surface cleanliness but requires 4 hours to clean, disinfect and “air out” the room. In addition the Vaporized Hydrogen Peroxide equipment cost more than $200,000 and requires a company representative located full-time at the hospital to operate the equipment.

Another new technology for terminal room cleaning is UV-C light. UV light has been used for surface disinfection for many years. Used properly UV-C can provide a 6-log level of disinfection. However, UV-C is difficult to use because the light must be directed at an exact angle to the surface, the light requires a long contact time and the light must be checked regularly to insure the proper wavelength. A properly cleaned and disinfected room using UV-C equipment takes more than 90 minutes.

These technologies and others meet the HICPAC cleaning guidelines for terminal room cleaning but they do not come close to the time requirements for most hospitals. Electrolyzed Water is the only new technology that can provide 6-log disinfection within the 27-minute time requirement. In addition electrolyzed water is non-toxic, requires no chemical storage, mixing, dries faster and does not require Staff to wear protective clothing. Electrolyzed water can eliminate the pressure and stress of the Environmental Service Staff reducing turnover. It has no odor or chemical residue that can cause patient sensitivities.

There are other electrolyzed water suppliers working to develop this market. A few of these companies are Integrated Environmental Technologies (IET), EnviroCleanse, EAU Technologies, Orbio Technologies and Ecolab.

IET and EnviroCleanse sell bottled and bulk liquid of electrochemically generate Hypochlorous Acid solution. Each company has registered US EPA biocide registration and its solutions are classified as surface disinfectants by the EPA. Both companies approach the market through a network of janitorial companies. This has limited their development of the market because these distributors do not have the application or industry knowledge to effectively support this market. Moreover, their electrochemically Hypochlorous Acid has a limited shelf life and contains salt-residues.

EAU Technologies, Orbio and Ecolab do not have US EPA biocide registration, but do supply an apparatus that can generate onsite an acidic sanitizing solution and simultaneously an alkaline cleaning solution. Orbio's apparatus only produces a cleaning solution, the others do not produce a sanitizer as classified by the EPA and thus all generated solutions have limited usage and do not provide the Environmental Service Staff with an all-inclusive apparatus and method to minimize the spread of nosocomial infections.

SUMMARY OF THE INVENTION

The present invention relates to the design of a self-containing apparatus capable of generating onsite three antimicrobial solutions as well to methods and procedures how the Environmental Service Staff implement and applies these onsite generated antimicrobial solutions to minimize the risk of spreading infections, especially in hospitals and human or animal health care facilities.

The apparatus produces onsite and on demand an antimicrobial cleaning solution, a sanitizing agent and a high level disinfectant, all as classified by the EPA. The methods and procedures described allow an Environmental Service Staff to more efficiently and effectively clean, sanitize and disinfect. The onsite generated solutions find use for deodorizing, cleaning, sanitizing and disinfecting surfaces predominantly in hospitals and human or animal health centers, but is also applicable for cruise-ships, hotels and other facilities whereas there is a high risk of spreading infectious diseases.

The present invention describes one apparatus to provide on demand all cleaning, sanitizing and disinfecting solutions required to effectively control infections in hospitals, human or animal health centers, cruise-ships, hotels and other facilities whereas there is a risk of spreading infectious diseases. The present invention can reduce a hospital's overall chemical costs, cut Environmental Service labor requirements and reduce the hospital liability insurance premiums.

The onsite generated Sodium Hydroxide cleaning solution can replace conventional all-purpose cleaners. The onsite generated Hypochlorous Acid sanitizing solution can replace conventional all-purpose sanitizers and the onsite generated Hypochlorous Acid disinfectant can replace conventional high level disinfectants.

The Sodium Hydroxide containing cleaning solution is based upon a very negative ORP (oxidation-reduction potential). The more negative the cleaning solution the greater is the cleaning power and the faster are its drying properties. Onsite generated Sodium Hydroxide solution's negative ORP has a very short shelf life, usually less than 1 hour in an open container exposed to air.

Onsite dispensed Sodium Hydroxide solution is a direct replacement to detergents and work in their cleaning process. For example, the Environmental Service Staff at the start of their shift fill an open container with a detergent solution and add 8 to 10 micro-fiber mop heads. One mop head per room is used to mop walls and floors. As the staff changes mop heads and agitates the solution, the ORP is quickly lost. The disclosed solution preserves the negative ORP and actually continues the electrolysis process making the ORP of the cleaning solution more negative. The solution can be incorporated into the mop head containers, spray bottles or other applicators. The product will maintain negative ORP even with the addition of dyes, foaming agents or other cleaning aids.

Once surfaces are cleaned with the onsite generated Sodium Hydroxide solution, the surface has a negative charge. At this point, either the onsite generated 250 ppm or the 460 ppm Hypochlorous Acid solution can be applied with an electrostatic spray device. This device will put a 5 to 10 mil coating on every surface within the room. Electrostatic sprayers can reach every side of a surface even if the sprayer is not pointed directly at the surface. Electrostatic spraying of a patient room takes less than 3 minutes. This technique enables the Environmental Surface Staff to take more time cleaning with the alkaline water and still finish under the 27-minute time requirement.

Accordingly, it is an objective of the instant invention to disclose an apparatus for the onsite generation of antimicrobial solutions by electrolysis of a dilute brine solution utilizing two or more electrolysis cells to deliver on demand to the Environmental Service Staff an effective general purpose cleaner that dissolves protein, emulsifies oils and fats and can be registered as a sanitizer by the US EPA; a fast-acting non-corrosive general purpose sanitizer than can be registered as disinfectant by the US EPA; and a high level disinfectant that can be classified as a sterilizer or sporicide by the US EPA, capable of killing all microorganisms, including MRSA (methicillin resistant staphylococcus aureaus), C. diff (clostridium difficle), VRE (vancomycin resistant enterococci) and acinetobactor baumannii.

It is a further objective of the instant invention to disclose methods and procedures for the Environmental Service Staff to apply antimicrobial solutions generated by electrolysis of a dilute brine solution utilizing two or more electrolysis on surfaces as infection control with the purpose to reduce the occurrence of infectious diseases in hospitals or human and animal health centers.

It is yet another objective of the instant invention to teach the use of an onsite generated Sodium Hydroxide solution based upon a very negative ORP which makes the Environmental Service Staff job easier, safer and less pressured by providing freshly generated cleaning solutions that are easily dispensed of.

It is a still further objective of the invention to disclose an onsite dispensed Sodium Hydroxide solution is a direct replacement to detergents in their cleaning process and can be incorporated into the mop head containers, spray bottles or other applicators while maintaining a negative ORP even with the addition of dyes, foaming agents or other cleaning aids.

Other objectives and advantages of this invention will become apparent from the following description taken in conjunction with any accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. Any drawings contained herein constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front right perspective view of the self-contained apparatus capable of generating onsite three antimicrobial solutions;

FIG. 2 is a front left perspective thereof;

FIG. 3 is a partial view of the apparatus illustrating two cells;

FIG. 4 is a partial view of the apparatus illustrating the sanitizing solution storage tank and the neutralizer tank;

FIG. 5 is a partial view of the apparatus illustrating the disinfecting solution storage tank, the acid storage tank and the dye storage tank;

FIG. 6 is a chart that classifies a variety of commonly used items in a hospital patient care room organized according by the degree of cleanliness or disinfection needed;

FIG. 7 is a chart that classifies a variety of commonly used items in a hospital exam room organized according by the degree of cleanliness or disinfection needed;

FIG. 8 is a chart that classifies a variety of commonly used items in a hospital waiting room organized according by the degree of cleanliness or disinfection needed;

FIG. 9 is a chart that classifies a variety of commonly used items in a hospital dining room organized according by the degree of cleanliness or disinfection needed; and

FIG. 10 is a chart that classifies a variety of commonly used items in a hospital work station organized according by the degree of cleanliness or disinfection needed.

DETAILED DESCRIPTION OF THE INVENTION

In order to produce three different antimicrobial solutions, the voltage, current, volume, conductivity and flow-patterns have to be changed during operation. The three different antimicrobial solutions are temporary stored in storage tanks located at the rear of the apparatus.

All liquids are freshly generated on demand. The apparatus drains generated solutions and drained periodically solutions from the storage tanks, when liquids are out of specification. The apparatus can also be set to drain tanks periodically to ensure freshness and will drain a specific storage tank if operator decides to drain. The cleaning solution contains no Free Available Chlorine; it has a pH of 10 to 13, a conductivity of 1000-5000 uS and an ORP of −800 to −1000 mV. The cleaning solution has a (yellow) color to distinguish it from the sanitizing solution and disinfect. The Sanitizing solution has a pH of about 4.5-5.5; has a conductivity of 1000-3000 uS and an ORP of +800 to +1000 mV. It consist 250 ppm (+/−10%) Free Available Chlorine. The disinfectant solution a pH of about 6.0-7.0; has a conductivity of 2000-5000 uS and an ORP of +800 to +1000 mV. It consist 460 ppm (+/−10%) Free Available Chlorine.

The quality of the antimicrobial solutions is verified by checking: a) PH (probe in inlet storage tank); b) ORP (probe in inlet storage tank); c) Conductivity (probe in mains water after dosage of saturated brine solution into the mains water; d) Free Available Chlorine. (FAC is indirectly measured; not using a probe). The Free Available Chlorine (FAC) is warranted by logging Flow, Voltage and Current, as at a certain flow, voltage and current, a certain FAC is produced. Flow, Voltage and Current of the sanitizing and disinfectant is monitored and kept within range. If range cannot be kept, solutions go to drain. The quality of the cleaning solution is verified by checking a), b) and c) as described above. All antimicrobial solutions are tested by having a pH/temp and an ORP probe in the inlet line of each storage tank. If probes read a value outside pre-set limits the storage tanks drain the solution that is out of specification.

All antimicrobial solutions that are within specification are temporary stored in 20-gallon polypropylene storage tanks mounted on the rear side of the frame. Liquids are delivered to a dispenser that is wall-mounted and not part of the main apparatus. The antimicrobial solutions are delivered using pumps located under the solution storage tanks. Different types of wall-mounted dispensers can be used. The antimicrobial solutions are pumped to the dispensers utilizing for each solution a dedicated diaphragm pump that includes a built-in pressure switch that starts/stops the pump. Each diaphragm pump delivers about 4-5 gpm at zero pressure. Pumps are self-priming and can run dry.

The antimicrobial solutions can be dispensed immediately next to the apparatus, but also in a separate room. The dispenser is wall-mounted above a sink, a drain or at least in an area that can be wetted. All materials that can be wetted should be of non-corrosive material. Different dispensers can be utilized. The Environmental Staff is already used with Plastic faucets, valves or push-dispensers. When opening the faucet, valve or pushing the dispenser, the line-pressure to the dispenser drops and the diaphragm pump starts delivering. When the faucet/valve is closed or the dispenser released the line-pressure increases which causes the diaphragm pump to stop. Plastic faucets with an electric Timer switch to start and stop a (peristaltic) pump are widely used in the industry, in particularly for the dosage of laundry detergents. For dispensing the onsite generated solutions, the time could be set for 1 quart, 1 gallon, 5 gallons or larger volumes. Dispensers are colored and marked, to distinguish the different products.

Referring now to FIGS. 1-5, the apparatus 10 is connected to a water faucet within the facility providing either reverse osmoses water or softened drinking water. Drinking water is connected to the Machine using a flexible hose and ⅝″ hose barb 12. A ½″ Ball valve 14 open or closes the drinking water to the Machine, then a 10 micron Cartridge Filter 16 ensures that particles are removed. A Pressure Reducing Valve 18 keeps the water pressure below 30-35 psi which can be checked by pressure gauge 20. A compact Float Valve 22 keeps the buffer tank 24 full. The buffer tank 24 is constructed from a 4″ pvc pipe and contains a minimal of 2 gallons of water. A Level-switch 26 inside the buffer tank 24 prevents the Supply Pump 28 from running dry, a direct Drive Seal-less Supply Pump which provides a constant flow and pressure to the Hydraulic Enclosure.

Drinking water enters the Hydraulic enclosure through ½ white PVC Pipe Sch40. A tee is connected whereas a push to fit connector is screwed into the tee to connect a ¼″ brine tube to a Peristaltic brine Pump 32. A ¼″ flex tube is connected to the Brine Tank. A 2-way solenoid valve 36 is installed to close flow of water from the buffer tank. After the solenoid valve 36 a ½′″ pipe 38 is widened to a 2″ pipe whereas brine can mix and whereas a 2″ tee 40 allows a conductivity meter to measure the conductivity of the electrolyte. At the bottom of the 2″ pipe a fitting is connected with a volume control valve 42. After the volume control valve 42, a flow-meter 44 is installed. From the flow meter 44 using push-to-fit connections 46, a ⅜″ flex tube 48 is connected to the inlet of the C-chamber of Cell 50. From the outlet of the C-chamber of Cell 50 a ½″ flex tube 52 is connected to the inlet of the C-chamber of Cell 54. From the outlet of the C-chamber of Cell 50 a ½″ flex tube is connected to the inlet of the degassing chamber 56 which is made of ¾″ pvc Pipe. The inlet is a push-to connect fitting screwed in the 4″ tee. From the top of the degassing-chamber 56 a ½″ flex tube is connected. This ½″ flex tube goes to the top of the NAOH storage tank. From the bottom of the degassing chamber 56 a flex tube is connected to the C-Supply Pump 58 wherein a ½″ flex tube is connected to the inlet of the A-chamber of Cell 54 From the outlet of the A-chamber of Cell 54, a ½″ Flex tube is connected to the inlet of the A-chamber of Cell 50. From the outlet of the A-chamber of Cell 50, a ½″ flex tube is connected to 3-way Pinch Valve 60. One stream after the pinch valve 60 goes to a Normally closed drain and the other stream after 60 goes to 3-way Pinch Valve 62 [Normally open]. One stream after 62 goes to the sanitizer storage tank 64 [normally open] and the other stream after 62 goes to the disinfectant storage tank 66 [normally closed]. The 4″ flex tube with cleaning solution flows through a Manifold 70 into the cleaning solution storage tank 66 from the top. Inside 70, a pH 72 and ORP 74 probe is installed to measure the quality of the cleaning solution. The ½″ flex tube with sanitizing solution flows through a Manifold 80 into the sanitizing solution storage tank from the top. Inside 80, a pH 82 and ORP 84 probe is installed to measure the quality of the sanitizing solution. The ½″ flex tube with the disinfectant solution flows through a Manifold 90 into the disinfectant storage tank 64 from the top. Inside 90, a pH 92 and ORP 94 probe is installed to measure the quality of the disinfectant. All three storage tanks have each an overflow, namely a ½″ pvc pipe sch.80. The overflow has a tee at the bottom of each storage tank whereas through a Pinch Drain Valve 106 the storage tanks can be drained. The ½″ pipe from each storage tank ends at the top of the Neutralizer Tank 107. All drained solutions are connected with to a 5-gallon tank which is filled with a pH neutralizing resin. On top of this tank are three inlets connected to the 20-gallon storage tanks. A 4th inlet is connected on the top to the drain valve inside the hydraulic enclosure. All inlets are ½″ fnpt bulkhead fittings and pipes are ½″ pipe sch.80.

All storage tanks have another outlet whereas a ½″ pipe is connected to the Dispenser pumps 110, 112, 115. From the Dispenser pumps, a ½″ pvc pipe sch.80 is connected to Flow meters 108, 114, 120. From the Flow meters there is a manifold 122 whereas flex hose, not shown, can be mounted to connect to the dispensers. All storage tanks have a 5″ vented lid and all solution storage tanks have a upper-level switch and a lower-level switch. Both switches up, stops filling and both switches down starts filling. The cleaning solution storage tank has on top an ¼″ push to fit connector whereas a ¼″ flex tube is connected with the Peristaltic Dye Pump 130. From the tank a ¼″ flex tube is connected to the Dye tank 34. Each time, onsite generation of the cleaning solution starts, a small peristaltic dosing pump doses small amount of a yellow D&C dye solution (for ˜5 seconds) into the cleaning solution storage tank. The dye is to help the operator distinguish between cleaning liquid and the sanitizing or disinfectant solution. The yellow color is associated with nowadays cleaning agents such as Lysol. The dye 34 tank has the same dimensions as the neutralizer tank 107 and a capacity of 5 gallons. The D&C yellow dye is extremely concentrated and a 5 gallon D&C yellow solution tank, metering into the cleaning solution tank 66 for 5 second at each start cycle would last for 6 months or longer. The sanitizer solution storage tank 64 has on top an ¼″ push to fit connector whereas a ¼″ flex tube is connected with the Peristaltic Dye Pump 150. From the DP an ¼″ flex tube is connected to the Citric Acid tank 152. A 5-gallon tank is placed next to the neutralizer tank, under the 3 storage tanks. This tank has a lid, so that citric acid powder can be added. Citric Acid powder is extremely concentrated and a 5 gallon concentrated citric acid solution tank, metering into the sanitizer solution tank for 5 second at each start cycle would last for 3 months or longer. A 14 gallon rectangular tank with a lid is placed next to the machine. Inside the tank a ½″ pipe, porous pipe is mounted that allows suction of brine, but rejects salt-particles. Also a level-switch is mounted to automatically fill the brine tank with water. At 4″ of the bottom the tank is marked with a fill-line of NACL. The level-switch is mounted 2″ below the top of the tank. So that the water level is 8″ from the bottom of the tank and 4″ above the layer of salt. About 11 lbs. (1 bag) of Granular food grade NACL is added at the time without overflowing the tank.

The apparatus Human Face interface will send periodically, but not less than every 15 minutes, two e-mails to an remote server with amongst other information, the following data: Machine Status; Flow of incoming water; Flow of the cleaning solution; Flow of the sanitizing solution; Flow of disinfectant solution; Voltage applied on each Cell, Current measure on each Cell, Brine pump speed, Minutes/Hours produced, Volume cleaning solution generated; Volume sanitizing solution generated, Volume Disinfectant generated and Conductivity and Temperature of electrolyte. At the end of the day (24 Hours), an extra e-mail is sent with the daily totals prior to resetting the daily timer. The HMI send also an email upon registering an ALARM. The following Data need to be processed: Time of Alarm registration; Alarm ID; Duration of alarm; Time of sending SMS to operator; Time of clearing alarm. Once operator receives alarm he can clear alarm and proceed with re-start procedure. A Daily report is generated using the data from the received e-mails. The Daily report contains amongst other information, the following data: Minutes/Hours produced; Volume cleaning solution generated; Volume sanitizing solution generated, Volume Disinfectant generated; Number of Starts/stops; Number of alarms; Average pH, temperature and ORP of the cleaning solution; Average pH, temperature and ORP of the sanitizing solution; Average pH, temperature and ORP of the disinfectant solution and average conductivity of the mains water.

Hospital and Health Care Centers are generally cleaned by removing dirt and dust using detergents, scouring powders, toilet bowl, and glass cleaners. This aspect of hospital cleaning is similar to that of an office building or hotel, wherein conventional general purpose cleaners can be replaced by the onsite generated cleaning solutions of the instant inventions.

In some areas of the hospital, the use of disinfectants is necessary to reduce the risk of infection. Patient rooms need cleaning and low level disinfecting and surgical suites require high-level disinfection and sterilization of instruments. These complex regimens create confusion, which can lead to multiple disinfectants being used or surfaces unnecessarily being disinfected. This practice results in an increased use of pesticides, exposure risk for staff and patients, and potential for spreading antimicrobial resistance. Without systems in place for selecting and purchasing cleaning chemicals a facility may have multiple chemicals in use. As an example, a hospital may have five different products on the shelf for each cleaning or disinfecting application. Multiple chemical products in use are not only costly, but make it difficult to manage in terms of safety, proper training, hazard communications, security, and waste management. Most, if not all low level disinfectants (sanitizers) can be replaced with the onsite generated sanitizing solution and the high level disinfectants can be replaced by the onsite produced disinfectant.

FIG. 6 is a chart that classifies a variety of commonly used items found throughout areas of healthcare facilities, in particular a hospital patient care room. It is organized according by the degree of cleanliness or disinfection needed. Cleaning and disinfecting appropriately helps healthcare facilities ensure adequate infection prevention, while reducing cleaning times, minimizing patient and staff exposures to toxic chemicals, and reducing procurement costs.

FIG. 7 is a chart that classifies a variety of commonly used items found throughout areas of healthcare facilities, in particular a hospital patient exam room. It is organized according by the degree of cleanliness or disinfection needed. Cleaning and disinfecting appropriately helps healthcare facilities ensure adequate infection prevention, while reducing cleaning times, minimizing patient and staff exposures to toxic chemicals, and reducing procurement costs.

FIG. 8 is a chart that classifies a variety of commonly used items found throughout areas of healthcare facilities, in particular a hospital waiting room. It is organized according by the degree of cleanliness or disinfection needed. Cleaning and disinfecting appropriately helps healthcare facilities ensure adequate infection prevention, while reducing cleaning times, minimizing patient and staff exposures to toxic chemicals, and reducing procurement costs.

FIG. 9 is a chart that classifies a variety of commonly used items found throughout areas of healthcare facilities, in particular a hospital dining room. It is organized according by the degree of cleanliness or disinfection needed. Cleaning and disinfecting appropriately helps healthcare facilities ensure adequate infection prevention, while reducing cleaning times, minimizing patient and staff exposures to toxic chemicals, and reducing procurement costs.

FIG. 10 is a chart that classifies a variety of commonly used items found throughout areas of healthcare facilities, in particular a hospital work station. It is organized according by the degree of cleanliness or disinfection needed. Cleaning and disinfecting appropriately helps healthcare facilities ensure adequate infection prevention, while reducing cleaning times, minimizing patient and staff exposures to toxic chemicals, and reducing procurement costs.

All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.

It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and any drawings/figures included herein.

One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.

Claims

1. An apparatus for the onsite generation of antimicrobial solutions by electrolysis of a dilute brine solution comprising: an apparatus having two or more electrolysis cells each consisting of an outer cylindrical electrode separated from an inner cylindrical electrode by a cylindrical ion-selective membrane arranged coaxially one within the other to create a cathode chamber and an anode chamber; a pair of end pieces to each of said cells where a space between said inner cylindrical electrode and said cylindrical ion-selective membrane and a space between the ion-selective membrane and the outer cylindrical electrode defines anode and cathode chambers; wherein one of said electrodes functions as an anode and the other electrode functions as a cathode to generate three different antimicrobial solutions utilizing different volumes and flow-patterns, applying different voltage and current on the electrolysis cells as well varying the conductivity of the diluted brine solution pumped through said electrolysis cells.

2. The apparatus of claim 1, wherein the antimicrobial solutions are during the onsite generation are checked for pH, Temperature and ORP before the antimicrobial solutions are temporarily stored in dedicated storage containers located at the rear of the apparatus always filled and ready to be dispensed on demand to dedicated dispensers.

3. The apparatus of claim 2 including a Programmable Logic Controller (PLC) receives signals from several level-switches in the solution storage tanks, so that the PLC prioritize what antimicrobial solution needs to be generated.

4. The apparatus of claim 2 wherein said measurement of pH, Temperature and ORP is adjusted to ensure that the dispensed antimicrobial solutions from the solution storage tanks meet a predefined EPA specification wherein properties are adjusted by controlling the voltage and current applied to the electrolysis cells, the flow and conductivity of the electrolyte and the flow pattern of the electrolyte.

5. The apparatus of claim 1, wherein the generation of antimicrobial solutions is monitored from a remote server that periodically reports and alarms the operator enabling the operator to remotely start, stop or adjust settings wherein an operator may remotely service, maintain and upgrade the apparatus as well invoice the user or owner of the apparatus for services provided and antimicrobial solutions used.

6. The apparatus of claim 6 including a Human Face Interface (HMI) to periodically send an e-mail containing all production data to a remote server for data storage whereas said HMI sends an e-mail to address any amoralities is said production data.

7. The apparatus of claim 1, wherein the active ingredient of the on-site generated antimicrobial cleaning solution consists of approximately 150 to 200 ppm Sodium Hydroxide (NAOH) and said cleaning solution has a conductivity between 1000 and 5000 us, an ORP between −500 and −900 mV and a pH between 11 and 13.

8. The apparatus of claim 7, wherein an antimicrobial efficacy of said cleaning solution is at least log 4 wherein the cleaning solutions is classified as a low level disinfectant using EPA standards and can be registered as sanitizer by the EPA.

9. The apparatus of claim 1 wherein each said cleaning solution includes a food grade dye.

10. The apparatus of claim 1, wherein the active ingredient of the on-site generated sanitizing solution consists of Hypochlorous Acid (HOCL) and wherein the sanitizing solution has a conductivity between 1000 and 3000 uS, an ORP between 800 and 1200 mV, a pH between 4.5 and 6.5 and approximately 250 ppm Free Available Chlorine (FAC).

11. The apparatus of claim 10 wherein the antimicrobial efficacy of the sanitizing solution is at least log 4 whereby the sanitizing solution is classified as a low level disinfectant using EPA standards and can be registered as sanitizer by the EPA.

12. The apparatus of claim 1 including a small amount of concentrated citric acid solution added to said solution to create a distinctive fragrance.

13. The apparatus of claim 1, wherein the active ingredient of the on-site generated disinfectant consists of Hypochlorous Acid (HOCL) and wherein the on-site generated disinfectant has a conductivity between 2000 and 6000 uS, an ORP between 800 and 1200 mV, a pH between 6 and 7 and approximately 460 ppm Free Available Chlorine (FAC).

14. The apparatus of claim 13, wherein the antimicrobial efficacy of the on-site generated disinfectant is at least log 6 wherein the solution is classified as a high level disinfectant using EPA standards and can be registered as sterilizer or sporicide by the EPA.

15. The apparatus of claim 1, wherein the brine solution is a saturated brine prepared in a brine tank using purified granular Sodium Chloride saturated in purified softened or reverse osmoses water by means of gravity wherein the saturated brine solution is pumped from the bottom of the brine tank utilizing a peristaltic pump and diluted with purified softened water or reverse osmoses water to achieve a predetermined conductivity in the electrolyte prior to electrolysis of the diluted brine solution.

16. The apparatus of claim 15 wherein conductivity is set by a Programmable Logic Controller (PLC) and the conductivity of the electrolyte controls the speed of the peristaltic pump to dose a saturated brine solution in the RO/softened water.

17. The apparatus of claim 1, wherein the stored antimicrobial solutions are delivered on demand to a nearby or remote dispensing station whereby buckets, bottles and containers can be filled by opening a faucet or valve.

18. The apparatus of claim 1, wherein a food grade dye as a powder or liquid is added to a dedicated storage tank filled with reverse osmoses water or softened water and whereas a small fraction of the concentrated dye-solution is added periodically to the cleaning solution using a peristaltic pump to give the cleaning solution a distinct color.

19. The apparatus of claim 1, wherein a food grade citric acid powder or concentrate is added to a dedicated storage tank filled with reverse osmoses water or softened water and whereas a fraction of the concentrated citric acid solution is added to the sanitizing agent using a peristaltic pump to give the sanitizing agent a distinct fragrance.

20. The apparatus of claim 1, wherein a neutralizing agent is added to a dedicated storage tank filled with solutions that did not meet the specifications and thus drained from the storage tanks as waste and/or directly disposed as waste from the electrolytic cells during electrolysis.

21. The apparatus of claim 20, wherein no acidic, nor any alkaline solutions are drained directly into the drain or sewage system to prevent corrosion, but wherein all rejected solutions are neutralized by flowing through a neutralizer tanks filled with coral, lime stone or another neutralizing media.

22. The apparatus of claim 1, wherein outer dimensions of the apparatus does not exceed 90 inch height, 48 inch width and 48 inch depth, weight of the apparatus does not exceed 1000 lbs, and the apparatus utilizes a 208-240 vAC single phase power source at a maximum load of 30 A.