RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Serial No. 08/446,442, filed May 22, 1995 and a continuation-in-part of U.S. application Serial No. 08/510,287 filed August 2, 1995.

TECHNICAL FIELD

The present invention relates to a novel method and apparatus for use of microwave energy to provide a pressure heating vessel. In a preferred embodiment, the invention relates to a novel apparatus and method for sterilizing medical waste.

BACKGROUND OF THE INVENTION

The present invention relates to a microwave apparatus and method for heating materials, objects, liquids or the like under pressure. In one aspect, the invention can be used for the sterilization of medical wastes by means of microwave energy used to generate sufficient heat and pressure to sterilize. While the invention will be described in relation to the preferred embodiment tailored for medical wastes, it will be apparent that it is suitable for a wide range of applications.

Medical waste is infectious refuse that can transmit a wide variety of diseases. Generators of medical waste include hospitals, doctors' offices, clinics, dental offices, laboratories, research facilities, nursing homes, and funeral parlors. As medical costs rise, an ever increasing number of long term illnesses are being treated at home, the result of which is medical waste mixed with ordinary household trash. Additionally, the quantity of medical waste has dramatically increased in recent years due to the expanded use of disposable, rather than reusable, products.

In many jurisdictions, the definition of medical waste has been broadened to include an ever widening variety of materials. The Center for Disease Control has issued recommended procedures whereby any material that comes into contact with any patient's body fluids be treated as if it were infectious. Examples of such waste include bandages, gloves, tubing, syringes, laboratory cultures, and pathological wastes. Furthermore, in response to an increase in illegal medical waste disposal, most states have issued statutes and regulations on the handling of medical waste from large and small scale

generators. In addition, the federal Medical Waste Tracking Act created a lifetime tracking system for infectious waste. Before sterilized waste can be disposed of as non-infectious, it must be rendered non-recognizable compared to its original form.

Typically, waste which is generated is isolated in special sealed containers until it can be treated. Except for chemical treatment, all infectious bacteria, viruses and organisms are normally destroyed by some form of heat. The most widely used forms of heat treatment are autoclaving, i.e., sterilization with steam, and burning at specially equipped incineration sites. Both retrofitting existing hospital incinerators and building new environmentally acceptable incinerators are extremely costly alternatives, while conventional autoclaving is often too slow and costly. Conversely, on site treatment greatly reduces disposal costs because the material need not be treated as hazardous. A rapid, on-site, low cost treatment for sterilizing or otherwise treating medical waste is, therefore, very desirable.

Sterilization has a number of definitions including those promulgated by the regulating agencies of various jurisdictions and the various definitions adopted by medical research facilities. For purposes of this application, "sterilization" means conditions sufficient to obtain a log 10 ⁶ reduction of the spore forming bacteria, bacillus stearothermophilus. The description contained herein is of an apparatus and method which will achieve that standard. Obviously the apparatus and method can also achieve lower standards. For purposes of this application, "disinfection" means any treatment not meeting the requirements of sterilization.

The generally acknowledged most reliable method of

sterilization is autoclaving, which entails the heating of items to at least about 212°F in a steam saturated atmosphere for periods of time ranging from about ten minutes to one day or more. Pressurized steam sterilization of instruments by autoclaving has been done by hospitals and medical offices for many years. However, large scale sterilization of medical waste is possible only if steam is able to penetrate voluminous waste for a sufficient time at a sufficient pressure and temperature to effect essentially complete sterilization of the wastes no matter what its location within the larger container. To this end, a pressure vessel is required in order to achieve sterilization as opposed to a vessel which is open to normal atmospheric conditions. After autoclaving or incineration which is sufficient to sterilize waste, residues can be deposited in landfills.

Another method of sterilization commonly used is dry heat. However, dry heat sterilization requires a lengthy period of heating. Other sterilization methods successfully used in limited situations include chemical vapor sterilization, bacteriocidal chemical treatment, and liquid disinfectant usage.

Recently, an interest has arisen in using microwave energy for sterilization. See, e.g., U.S. Letters Patent Nos. 5,098,665, 5,124,125, 5,213,758, 5,246,674, and

5,223,231. The devices of these patents transmit multimode microwaves. Thus, they are relatively inefficient in transmitting microwave energy to the load to be treated. In addition, these devices can only propagate or transmit the microwaves in a linear fashion.

Thus, there remains a continuing need for a quick, reliable and inexpensive way to locally sterilize infectious waste, and for a device which will permit the

use of microwave energy in a large pressure vessel. The present invention answers these needs and has the following advantages:

(a) it allows a more efficient use of microwaves to treat a large pressure vessel;

(b) it increases the energy efficiency of microwave ovens;

(c) it provides, in the sterilization embodiment, a device which can produce sufficient heat to sterilize throughout the entire volume of waste;

(d) it provides, in the preferred sterilization embodiment, a compact apparatus that does not require drains;

(e) it provides an automatic control of processing; and

(f) it provides a apparatus highly efficient in transmitting energy to the containment vessel.

OBJECTS OF THE INVENTION It is an object of the invention to provide a microwave waste sterilizer that is highly efficient in the use of the microwave energy which is broadcast.

It is further an object of the invention to provide a microwave waste sterilizer that allows waste containers used in the sterilization process to be reused.

It is still further an object of the invention to provide a microwave sterilization process that can recycle the moisture added and condensate formed during the process. It is even further an object of the invention to provide a microwave sterilization process that generates all necessary pressure internally, thus eliminating cold spots.

It is yet another object of the invention to provide a process of introducing microwave energy into a chamber in a uniform and dispersed pattern.

SUMMARY OF THE INVENTION

The present invention relates to a pressure vessel utilizing microwave energy. The vessel includes a first wall member defining a first portion of the pressure vessel and a second wall member defining a second portion of the pressure vessel. The first and second pressure hulls are releasably and sealably closable. At least one of said walls has a portion thereof constructed of a material substantially transparent to microwaves. The apparatus further comprises a coaxial microwave generating assembly operatively positioned adjacent to the portion of the pressure hull which is substantially transparent to microwave energy to provide for the transmission of coaxial microwaves into the pressure vessel. In one embodiment of the invention there is provided a microwave waste sterilizer comprising an upper outer shell, a lower outer shell, an upper means for guiding microwave energy connected to the upper outer shell, a lower means for guiding microwave energy connected to the lower outer shell, an upper means for dispersing microwave energy connected to the upper means for guiding microwave energy, a lower means for dispersing microwave energy connected to the lower means for guiding microwave energy, and a clamp releasably holding the upper outer shell and the lower outer shell together.

In another aspect, the present invention relates to a pressure vessel which is releasably and sealably closable and which has at least one portion made from a material substantially transparent to microwaves which defines a passageway therethrough. Adjacent to said microwave transparent portion of the pressure vessel is a coaxial microwave generating assembly having a magnetron, waveguide and linear element extending from the output end

of the waveguide. The coaxial microwave generating assembly is positioned operatively adjacent to the portion of the pressure hull which is transparent to microwave energy such that the linear member passes through the passageway of the substantially transparent material. In the preferred embodiment, the linear member defines a passageway through which fluids such as water may be injected into the pressure vessel. In a preferred embodiment, a conical member is attached to the outside of the linear element such that the base of the cone is adjacent to the end of the linear element extending into the pressure vessel. Further, in this preferred embodiment, the pressure vessel hull, or a liner provided therein, is shaped in a parabolic form. The cone and parabola are tuned such that a coaxial microwave field is established in the majority of the pressure vessel.

The invention also relates to providing a pressure vessel as described above in which a nozzle is attached to the end of the linear element extending into the pressure vessel to permit emission of a spray of water into the vessel. Preferably the spray pattern is tuned such that small droplets of water are thrown into the path of the microwaves entering the unit, are heated and are flashed to steam. It is preferred that the specific spray pattern be selected such that it optimizes the heating of the injected water by the microwaves.

In another aspect, the present invention relates to an apparatus suitable for the sterilization of waste material. The apparatus comprises a pressure vessel which is releasably and sealable closeable. The pressure vessel has an upper portion having at least one section made of a material substantially transparent to microwave energy, said material defining a passageway therethrough. The

lower portion of the pressure hull has a second section of material substantially transparent to microwave energy, said material defining a passageway therethrough. Within the lower portion of the pressure vessel is a floor made of material substantially transparent to microwave energy. Positioned in operative association with the substantially transparent microwave portions of the pressure hull are coaxial microwave generating assemblies. These coaxial microwave generating assemblies include a linear element around which the microwaves can couple and thereby form a coaxial microwave. The linear elements extending from the coaxial microwave generating assemblies pass through the passageways of the substantially microwave transparent material forming portions of the pressure hull. In the preferred embodiment, at least one of said linear elements defines a passageway through which water may be injected into the pressure vessel. In a preferred embodiment, at least one of the linear elements defines a passageway allowing the drainage of condensate and steam therethrough. At the second end of said drainage or outlet passageway is a flash chamber to flash steam to a condensate. The flash chamber has two exit conduits. One to a filter which exhausts to the atmosphere and the other a drain conduit for liquid which is connected to a liquid storage reservoir.

In another aspect, the present invention relates to a coaxial microwave generating assembly comprising a waveguide having a first and second end, and a magnetron adjacent to the first end for generating microwave energy. The waveguide defines an axis and at said second end of said waveguide is a linear element adjacent to said second end which is coaxial with the axis of a waveguide. In the preferred embodiment, the invention relates to a coaxial

microwave generating assembly having a "t" shaped waveguide with a main waveguide section having a first and second end. Proximate to the first end thereof is a magnetron for generating microwaves. At the second end of the main waveguide section are a first reflective waveguide section and an output waveguide section each defining an axis. The axes of the first reflective waveguide section and the output waveguide section are perpendicular to the axis of the main waveguide section. The axes of the first reflective waveguide section and the output waveguide section are preferably coaxial. Adjacent to the first reflective waveguide section and output waveguide section is a second reflective waveguide section defining an axis. Preferably the axis of the second waveguide section is coaxial with the axis of the main waveguide section.

Passing through the waveguide's output portion is a linear member having an axis, and said axis being coaxial with the axis of the output waveguide. In the preferred embodiment, this linear member is a conduit defining a passageway through which liquids such as water may be injected through the coaxial microwave generating assembly.

In another embodiment of the invention there is provided a method for sterilizing waste materials. The method comprises placing waste materials in a reusable plastic waste container, placing the waste container in a microwave waste sterilizer, broadcasting an upper magnetron and a lower magnetron simultaneously so as to generate microwaves within the microwave waste sterilizer to heat the microwave waste sterilizer in the presence of water to a predetermined pressure, maintaining the pressure for a predetermined time period, stopping the

generation of microwaves, releasing the pressure until near atmospheric conditions exist within the microwave waste sterilizer, opening the waste sterilizer; and removing the waste container. In yet another embodiment of the invention there is provided a method for dispersing microwave energy into a chamber. The method comprises broadcasting microwave energy across a chamber, reflecting the microwave energy from a surface of the chamber, coupling the microwave energy onto a means for coaxial guidance, changing a first direction of flow of the microwave energy to a second direction of flow substantially parallel to the means for coaxial guidance, propagating the microwave energy in the second direction of flow within a means for guiding microwave energy, splitting the microwave energy in a means for dispersing microwave energy, and creating a flux field of substantially uniform flux.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more readily understood from the following drawings together with the detailed description. The drawings are not restrictive of the invention, but rather, illustrative.

FIGURE 1 is a simple cross sectional view of the components of one embodiment of the apparatus of the present invention.

FIGURE 2a is an isolated cross-sectional view of the coaxial microwave generating assembly. FIGURE 2b is an end view of a waveguide section.

FIGURE 3 is a schematic showing the relationship between the microwave pressure vessel and the remaining components of the present invention. FIGURE 4 is a simple cross sectional view of the conically shaped member.

FIGURE 5a is a flow chart illustrating the operation of the present invention. FIGURE 5b is a flow chart illustrating the operation of a preferred embodiment. FIGURE 6 is an electrical block diagram of the preferred controller.

FIGURE 7 is a diagram of the Operator Interface Unit.

FIGURE 8 is a cross-sectional view showing another embodiment of the sterilizer as assembled. FIGURE 9 is an exploded view of the upper sections.

FIGURE 10 is an exploded view of the lower sections.

FIGURE 11 is a cross-sectional view of the upper sections as assembled.

FIGURE 12 is a cross-sectional view of the lower sections as assembled.

FIGURE 13 is a cross-sectional view of the upper outer shell.

FIGURE 14 is a cross-sectional view of the lower

outer shell.

FIGURE 15 is a cross-sectional view of another embodiment of the waveguide and magnetron.

FIGURE 16 is a cross-sectional view of the upper z- neck.

FIGURE 17 is a cross-sectional view of a conic support.

FIGURE 18 is a cross-sectional view of a collar.

FIGURE 19 is a cross-sectional view of an upper inner liner.

FIGURE 20 is a cross-sectional view of a deflection cone.

FIGURE 21 is a cross-sectional view of a lower z- neck. FIGURE 22 is a cross-sectional view of a lower dielectric disc.

FIGURE 23 is a cross-sectional view of an adaptor.

FIGURE 24 is a cross-sectional view of a lower inner liner. FIGURE 25 is a cross-sectional view of a lower deflector.

FIGURE 26 is a sectional view of the inside surface of a parabolic shaped bell, depicting a curvature of the inside surface.

DETAILED DESCRIPTION

Referring now in detail to the drawings and particularly to FIGURE 1 there is shown an apparatus useful, e.g., for the generation of steam and pressure by microwave energy.

The apparatus, comprising microwave pressure vessel 10, has a pressure hull (shell) 12 defining a volume. The hull 12 has upper and lower portions, 12a and 12b respectively, which are movable with respect to one another such that the hull 12 may be opened and closed. Within hull 12 is a liner 14, which, in the preferred embodiment, has two portions 14a and 14b attached to hull portions 12a and 12b, respectively. Openings or passageways 16 are provided in the liner 14 to provide communication between the space or volume 18 located between the liner 14 and the hull 12. The liner 14 preferably has a predetermined shape to improve efficiency and to focus the microwave energy as will be discussed below. While the liner 14 is preferred, it is not necessary. The pressure hull 12 may be used alone since it may be of any shape including the predetermined shape of the liner 14. However, manufacture of a pressure hull in the predetermined shape of the liner is expensive. Thus, it is preferred to use a hull of standard pressure vessel type and to attach thereto a liner of predetermined shape to promote the highest efficiency. Suitable latches (clamps) 28 are provided to hold the upper hull 12a and the lower hull 12b together so that pressure can be contained within the vessel 10. The hull 12 or liner 14 defines a treatment chamber

20 adapted to receive a container 26, which is substantially transparent to microwave energy, for holding materials, objects, liquids and the like. Operatively

associated with the hull 12 is a microwave generating assembly 30 for generating and transmitting microwaves into the treatment chamber 20. A controller 68 (Fig. 3) can be provided for regulating the source of microwaves. The apparatus of the invention is configured for the co¬ axial transmission of microwaves into the treatment chamber 20 and their single mode distribution into the material to be treated. Preferably, the pressure vessel uses liner 14 to aid in the formation, transmission and utilization of coaxial microwaves in the treatment chamber 20 and their single mode distribution into the chamber where they impinge on the material to be treated.

Preferably, the apparatus comprises a treatment chamber 20 defined by a upper hull 12a and a lower hull 12b, which, when sealed, form a cylindrical body that narrows, preferably in a parabolic arch, to a cylindrical neck 22 at either end of the apparatus. As illustrated in FIGURE 1, the parabolic arch is configured from the liner 14. The openings of the necks are sealed with a material capable of acting as a barrier seal to contain pressure and steam, yet which is substantially transparent to microwaves, i.e., a material which allows microwave energy to pass through with acceptable loss. Preferably, the necks are sealed with a polytetra-fluoroethylene Teflon dielectric disk 24 of sufficient thickness to contain the desired amount of pressure. A Teflon disk of about 1 inch in thickness has been found sufficient to contain pressures up to 22 pounds per square inch gauge.

Operatively associated with the neck of the upper hull 12a is a microwave generating waveguide assembly 30 communicating with the treatment chamber 20. This waveguide assembly is comprised of a microwave generator 32 and a waveguide 34. Preferably the microwave generator

32 is a magnetron capable of generating microwave energy. More preferably, it is a magnetron capable of operating at 2450 megahertz, a standard frequency which is readily available. The waveguide 34 comprises at least one rectangular waveguide section. In the preferred embodiment, arranged within the waveguide are tuning members 36 used to tune the microwaves to achieve maximum output. Most preferably, three tuning members 36 are provided. Referring now to Figure 2, the preferred microwave generating assembly is shown (like numbers in the drawings refer to like elements) . The waveguide 34 is "t" shaped and has a main waveguide section 34a with the microwave generator 32 adjacent to the first end. At the second end of the main waveguide section are an output waveguide section 34b having an axis perpendicular to the axis of the main waveguide section and a first reflective waveguide section 34c positioned at the second end of the main waveguide 34a opposite to and coaxial with the output waveguide 34b. A second reflective waveguide section 34d, positioned adjacent to the first reflective waveguide section 34c and output waveguide section 34b, is coaxial with main waveguide section 34a. Linear member 38 (described below) passes through the waveguide coaxially with the axis of the output waveguide section 34b.

Each waveguide section preferably has the same cross section. The waveguide cross section is preferably selected such that one dimension "w" is the length of a full wave and another dimension "h" is the length of half a wavelength, as shown in Figure 2b. The exact dimensions of the waveguide sections depend on the wavelength of the microwaves utilized. At a wavelength of 2450 megahertz the waveguide sections are preferably 4.84 inches in width

and 2.42 inches in height.

Referring still to Figure 2, an adjustable reflector or tuning member 36 is provided in the main waveguide section 34a, first reflective section 34c and second reflective waveguide section 34d. Each is provided with an adjustment device, such as a screw 37. Microwaves emitted from the generator 32 are propagated in both directions in the main waveguide 34a. Waves traveling towards the first end of the main waveguide section 34a impact on the reflector 36 and reflect back towards the linear element 38. The reflector 36 is adjusted such that the reflected waves are in harmony with waves originally propagated in the direction of the linear member 38. As the waves reach the linear member 38 some couple to it and travel coaxially along its length. Waves which do not couple with the linear member are reflected back towards the linear member by the reflector 36 in the second reflective waveguide section 34d. Waves which couple to the linear member 38 travel in both directions along the linear member 38. Those traveling away from the output waveguide section 34b are reflected back towards the output waveguide section 34b by the reflector 36 in the first reflective waveguide section 34c. The waveguide can be sealed with a Teflon dielectric disk 100 or other material transparent to microwaves.

Referring again to Figure 1, traversing the waveguide 34 of the microwave generating assembly 30 and seal 24 of the upper hull 12a and projecting into the treatment chamber 20 is a linear member 38 capable of the coaxial transmission of microwaves as described above into the treatment chamber 20. Connected near the lower apical end of the linear member 38 is a conically shaped member 42. The tuning members or reflectors 36 are positioned such

that they focus the microwaves emitted by the microwave generator 32 onto linear member 38 where the waves associate (or couple) with the linear member 38 in a coaxial fashion and are propagated through the sealing disk 24 into the treatment chamber 20 in a co-axial fashion along the length of the linear member 38.

Secured to the lower hull 12b defining the treatment chamber is a floor member 40. Preferably the floor member 40 is a disk substantially transparent to microwaves pierced by a plurality of vents 44 that communicate with drain conduits 47 which are connected to an outlet conduit 46 located beneath the floor member 40 and traversing the seal 24 of the cylindrical neck 22 of the lower hull 12b. Located within the outlet conduit 46 is a sensor 48 capable of measuring the pressure within the treatment chamber 20. To contain the pressure and steam within the treatment chamber 20, a valve 66 is attached to the outlet conduit 46. Referring to Figure 3, the sensor 48 and valve 66 are operatively connected to a controller 68 capable of evaluating the signal generated by the sensor 48 and, in response thereto, regulating the release of steam and pressure from the treatment chamber 20. The controller can also be operatively connected to the microwave generator(s) 32 and can regulate the microwave generator in response to the signal received from the sensor 48.

Referring again to Figure 1, preferably, the outlet conduit 46, divides, after valve 66, into two or more secondary outlet conduits 50, each of which is attached, at its far end to a flash chamber 52. Preferably, the flash chamber 52 is a cylindrically shaped member having an input end 54, an output end 56, and a diameter significantly larger than the diameter of the secondary

outlet conduit 50 so as to affect a rapid expansion and cooling of the vented steam. The flash chambers preferably are filled with a material 60, preferably stainless steel wool, capable of promoting condensation and thereby reducing the temperature of the vented gases. After the condensate has been removed the gases exit the container at its output end 56 which is connected to an exhaust conduit 62 communicating with the environment. The gases are preferably passed through a filter 64 capable of trapping noxious gases, preferably a charcoal filter, before they are released into the atmosphere. Flash chamber 52 also has a condensate outlet 68 communicating with a storage chamber or holding tank 70. (See Figure 3) . The microwave generating assembly 30, conically shaped member 42, pressure vessel 10, and the linear member 38 are configured such that the microwaves are transmitted into the treatment chamber 20 along the linear member 38 in a coaxial fashion, then along the outside of the conically shaped device 42 until they reach its periphery and then are transferred to the inside of the chamber.

In order to efficiently utilize the co-axial microwave energy moving along linear member 38 it is necessary to decouple that energy from the linear member 38 and to spread it out. The inventors, while not being bound to any theory of operation, believe that the conically shaped device 42 helps decouple the coaxial wave from the linear member 38 and cause it to widen out and travel coaxially into the chamber 20. It has been found that if conical member 42 is hollow it operates better. It is also believed that the conical member 42 may be acting as a capacitor which, upon discharge, emits a

broad, uniform, single-mode microwave field into the material to be treated. Thus, while a linear member 38 alone, without conical device 42, may be useful in chambers of small diameter, the cone 42 has been found to be useful in chambers with a diameter which is more than 10 diameters of the linear member. These elements, however, should be tuned for the particular shape of each individual unit. It has been determined that a parabolic reflector disposed about the linear member improves efficiency. The initial parabola shape can then resolve into a general cylindrical shape. As shown in Figure 1 the appropriate configuration can be provided by the liner 14, or, alternatively, the pressure hull 12 may be shaped as desired and the liner deleted. The base of the cone should be in the vicinity of a plane passing through ends the narrower portion of the parabola.

It has been found that a ratio representing the base of the cone to the maximum diameter of the parabolic reflector can effectively be used in the range of about 1:3 to about 7:12. The angle forming the apex of the cone has been found to be useful between 30° and 90°. The length of the cone generally should be about 40 to 60% of the length of the parabola. Preferably the cone is an isosceles cone where the apex angle is 60°. Figure 4. Much of the specific shapes and tuning for each individual vessel shape adopted is determined by experimentation. One can experimentally determine the shape of the microwave exiting the end of the linear member 38 by taking a number of shallow trays of Bisquick mix, placing them in the unit and then subjecting them to microwaves. The pattern of cooked and uncooked dough in each layer will allow one to visualize where the microwaves are being concentrated. One can determine the appropriate cone

shape by observing the pattern of baking in the Bisquick mix. When the unit is suitably tuned, the Bisquick trays will exhibit concentric rings where material is more thoroughly baked with interposed rings of lesser baking. In the preferred embodiment, associated with the neck

22 of the lower hull 12b is a second microwave generating assembly 30 communicating with the treatment chamber 20 and comprising a microwave generator 32 and a waveguide 34. Preferably, the second microwave generating assembly 30 is of the same type and construction as the upper microwave generating assembly.

Traversing the waveguide of the second microwave generating assembly 30 and the seal 24 of the lower hull 12b is the outlet conduit 46. Connected near its apical end is an inverted, conically shaped member 42.

The tuning members or reflectors 36 of the second microwave generating assembly 30 are positioned such that they focus the microwaves emitted by the microwave generator 32 onto outlet conduit 46 whence the waves associate (or couple) with outlet conduit 46 and are propagated through the sealing disks 24 into the treatment chamber 20 in a co-axial fashion along the length of the outlet conduit 46. Drain conduits 47 are preferably made from a material substantial transparent to microwaves so as not to disrupt the energy pattern associated with outlet conduit 46.

The microwave generating assemblies 30, conically shaped members 42, pressure vessel 10, linear member 38 and the outlet conduit 46 are configured such that the microwaves are transmitted into the treatment chamber 20 along the linear member 38 and the outlet conduit 46 in a coaxial fashion, then along the outside of the conically shaped devices 42 until they reach their periphery and

then are transferred to the inside of the chamber 20. To maximize efficiency it is preferred that the microwaves transferred into the treatment chamber 20 by the liner member 38 and outlet conduit 46 be noninterfering. Non-interfering microwave fields are achieved by tuning the waves as described above.

To generate steam, water can be added to the treatment chamber with the material, object, liquid or the like to be treated. Preferably, linear member 38 is a liquid injection conduit through which water or other liquids can be introduced into treatment chamber 20. Preferably, the water is sprayed into the chamber 20 by nozzle 72 located at the lower apical end of the liquid injection conduit (linear member 38) . Referring now to Figure 3, water is supplied to the liquid injection conduit 38 by a water inlet conduit 74. The water supplied to the liquid injector unit is regulated by a valve 76 located between the liquid injector unit 38 and a conventional source of water (not shown) . An additional source of water is the condensate located in holding tank 70. Preferably, holding tank 70 is in fluid communication with the water inlet conduit 74. Water is recycled by moving it from the holding tank to the water inlet conduit 74 by a pump 84. Located between the holding tank and water inlet conduit is a valve 78 for regulating the flow of recycled water into the water inlet conduit. In the sterilization of medical wastes, water is injected into the path of the microwaves to generate steam and heat until a pressure of about 22 psi (gauge) is reached as measured by the pressure sensor 48 located within outlet conduit 46.

To efficiently generate steam in those applications where steam is desired, water should be sprayed into the

path of the microwaves such that the water is heated and flashed to steam. The heating is affected by the amount of water added, the length of the spray duration and the interval between water injection. By plotting pressure and temperature against time for various cone configurations one can determine the cone angle that achieves the best heating. By varying the length of each injection and the interval between injection, one can determine the optimum conditions for injection. It has been found that the injection of about 4 cups of water by injection of water for about 30 seconds 10 times over 10 minutes gives good results for the preferred embodiment described below.

It has also been found that the path of the injected water is important to achieve optimum heating and steam generation. It is important to disperse the injected water into the path of the microwaves such that the water is heated and vaporized to steam. This can be easily done experimentally by selecting different spray nozzles and varying the spray pattern in the apparatus. Spray nozzles are available which will emit sprays having different spray angles. By plotting the pressure and temperature against time, one can determine the most efficient spray pattern for a particular unit simply by testing a variety of nozzles and spray shapes. It has been found that a spray angle of between about 60° to 135° is useful. In the preferred embodiment, the spray angle is about 120°.

The sensor 48 is operatively connected to a controller 68 capable of evaluating the signal generated by the sensor. The controller 68 is further operatively connected to the microwave generators 32 and valves 66, 76, and 78, and capable of regulating them in response to the signal from the sensor. The controller is also

connected to pump 84, and motors 80 and 82. Motor 82 is connected to an apparatus to raise and lower the upper portion of the pressure vessel. Motor 80 drives the mechanism to operate latches 28. Any conventional means to raise and lower the pressure hull 12 and to engage and disengage the latches 28 may be employed. Although the unit may be operated manually, it is preferred that it be controlled by the controller unit 68 which has been programmed to coordinate the functioning of the unit. Processing starts with the vessel open. Waste is placed in the vessel preferably within waste container 26. Once the apparatus is started, the controller initiates first motor 82 to lower the top of the vessel to the closed position and then motor 80 to close latches 28. The controller then closes valve 66, opens valve 78, and/or valve 76 and activates pump 84 and the microwave generator(s) 32. Further operation of valve 78 and/or valve 76 and pump 84 is preferably controlled by the program in the controller. Figure 5a shows a flow diagram of the controller processor. The controller receives the pressure signal, which is correlated to the temperature within the vessel 10, from sensor 48 and compares that signal to a pressure set point. Thus, the setpoint pressure is selected on the temperature desired within the vessel. One may also add a temperature monitor if so desired. Since the pressure measured is gauge pressure, at different altitudes different gauge pressures may be required to achieve the same temperature within the vessel. Generally it has been found that when the atmospheric pressure is around 14.7 that a gauge pressure of 22 psi will correspond to a temperature in the range of about 268°F to about 275°F in the vessel. This temperature is sufficient to achieve

sterilization in the preferred embodiment. After comparing the pressure signal to the setpoint the controller 68 opens the water supply and turns on the microwave generator(s) 32. Preferably, the initial water is supplied from reservoir 70. Once reservoir 70 is emptied, the controller preferably shuts down pump 84, closes valve 78 and then opens valve 76.

In the event that the pressure exceeds the setpoint the controller 68 then shuts off the water supply, and deactivates the microwave generator(s) 32. Where the water is added by means of the liquid injection conduit 38, a final injection of water may be provided by the controller 68 to slightly cool the load before the water supply is cut off. In the preferred embodiment (Figure 5b) , exceeding the set pressure initiates a timer. The controller 68 continues to monitor the pressure in the vessel and maintains it at a level greater than or equal to the setpoint by initiating and terminating additional injections of water and activating and inactivating the microwave generators 32 as needed. After the desired time has elapsed, the controller shuts off the water supply and the microwaves and interrupts the comparator circuit.

The controller then opens the valve 66 permitting the steam and gases to exhaust from the vessel. Pressure is continually monitored and once it reaches a set pressure the vessel may be open. Motor 80 is activated opening claims 28 and thereafter motor 82 is activated to open the pressure vessel.

The controller, illustrated in Figure 6, is preferably a microcomputer and can be, for example, a Programmable Logic Computer (PLC) , model 61200-A120, manufactured by Telemecanique. Operator access to the PLC and the controls of the microwave heating system is

through a control panel, illustrated in Fig. 7, which consists of an Operator Interface Unit with an LCD screen, 10 functions keys and a numeric keypad. The present invention also relates to a process for heating under pressure materials, objects, liquids and the like. In one aspect, the invention is a process for the sterilization of medical wastes. However, it will be apparent that the process is also suitable for a wide range of applications. The process for sterilization of medical wastes involves:

(a) placing medical wastes within a pressure vessel tuned to transmit co-axial and single-mode microwaves;

(b) adding water to wet said medical wastes; and

(c) subjecting said medical wastes to microwave radiation sufficient to generate sufficient steam and pressure for a sufficient time to sterilize said medical wastes.

Alternatively, the medical wastes may be sterilized by: (a) placing medical wastes within a pressure vessel tuned to transmit co-axial and single-mode microwaves;

(b) subjecting said medical wastes to microwave radiation; and

(c) injecting sufficient water into the path of the microwaves to generate sufficient steam and pressure for a sufficient time to sterilize said medical wastes.

A device of the present invention found to be useful has an overall length, measured from the upper seal 24 to the lower seal 24 of the pressure vessel, of about 4 feet. The maximum diameter of the pressure vessel is about 2 feet, with the cone(s) having a base from about 8 to 10 inches in diameter. The base of the cones is about 11 to 12 inches from the seals.

In one embodiment of the invention, with reference to FIGURE 8 - FIGURE 25, there is provided a microwave waste sterilizing 102 for sterilizing items as numerous as infectious medical waste, contaminated food products and animal tissue. The microwave waste sterilizer comprises an upper outer shell 104, a lower outer shell 106, an upper means for guiding microwave energy 108 connected to the upper outer shell 104, a lower means for guiding microwave energy 110 connected to the lower outer shell 106, an upper means for dispersing microwave energy 112 connected to the upper means guiding microwave energy 108, a lower means for dispersing microwave energy 114 connected to the lower means for guiding microwave energy 110, and a clamp 116 releasably holding the upper outer shell 104 and the lower outer shell 106 together.

The upper outer shell 104, shown in FIGURE 13, is generally bell shaped and has an inside surface 118, an outside surface 120, a flanged bottom end 122, a longitudinal axis, and a hole 124 at the apex of the bell shape. The hole 124 is coaxial with the longitudinal axis. The mating lower outer shell 106, shown in FIGURE 14, is generally bowl shaped and has an inside surface 236, an outside surface 238, a flanged top end 240, a longitudinal axis, and a hole 242 at an apex of the bowl shape. This hole 242 is coaxial with the longitudinal axis of the lower outer shell. The flanged ends of the upper and lower outer shells are designed to be held together by the clamp 116 to form a pressure vessel.

FIGURE 9 shows the upper means for guiding microwave energy 108 which comprises a upper coaxial tube (linear element) 126 having an outside surface 128, a first end, a second end 130, an outside diameter, and a longitudinal axis, a substantially rectangular box shaped upper

waveguide, a magnetron 152, a tubular first upper coax 154, a tubular upper conductor plug 160, a tubular second upper coax 162, a substantially can shaped upper z-neck 170, a tubular upper dielectric disc 184, and a funnel shaped conic support 192.

As shown in FIGURE 15, the upper waveguide 132 is a box which has a top plate 134 having an outside surface 136 and a bottom plate 138 having an outside surface 140. The top plate 134 has a first end 142, a second end 144, a first hole 146 between the first end 142 and a center of the top plate and a second hole 148 near the second end 144. The second hole has a diameter smaller than a diameter of the first hole 142. The bottom plate 138 is substantially parallel to the top plate 134 and has a hole 150 of a diameter substantially the same as the diameter of the first hole 146 in the top plate 134. The hole 150 in the bottom plate 138 is oriented in axial alignment with the first hole 146 in the top plate 134. The magnetron 152 is connected to the top plate 134 of the upper waveguide 132 at the second hole 148 so that waves produced by the magnetron 152 are broadcast within the rectangular box shaped upper waveguide. A magnetron identical to one used in a standard household microwave may be successfully used. Magnetrons varying from 300 watts to 3000 watts have been installed; however, a 1400 watt magnetron, such as model 2MI21A-53 from Richardson Electronics Ltd., has been used with good results. In a preferred embodiment, the upper wave guide 112 also has a first movable end block (tuning member) 318 and a second movable end block (tuning member) 320. Each movable end block has the characteristic of a tuning short to help tune the microwaves being broadcast.

The first upper coax 154 has a first end 156, a

second end 158, an inside surface defining a diameter substantially the same as the diameter of the first hole 146 in the top plate 134 of the upper waveguide 132, and a longitudinal axis. The first end 156 is connected to the outside surface 136 of the top plate 134 so that the longitudinal axis is co axial with the first hole 146 and the first upper coax 154 is in covering relationship to the first hole 146. A welded connection has proved successful, although other attachment means could be used. The upper conductor plug 160 has a first end, a second end, an outside diameter substantially the same as the inside diameter of the first upper coax 154, an inside surface defining a diameter substantially the same as the outside diameter of the upper coaxial tube 126, and a longitudinal axis. The upper conductor plug 160 is closely received by the second end 158 of the first upper coax 154. In a preferred embodiment, the upper plug may be adjusted up and down within the first coax, thus allowing the conductor plug to function as a tuning short. The first upper coax and upper conductor plug help direct and turn the microwave energy from the upper waveguide to the upper coaxial tube.

The second upper coax 162 has a first end 164, a flange end 166, an inside surface 168 having a diameter substantially the same as the diameter of the hole 150 in the bottom plate 138 of the upper waveguide 132, and a longitudinal axis. The flange end 166 is substantially ring shaped and has a generally cylindrical inside surface coincident with the inside surface 168 of the second upper coax 162. The first end 164 is connected to the outside surface 140 of the bottom plate 138 so that the longitudinal axis is coaxial with the hole 150 and the second upper coax 162 is in covering relationship to the

hole 150. A welded connection has proved effective.

FIGURE 16 shows the upper z-neck 170 witch has a top end 172, a flange end 174, a generally tubular sidewall 176 having an outside surface 178 connecting the top end 172 and the flanged end 174 and an inside surface 180 having a diameter greater than the diameter of the second upper coax 162, and a longitudinal axis. The top end 172 has a hole 182 coaxial with the longitudinal axis. This hole 182 has a diameter substantially the same as the diameter of the inside surface 168 of the second upper coax 162. The flange end 174 is substantially ring shaped and has a generally cylindrical inside surface coincident with the inside surface 180 of the upper z-neck 170. The top end 72 is connected to the flange end 66 of the second upper coax 62. A bolted attachment has proved successful. The flange end 174 is connected to the outside surface 120 of the upper outer shell 104 in covering relationship to the hole 124 in the apex of the upper outer shell 104. Again, a bolted attachment has proved successful. The upper z-neck and second upper coax help to direct the microwave energy towards the upper means for dispersing microwave energy.

The upper dielectric disc 184 has a first end 186, a second end 188, an outside diameter, a longitudinal axis, and an inside surface defining a diameter 190 substantially the same as the outside diameter of the upper coaxial tube 126. The conic support, shown in FIGURE 17, has an inside surface defining a diameter substantially the same as the outside diameter of the upper coaxial tube 126, a top surface 194 which has an outside diameter smaller than the outside diameter of the upper dielectric disc 184, a bottom surface 196 which has an outside diameter smaller than the outside diameter of

the top surface 194, and a longitudinal axis. The top surface 194 is connected to the second end 188 of the upper dielectric disc 184 by use of an adhesive such as silicon chalk. The upper dielectric disc 184 and the conic support 192 need to have the characteristic of being substantially transparent to microwaves, thus functioning as windows. It has been found that virgin polytetrafluorethylene works well with the type microwaves being broadcast. The longitudinal axes of the upper shell 104, upper coaxial tube 126, first upper coax 154, upper conductor plug 160, second upper coax 162, upper z-neck 170, dielectric disc 184, and conic support 192 are all coaxial. Further, the upper coaxial tube 126 extends through the upper conductor plug 160, first upper coax

154, upper waveguide 132, second upper coax 162, upper z- neck 170, upper dielectric disc 184 and conic support 92. The upper coaxial tube, upper waveguide, first upper coax, upper conductor plug, second upper coax, and upper z-neck are made from a microwave friendly material, such as silver, nickel or aluminum. Aluminum is preferred for ease of fabrication and cost.

The upper means for dispersing microwave energy 112, also shown in FIGURE 9, comprises a generally ring shaped collar 198, an upper liner 204, a hollow deflection cone 226, and a tubular upper deflector collar 234. The collar, shown in FIGURE 18, has a first end 200, a second end 202, an outside diameter, a first generally cylindrical inside surface 402 having a first inside diameter adjacent to the first end 200, a second generally cylindrical inside surface 404 having a second inside diameter which is smaller than the first inside diameter, a first annular shoulder 406 joining the first generally

cylindrical surface 402 with the second generally cylindrical 404 surface, a third generally frustoconically shaped inside surface 408 adjacent to the second end and converging from the second end 202 toward a longitudinal axis of the collar 198 at an angle of about 5 degrees, and a second annular shoulder 410 joining the second generally cylindrical surface 404 with the third generally frustoconically shaped inside 408. The first inside diameter is substantially the same as the outside diameter of the upper dielectric disc 184 so as to closely receive the upper dielectric disc 184. The second inside diameter is substantially the same as the diameter of the hole 182 in the top end 172 of the upper z-neck 170. The second inside diameter and the frustoconically shaped inside surface 408 are larger than the outside diameter of the conic support 192. The outside diameter of the collar is smaller than the diameter of the inside surface 180 of the upper z-neck 170 so that the upper dielectric disc 184, conic support 192 and collar 198 all nest within the upper z-neck 170. The collar is preferably made from aluminum.

FIG 19 shows the upper liner which has a longitudinal axis and comprises a parabolic shaped bell portion 206 having a first end 208 having an inside diameter, a second end 210 having an inside diameter larger than the inside diameter of the first end 208, an inside surface 212, and an outside surface 214, and a tubular shaped extension portion 216 having a first end 218 connected to the second end 210 of the parabolic shaped bell portion 206, a second flanged end 220, an inside surface 222, and an outside surface 224. The parabolic shape depicted in FIGURE 26 has been used with good results. The outside surface 214 of the parabolic shaped bell portion 206 at the first end 208 is connected to the third generally frustoconically

shaped inside surface 408 of the collar such that the upper dielectric window is substantially on top of the bell portion in covering relationship to the first end and the conic support is within the bell portion at the first end. The second flanged end 220 of the extension portion 216 nests against the flanged bottom end 122 of the upper outer shell 104. The flanged end is designed to not only provide a pressure seal when the system is clamped together, but to provide an RF energy seal for the system. The outside 214, 224 of the parabolic shaped bell portion 206 and the tubular shaped extension portion 216 of the upper inner liner 204 are adjacent to the inside surface 118 of the upper outer shell 104. In a preferred embodiment, the upper liner is constructed from aluminum and the parabolic bell shaped portion is formed by spinning. The parabolic shaped bell portion and the extension portion may be made from a single piece, however, it has been found easier to fabricate the portions as separate parts and then weld them together. The upper deflection cone 226, shown in FIGURE 20, has a truncated first end 228, a second end 230, a longitudinal axis, and an outside surface 232 converging from the second end 230 towards the first end 228 at an angle between 45 degrees and 55 degrees. The truncated first end 228 has an inside diameter substantially the same as the outside diameter of the upper coaxial tube 126 and the cone is attached to the outside surface 128 of the upper coaxial tube 126 at the truncated first end 228 at a position between the collar 198 and the second end 230 of the deflector cone 226. A welded attachment has proved successful. It is preferred that the cone be placed in position such that the second end 230 and the bottom of the parabolic shaped bell portion are contained in the

same plane. The outside surface 232 of the deflection cone 226 is adjacent to the inside surface 212 of the parabolic shaped bell portion 206. The deflection cone, like the upper liner, is preferably fabricated from aluminum.

The upper deflection collar, otherwise known as a "donut" has a first end, a second end, an outside diameter substantially smaller than an inside diameter of the second end 230 of the deflection cone 226, an inside surface having a diameter substantially the same as the outside diameter of the upper coaxial tube 126, and a longitudinal axis. The inside surface is connected to the upper coaxial tube 126 near the second end 130 of the upper coaxial tube 126 such that a plane which contains the second end 230 of the deflection cone 226 passes through the upper deflection collar normal to the longitudinal axis of the upper deflection collar. The upper deflector collar is preferable made from aluminum. While not wishing to be bound to any theory of operation, it is believed that the microwave energy travels down the upper coaxial tube from the upper means for guiding microwave energy into the upper means for dispersing microwave energy, where it is split into three paths, the first being between the upper liner and the deflection cone. The second path is along the inside surface of the deflection cone and the third path is along the upper coaxial tube. The upper deflection collar acts to redirect energy which stands off the second end of the deflection cone. The waves are redirected into the inside of the deflection cone or to the parabolic shaped bell portion of the upper liner.

The longitudinal axes of the upper outer shell 104, upper coaxial tube 126, collar 198, upper liner 204,

deflection cone 226 and upper deflection collar 234 are coaxial. Further, the upper coaxial tube 126 extends through the collar 198, parabolic shaped bell portion 206, deflection cone 226 and upper deflection collar 234. FIGURE 7 shows the lower means for guiding microwave energy 110. Similar to the upper means for guiding microwave energy, the lower means for guiding microwave energy comprises a lower coaxial tube 244 having an outside surface 246, a first end 248, a second end 250, an outside diameter, and a longitudinal axis, a substantially rectangular box shaped lower waveguide 252, a magnetron 152', a tubular lower coax 272, a tubular lower conductor plug 278, a substantially can shaped lower z-neck 280, and a generally tubular lower dielectric disc 292. The lower waveguide 252, shown in FIGURE 15, is identical to that described for the upper waveguide, only upside down. There is a top plate 258 having an outside surface 260 and a bottom plate 254 having an outside surface 256. The bottom plate 254 has a first end 262, a second end 264, a first hole 266 between the first end 262 and a center of the bottom plate and a second hole 268 near the second end 264. The second hole has a diameter smaller than a diameter of the first hole 266. The top plate 158 is substantially parallel to the bottom plate 254 and has a hole 270 of a diameter substantially the same as the diameter of the first hole 266 in the bottom plate 254. This hole 270 in the top plate 258 is in axial alignment with the first hole 266 in the bottom plate 254. A magnetron 152' is connected to the bottom plate 254 of the lower waveguide 252 at the second hole 268 so that waves produced by the magnetron 152' are broadcast within the rectangular box shaped lower waveguide 252. The lower magnetron is similar to the upper magnetron. When

energized, the upper and lower magnetrons are set to broadcast at least 120 degrees out of phase with each other. In a preferred embodiment the lower wave guide 252 also has a first movable end block 322 and a second movable end block 324. Each movable end block functions as a tuning short.

The lower coax 272 has a first end 274, a second end 276, an inside surface defining a diameter substantially the same as the diameter of the first hole 266 in the bottom plate 254 of the lower waveguide 252, and a longitudinal axis. The first end 272 is connected to the outside surface 256 of the bottom plate 254 so that the longitudinal axis is coaxial with the first hole 266 and the lower coax 272 is in covering relationship to the first hole 266. A plate may be attached to the first end to act as a stiffener. If used, the plate must have a hole substantially the same as the inside diameter of the lower coax. A lower conductor plug 278 is used in association with the lower coax. The conductor plug has a first end, a second end, an outside diameter substantially the same as the inside diameter of the lower coax 272, an inside surface defining a diameter substantially the same as the outside diameter of the lower coaxial tube 244, and a longitudinal axis. The lower conductor plug 278 is closely received by the second end 276 of the lower coax

272. In a preferred embodiment, the position of the lower conductor plug is adjustable within the lower coax so that the lower conductor plug functions as a tuning short. The lower coax and lower conductor plug help direct and turn the microwave energy from the lower waveguide to the lower coaxial tube.

FIGURE 21 shows the lower z-neck 280 which has a bottom end 282, a flange end 284, a generally tubular

sidewall 286 having an outside surface connecting the bottom end 282 and the flanged end 284 and an inside surface 288 having a diameter greater than the diameter of the hole 270 in the top plate 258 of the lower waveguide 252, and a longitudinal axis. The bottom end 282 has a hole 290 coaxial with the longitudinal axis. The hole 290 has a diameter substantially the same as a diameter of the hole 270 in the top plate 258 of the lower waveguide 252. The flange end 284 is substantially ring shaped and has a generally cylindrical inside surface coincident with the inside surface 288 of the lower z-neck 280. The bottom end 282 is connected to the top plate 258 of the lower waveguide 252 so that the hole 290 in the bottom end 282 is coaxial with the hole 270 in the top plate 258 and the bottom end 282 is in covering relationship with the hole 270. The flange end 284 is connected to the outside surface 238 of the lower outer shell 106 in covering relationship to the hole 242 in the apex of the bell shape of the lower outer shell 106. A plate may be used between the lower z-neck and the lower waveguide to act as a stiffener. If used, the plate must have a hole substantially the same as the hole in the top plate of the waveguide. The lower z-neck helps to direct the microwave energy towards the lower means for dispersing microwave energy.

The lower dielectric disc 292, shown in FIGURE 22, has a first end 502, a second end 504, a longitudinal axis, a first outside surface 506 adjacent to the first end 502 and having a first outside diameter, a second outside surface 508 adjacent to the second end 504 and having a second outside diameter which is greater than the first outside diameter, a first annular 510 joining the first outside surface 506 and the second outside surface

508, and an inside surface defining a diameter substantially the same as the outside diameter of the lower coaxial tube 244. The lower dielectric disc 292 is positioned in the lower z-neck 280 in covering relationship with the hole 290 in the bottom end 282 of the lower z-neck 280. The lower dielectric disc 292 has the characteristic of being substantially transparent to microwaves, thus functioning as a window. It has been found that virgin polytetrafluorethylene functions well as the dielectric material.

The longitudinal axes of the lower outer shell 106, lower coaxial tube 244, lower coax 272, lower conductor plug 278, lower z-neck 280 and lower dielectric disc 292 are coaxial. Further the lower coaxial tube 244 extends through the lower conductor plug 279, lower coax 272, lower waveguide 252, lower z-neck 280 and lower dielectric disc 292.

The lower waveguide, lower coaxial tube, lower coax, lower conductor plug, and lower z-neck are made from a microwave friendly material such as silver, nickel or aluminum. Aluminum is preferred for ease of fabrication and cost.

The lower means for dispersing microwave energy is shown in FIGURE 12. The system comprises a generally tubular adaptor 294, a lower inner liner 296, and a lower deflector 314. The adaptor 294, shown in FIGURE 23, has a first end 602, a second end 604, a first inside surface 606 adjacent to the first end 602 and having a first inside diameter, a second inside surface 608 adjacent to the second end 604 and having a second inside diameter smaller than the first inside diameter, a first annular shoulder 610 joining the first inside surface 606 and the second inside surface 608, a first outside surface 612

adjacent to the first end 602 and having a first outside diameter, a second outside surface 614 adjacent to the second end 604 and having a second outside diameter smaller than the first outside diameter, a second annular shoulder 616 joining the first outside surface 612 and the second outside surface 614, and a longitudinal axis. The first inside diameter is substantially the same as the first outside diameter of the lower dielectric disc 292 so as to closely receive the lower dielectric disc 292. The second inside diameter is substantially the same as the diameter of the hole 290 in the bottom end 282 of the lower z-neck 280. The first outside diameter is smaller than the diameter of the inside surface 288 of the lower z-neck 280. This allows the lower dielectric disc 292 and the adapter 294 to nest within the lower z-neck 280. The adaptor is preferably made from aluminum.

FIGURE 24 shows the lower liner 296 which is symmetric about a longitudinal axis and comprises a substantially tubular shaped portion 298 and a parabolic shaped bell portion 306 which is connected to the tubular shaped portion at a point of transition. The tubular portion has an inside surface 300, an outside surface 302, and a flanged end 304. The parabolic shaped bell portion has a first end 308 having an inside diameter smaller than an inside diameter of the tubular shaped portion an inside surface 310 and an outside surface 312. The parabolic shape depicted in FIGURE 26 has been used with good results. It has been found beneficial if the point of transition between the tubular portion and the parabolic shaped bell portion is generally a sharp angle near to 90 degrees. The outside surface 312 of the parabolic shaped bell portion 306 at the first end 308 is closely received by the first inside surface 606 of the adaptor 294. The

flanged end 304 of the tubular shaped portion 298 nests against the flanged top end 240 of the lower outer shell 106. As in the upper inner liner, the flanged end is designed to not only provide a pressure seal when the system is together, but to provide an RF energy seal for the system. The outside surfaces 302, 312 of the tubular portion 298 and the parabolic shaped bell portion 306 of the lower inner liner 296 are adjacent to the inside surface 136 of the lower outer shell 106. In a preferred embodiment, the lower inner liner is fabricated from aluminum and is formed by a spinning process.

The lower deflector 314, shown in FIGURE 25, has a first end 702, a second end 704, a first generally frustoconically shaped outside surface 706 adjacent to the first end 702, a second generally frustoconically shaped outside surface 708 adjacent to the second end 704, a third generally cylindrical outside surface 710 connecting the first outside surface 706 and the second outside surface 708, and a longitudinal axis. The first frustoconically shaped outside surface 706 converges away from the first end 702 at an angle of between about 8 degrees and 25 degrees. The second frustoconically shaped outside surface 708 converges away from the second end 704 at an angle between about 8 degrees and 25 degrees, thereby substantially mirroring the first frustoconically shaped outside surface 706. The second end 704 is connected to the second end 250 of the lower coaxial tube 244 such that a common plane passes through the lower deflector and the near 90 degree point of transition between the tubular portion 298 and the parabolic shaped bell portion 306 of the lower inner liner 296. The lower deflector is preferably made from aluminum.

The microwave energy travels up the lower coaxial

tube from the lower means for guiding microwave energy into the lower means for dispersing microwave energy, where it is split info two paths, the first being between the liner and the deflector and the second pith being along the lower coaxial tube. The lower deflector acts to redirect energy which stands off the near 90 degree point of transition between the tubular portion 298 and the parabolic shaped bell portion 306 of the lower liner. The energy is redirected towards the parabolic shaped bell portion and a central area within the lower liner. A nipple 316 may be added to the second end 704 of the deflector 314 to further tune the microwave energy which stands off the inner liner at the near 90 degree point of transition between the tubular portion 298 and the parabolic shaped bell portion 306. The nipple should be cylindrical with a longitudinal axis coaxial with the longitudinal axis of the deflector 314.

The longitudinal axes of the lower outer shell 106, lower coaxial tube 244, adaptor 294, lower inner liner 296 and deflector 214 are coaxial. Further, the lower coaxial tube 244 extends through the adapter 294, parabolic shaped bell portion 306 of the inner liner 298 and deflector 314.

In a preferred embodiment, the microwave waste sterilizer 102 should also include a reusable plastic waste container, a disc shaped support tray 316 positioned to support the waste container within the microwave waste sterilizer 102, a liner heater, and a means for external control. The support tray 318 needs to have the characteristic of being substantially transparent to microwaves. A disc made from virgin polytetrafluorethylene works well. The liner heater reduces the process time by preheating the metallic parts of the system, thereby offsetting loss of heat generated

by the microwaves to the metallic parts of the sterilizer. The means for external control can be any electronic control system, such as a microcomputer.

As stated previously, the flanged ends of the upper and lower outer shells are designed to be held together by a clamp. Preferably, the clamp 116 releasably connects the bottom flanged end 122 of the upper outer shell 104 and the top flanged end 240 of the lower outer shell 106 such that the upper 126 and lower 244 coaxial tubes are aimed at each other. The clamp 116 should also allow the clamped microwave waste sterilizer 102 to maintain an internal pressure between 0.138 Mpa (20 psig) and 1.38 Mpa (200 psig) . It has been found that a split ring clamp that forms to a surface of the flanged end at an angle will provide the greatest amount of holding tension with a minimum of pressure to the clamp. Further, the use of a o-ring in the pressure seal area may be employed to act as both a gasket and a relief valve, preventing the sterilizer from over-pressurizing. The flanged ends of the lower liner can contain a circumferential groove to accept the o-ring. Compressing the o-ring by the clamping process to a compression of about 20 percent has proved satisfactory.

The microwave waste steam can be made to fit into a superstructure which is only slightly larger than a refrigerator. A hydraulic system, such as those available from Tokyo Sintered Metals Corp., Toyko, Japan, can be used with good results to open and close the clamp and to raise and lower the upper portion of the sterilizer. The cylinders may be suspended from the top of the superstructure. The lower portion of the sterilizer can be mounted on a drawer assembly to allow the operator to open the drawer, once the upper portion is raised, and to

place or remove the reusable plastic waste container in the lower portion. Any moisture added and condensate formed during the sterilization process can be gathered and recycled as moisture addition for the next cycle. Therefore, an external drain is not necessary.

In another embodiment of the invention, there is provided a method for sterilizing waste materials. The method comprises placing waste materials in a reusable plastic waste container, placing the waste container in a microwave waste sterilizer, clamping the microwave waste sterilizer closed, broadcasting an upper magnetron and a lower magnetron simultaneously so as to generate microwave energy within the microwave waste sterilizer, injecting water into the microwave waste sterilizer, maintaining a predetermined pressure within the microwave waste sterilizer for a predetermined time period, ceasing the generation of microwave energy, venting the microwave waste sterilizer, opening the waste sterilizer, and removing the waste container. In a preferred embodiment of the process, the lower magnetron unit broadcasts at least 120 degrees out of phase from the upper magnetron unit. Also, the water is injected in a pre-deter ined number of batches. The injected water, along with any condensate, can be trapped and recycled for the next cycle, eliminating the need for an outside drain.

The microwave waste sterilizer 102 comprises a generally bell shaped upper outer shell 104, a generally bowl shaped lower outer shell 106, an upper means for guiding microwave energy 108 connected to the upper outer shell, a lower means for guiding microwave energy 110 connected to the lower outer shell, an upper means for dispersing microwave energy 112 connected to the upper means for generating microwaves, a lower means for

dispersing microwave energy 114 connected to the lower means for generating microwaves, and a clamp 116 releasably holding the upper shell and the lower shell together, all substantially as previously described. In yet another embodiment of the invention there is provided a method for dispersing microwave energy into a chamber. The method comprises broadcasting microwave energy across a chamber, reflecting the microwave energy from a surface of the chamber, coupling the microwave energy onto a means for coaxial guidance and changing direction of flow to a new direction of flow substantially parallel to the means for coaxial guidance, propagating the microwave energy in the new direction of flow within a means for guiding microwave energy, splitting the microwave energy-in a means for dispersing microwave energy, and broadcasting the dispersed microwave energy into a chamber in a flux field of substantially uniform flux. The microwave energy is split into two paths by the means for dispersing microwave energy and the resultant flux field is substantially cone shaped.

Referring to the figures, the chamber used to broadcast microwave energy comprises a substantially rectangular box shaped waveguide 252 and a coax 272. The waveguide 252 has a first side plate 254 having an outside surface 256, a second side plate 258 substantially parallel to the first side plate and having an outside surface 260, a first movable end block 322 substantially normal to the first and second side plates 254, 258 and a second movable end block 324 substantially parallel to the first movable side plate 322. The first side plate 254 has a first end 262, a second end 364, a first hole 266 between the first end and a center of the first side plate and a second hole 268 near the second end having a

diameter smaller than a diameter of the first hole. The second side plate 258, has a hole 270 of a diameter substantially the same as the diameter of the first hole 266 in the first side plate 254. The hole 270 in the second side plate is oriented in axial alignment with the first hole 266 in the first side plate. The first and second movable end blocks 322, 324 each have the characteristic of a tuning short. A magnetron 152 is connected to the first side plate 254 of the waveguide at the second hole 268 so that waves produced by the magnetron are broadcast within the rectangular box shaped waveguide. The tubular coax 272 has a first end 274, a second end 276, an inside surface defining a diameter substantially the same as the diameter of the first hole 266 in the first side plate of the waveguide, and a longitudinal axis. The first end 274 is connected to the outside surface 256 of the first side plate 254 so that the longitudinal axis is coaxial with the first hole 266 and the coax 272 is in covering relationship to the first hole 266. A tubular conductor plug 278 is closely received by the second end 276 of the coax. The conductor plug 278 has a first end, a second end, an outside diameter substantially the same as the inside diameter of the coax, an inside surface defining a diameter substantially the same as an outside diameter of a coaxial tube 244, and. a longitudinal axis. The position of the conductor plug 278 is adjustable within the coax 272 and the conductor plug has the characteristic of a tuning short. The means for coaxial guidance comprises a coaxial tube 244 having an outside surface 246, a first end 248, a second end 250, an outside diameter and a longitudinal axis. The coaxial tube is preferably made from aluminum.

The means for guiding microwave energy comprises a substantially can shaped z-neck 280 and a generally tubular dielectric disc 292. The z-neck 280 has a first end 282, a flange end 284, a generally tubular sidewall 286 having an outside surface connecting the first end 282 and the clanged end 284 and an inside surface 288 having a diameter greater than the diameter of the hole 270 in the second side plate 258 of the waveguide, and a longitudinal axis. The first end 282 has a hole 290 coaxial with the longitudinal axis and having a diameter substantially the same as a diameter of the hole 270 in the second side plate 258 of the waveguide. This first end 282 is connected to the second side plate 258 of the waveguide so that the hole 290 in the first end 282 is coaxial with the hole 270 in the second side plate and the first end 282 is in covering relationship with the hole 270. The flange end 284 is substantially fin shaped and has a generally cylindrical inside surface coincident with the inside surface 288 of the z-neck. The z-neck is preferably made from aluminum. The dielectric disc 292 has a first end 502, a second end 504, a longitudinal axis, a first outside surface 506 adjacent to the first end 502 and having a first outside diameter, a second outside surface 508 adjacent to the second end 504 and having a second outside diameter which is greater than the first outside diameter, a first annular shoulder 510 joining the first outside surface 506 and the second outside surface 508, and an inside surface defining a diameter substantially the same as the outside diameter of the coaxial tube 244. The dielectric disc 292 is positioned in the z-neck 280 in covering relationship with the hole 290 in the first end 282 of the z-neck. The dielectric disc has the characteristic of being substantially transparent to

microwaves. It has been found that virgin polytetrafluorethylene works well for the type microwaves broadcast.

The means for dispersing, microwave energy comprises a generally tubular adaptor 294, a generally bowl shaped outer shell 106, an inner finer 296 and a deflector 314. The adaptor 294 has a first end 602, a second end 604, a first inside surface 606 adjacent to the first end 602 and having a first inside diameter, a second inside surface 608 adjacent to the second end 604 and having a second inside diameter smaller than the first inside diameter, a first annular shoulder 610 joining the first inside surface 606 and the second inside surface 608, a first outside surface 612 adjacent to the first end 602 and having a first outside diameter, a second outside surface 614 adjacent to the second end 604 and having a second outside diameter smaller than the first outside diameter, a second annular shoulder 616 joining the first outside surface 612 and the second outside surface 614, and a longitudinal axis. The first inside diameter is substantially the same as the first outside diameter of the dielectric disc 292 so as to closely receive the dielectric disc. The second inside diameter is substantially the same as the diameter of the hole 290 in the first end 282 of the z-neck 280 and the first outside diameter is smaller than the diameter of the inside surface 288 of the z-neck 280 such that the dielectric disc 292 and the adapter 294 nest within the z-neck 280. The adaptor is preferably made from aluminum. The outer shell 106 has an inside surface 236, an outside surface 238, a longitudinal axis and a hole 242 at an apex of the bowl shape. The outside surface 238 is connected to the flange end 284 of the z-neck 280 so that

the z-neck is in covering relationship to the hole 242 in the apex of the bell shape of the outer shell.

The inner finer 296 has a longitudinal axis and two portions, namely a substantially tubular shaped portion 298 having an inside surface 300 and an outside surface

302, and a parabolic shaped bell portion 306 connected to the tubular shaped portion 298 at a point of transition. The parabolic shaped portion 306 has a first end 308 which has an inside diameter smaller than an inside diameter of the tubular shaped portion 298, an inside surface 310 and an outside surface 312. The inner liner 296 is connected to the adaptor 294 at the first end 308 of the parabolic shaped bell portion such that the outside surface 312 at the first end 308 is closely received by the first inside surface 606 of the adaptor 294. The outside surfaces 302, 312 of the tubular shaped portion 298 and the parabolic shaped bell portion 306 of the inner finer are adjacent to the inside surface 236 of the outer shell 106. In a preferred embodiment, the liner is constructed from aluminum and is formed by spinning.

The deflector has a first end 702, a second end 704, a first generally frustoconically shaped outside surface 706 adjacent to the first end 702, a second generally frustoconically shaped outside surface 708 adjacent to the second end 704, a third generally cylindrical outside surface 710 connecting the first outside surface 706 and the second outside surface 708, and a longitudinal axis. The first frusticonically shaped outside surface 706 converges away from the first end 702 at an angle of between about 8 degrees and 25 degrees. The second frustoconically shaped outside surface 708, which mirrors the first frustoconically shaped surface, converges away from the second end 704 at an angle between about 8

degrees and 25 degrees. The second end 604 is connected to the second end 250 of the coaxial tube 244 such that a common plane passes through the lower deflector and the near 90 degree point of transition between the tubular- portion 298 and the parabolic shaped bell portion 306 of the lower inner liner 296. The deflector is preferably made from aluminum.

The longitudinal axes of the outer shell, coaxial tube, coax, conductor plug, z-neck, lower dielectric disc, adaptor, inner liner and deflector are coaxial. Also, the coaxial tube extends through the conductor plug, coax, waveguide, z-neck, lower dielectric disc, adapter, parabolic shaped bell portion of the inner liner and deflector. While not wishing to be bound to any theory of operation, it is believed that the microwave energy is split along at least two paths within the means for dispersing microwave energy. The first path is formed by the coaxial tube. The second path is formed by the inside surfaces of the tubular shaped portion and the parabolic shaped bell portion of the inner liner. The portion of energy that follows the coaxial tube travels down the coaxial tube to the deflector. The energy traveling along the inside surface of the parabolic shaped bell portion reaches the point of transition between the parabolic shaped bell section and the tubular section and changes direction. Much of this energy is directed toward the deflector. A portion of the energy which reaches the deflector is reflected back towards the inner liner, eventually returning to the deflector. Other energy is dispersed from the deflector into a solid cone shaped flux field. The flux field is substantially uniform, thus eliminating cold spots seen when the microwave energy is

narrowly focused. A nipple 316 may be added to the second end 604 of the deflector 314 to further tune the microwave energy which stands off the inner liner at the near 90 degree point of transition between the tubular portion 298 and the parabolic shaped bell portion 306. The nipple should be cylindrical with a longitudinal axis coaxial with the longitudinal axis of the deflector 314.

The foregoing provides a description of the preferred embodiments, however, it should be noted that numerous structural changes and modifications may be made without departing from the spirit of the invention.