Final Report DL Spring 2009

Solar Autoclave with Sterilization Indicator
ECE/MEE 432L, Design and Manufacturing Clinic

April 2009
Sponsor: ETHOS
Team Members:
Staci Grey
Christopher McGuinness
Ryan Smolik
Corey Vossler
Kyle Zeller
Industry Mentor:
Susan Kinne
Faculty Mentors:
Margaret Pinnell
John Hageman
Don Schenk
Eric Lang
Phil Doepker
NOTICE
This report represents the results of a student project at the
University of Dayton. Because of the matter of this project, the
faculty and student team members do not warrant or guarantee
the accuracy of the results nor that they are suitable for any
particular purpose. The sponsor agrees that if ideas, concepts or
designs from this project are implemented, the sponsor is solely
responsible for the reliability, performance and safety of the
concepts and designs, and shall indemnify and hold harmless
the University of Dayton, employees, students and any other
representatives from and against all claims, losses or damages
arising out of scope of this agreement.
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Table of Contents
Summary 7
1.1 Purpose 7
1.2 Results 7
1.3 Conclusions 7
1.4 Recommendations 7
Background and Research 8
2.1 Solar Autoclave 8
2.2 Pressure Release Valve 9
2.3 Sterilization Indicator 10
Specifications 11
3.1 Functional Requirements 11
3.2 Design Requirements 11
3.3 Design Criteria 11
3.4 Deliverables 12
Procedure 13
4.1 Establish Need 13
4.2 Proposal and Specifications 13
4.3 Research 16
4.4 Conceptual Design 16
4.5 Embodiment Design 16
4.6 Initial Calculations and Testing 16
4.7 Engineering Calculations 16
4.8 Final Design 17
4.9 Prototype Fabrication 17
4.10 Prototype Testing/Data Analysis 17
4.11 Cost Estimation 17
4.12 Final Presentation 17
4.13 Final Report 17
Embodiment Design 18
5.1 Pressure Vessel 18
5.2 Outlet Valve 19
Calculations 21
6.1.1 Variables 21
6.1.2 Calculations and Equations 21
6.1.3 Analysis 22
6.3 Water Amount 22
Prototype Development and Testing 23
7.1 Pressure Vessel Testing 23
7.1.1 Temperature Testing 26
7.1.2 Air Pressure Testing 28
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7.2.1 End Cap as Regulator 29
7.2.2 Nut and Bolt Fixture as Regulator 31
7.2.3 Safety Valves 33
7.2.4 Check Valve 35
Results 38
8.1 Pressure Vessel 38
8.1.1 Pressure Seal Testing 38
8.1.2 Temperature Testing 38
8.1.3 Air Pressure Testing 38
8.2.1 Verification of Final Design 40
Manufacturing Instructions & Nicaragua Test Plans 42
9.1 Manufacturing Procedure – Pressure Vessel 42
9.1.1 Materials 42
9.1.2 Tools 42
9.1.3 Procedure 42
9.2 Manufacturing Procedure – Sterilization Indicator 45
9.3 Nicaragua Test Plans 46
Cost Estimation 48
Conclusions 50
Recommendations 51
References 52
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Appendix Table of Contents
Appendix A Design Project Agreement
Appendix B Contact Information
Appendix C Project Proposal
Appendix D Weekly Status Reports
Appendix E Final Gantt Chart
Appendix F First Oral Presentation
Appendix G Second Oral Presentation
Appendix H Final Oral Presentation
Appendix I Meeting Minutes
Appendix J Individual Conceptual Designs
Appendix K Decision Analysis Sheets (Team)
Appendix L Embodiment Designs
Appendix M Learn, Lead and Serve Grant Application
Appendix N Miscellaneous Calculations & MATLAB Code
Appendix O Miscellaneous Engineering Drawings
Appendix P Project Expenses
Appendix Q Purchase Receipts
Appendix R Miscellaneous Research
Appendix S Structural & Sealant Test Data
Appendix T Oven Air Pressure Test Data
Appendix U Project Description Form
Appendix V Solar Autoclave Final Report
Appendix W Solar Autoclave Technical Report
Appendix X Design of a Sterilization Indicator
Appendix Y Rough Draft – Graded – John Hageman
Appendix Z Rough Draft – Graded – Don Schenk
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List of Tables and Figures
Figure 4.1 Gantt Chart
Figure 4.2 Gantt Chart (Continued)
Figure 5.1 Embodiment Design – Assembled Pressure Vessel
Figure 5.2 Embodiment Design – Deconstructed Pressure Vessel
Figure 5.3 Embodiment Design – Outlet Valve
Figure 5.4 Embodiment Design – Sterilization Indicator
Figure 6.1 External Temperature as a Function of Indicator Height and Diameter
Figure 7.1 Valve Assembly with Hydraulic Pump Attached
Figure 7.2 Strain Gages – Side of Can
Figure 7.3 Strain Gages – Bottom of Can
Figure 7.4 Pouring Hydraulic Oil into Can
Figure 7.5 Hydraulic Oil Pressure Test Setup
Figure 7.6 Bottom of Can and Hoop Stresses
Figure 7.7 Temperature Test Setup with Plastic Tubing
Figure 7.8 Melted Plastic Tubing
Figure 7.9 Temperature Test Setup with Copper Tubing
Figure 7.10 Air Pressure Testing with Plexiglas Shield
Figure 7.11 End Cap
Figure 7.12 End Cap Regulator Final Cap with Plate
Figure 7.13 End Cap Regulator Concept
Figure 7.14 End Cap Regulator Testing
Figure 7.15 Nut and Bolt – 1/2"
Figure 7.16 Nut and Bolt – 1/4"
Figure 7.17 Nut and Bolt Pressure Regulator System
Figure 7.18 Safety Valve – Rubber Plug
Figure 7.21 Purchased Check Valve
Figure 7.22 Sterilization Indicator – Initial Heat Transfer Verification Test
Figure 7.23 Airless Sterilization Indicator Concept
Figure 7.24 Airless Indicator – Post Experiment
Figure 7.25 Vented Sterilization Indicator Concept
Figure 8.1 Oven Testing of Solar Autoclave
Figure 9.1 Marking the Corner Holes
Figure 9.2 Cap after Drilling Holes
Figure 9.3 Assembled Autoclave and Valve Assembly
Figure 9.4 Sterilization Indicator for Manufacturing Procedure
Table 8.1 Force (Weight) Required to Maintain Pressure for Fabricated Vent Pipe
Table 10.1 Manufacturing Cost Per Solar Autoclave
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1.0 Summary
1.1 Purpose
The primary objective of this project has been to develop a solar autoclave, or medical instrument sterilizer,
with an integrated sterilization indicator to validate each process to be used in rural communities in Nicaragua
by local nurses. The objective for this semester was to continue the development of the open-ended cylinder
solar autoclave design and to integrate a working sterilization indicator that will serve as a reliable post-
process verification. The solar autoclave was to be taken from an initial design, reevaluated, improved,
prototyped, tested, and turned into a final reliable design. The final design must consistently sterilize surgical
instruments to the standards practiced, including holding a specified minimal temperature and pressure across
a period of time. The incorporation of the sterilization indicator is a necessity as it provides a visual way for
the local nurses to validate each process.
1.2 Results
Research and testing performed in previous semesters allowed the team to continue in the current semester to
improve the open-ended cylinder design for the solar autoclave. Conceptualization from the previous
semester led the team to continue the phase-change material indicator design. Re-evaluating the
recommendations left from last semester as well as developing new conceptual designs for both products led
to testing of the new ideas. The team performed cycles of testing, implementing improvements at each phase.
At the conclusion of the testing the final design contained an aluminum end plate, a new sealant, a pressure
release valve, and easy-to-access assembly. The final design of the sterilization indicator was vented in a
simple way to ensure stability and to make it easier to use but was found to be unreliable as a final design.
1.3 Conclusions
By improving and adding components to the previous semester’s activity, a final design of the solar autoclave
system has been delivered. Necessary improvements to the system developed from the extensive testing
performed throughout the semester on all three main components. The end-opening pressure vessel has been
proved to be able to withstand the pressure loads as well as the high temperatures of the sterilization cycle.
The sterilization indicator has been prototyped and tested to ensure accuracy. The pressure relief valve has
been designed and implemented into the final system. The final solar autoclave design meets the design
requirements and criteria. Engineering drawings have been made, testing is completed, and manufacturing
instructions and further testing procedures have been written for the final design.
1.4 Recommendations
The final design has been verified through extensive testing, but further investigation will involve testing the
entire autoclave system to verify sterilization. The entire system including the solar cooker, the pressure
vessel, sterilization indicator, and pressure release valve must be tested together and verified to work in the
Nicaraguan climate. The amount of water needs to be studied using various amounts to make sure that the
optimum level is being used. In addition, further testing must be conducted to verify endurance of the design
across its lifespan for safety and maintenance purposes. The financial cost of the entire system also needs to
be further considered to keep production costs at a minimum.
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2.0 Background and Research
The primary objective for this semester was to continue the development of the solar autoclave and integrate a
working sterilization indicator that will serve as a reliable post-process verification. In order to accomplish
this objective the team used the completed work of groups from the previous semesters, finalized their designs
and integrated them together into working form. The team had recommendations provided from the previous
teams to guide the testing and design process. As a result of extensive previous work on this project, the
background and research section contains material compiled only from this semester. Previous team reports
and background information will be provided in the appendices. Specifically, this semester the research was
divided into three sections: pressure vessel testing and improvements, pressure relief valve design, and
sterilization indicator design.
2.1 Pressure Vessel Research
The majority of the research into the solar autoclave was conducted last semester. This information was
utilized along with additional research conducted on pressure cookers and autoclaves this semester. There is
very little research on solar autoclaves as this is a relatively new idea. A patent search was performed and it
was found that no patent exists for such a design. There is significant information on solar cookers available;
however the information on solar cookers only pertained to temperatures of 100°C. This lower temperature is
all that is required to boil water, which is a main function of a solar cooker in third world countries.
A pressure cooker is a relatively inexpensive pan with a lid that is placed on top and locked into position. A
more traditional pressure cooker has two outlet valves: a safety valve and a pressure regulator. The safety
valve usually consists of a rubber grommet or plug that will expel from the lid above a certain pressure, should
the regulator not be functioning properly. The pressure regulator allows the user to know that the desired
pressure has been reached, indicated by the weight jostling and the audible hissing sound. In more modern
pressure cookers, there is no safety plug instead the gasket seal in the lid will blow out if the pressure exceeds
a safe amount. The pressure regulator on more modern pressure cookers is a spring valve which acts as a
regulator and a check valve, ensuring that pressure is maintained during operation and that no vacuum occurs
after the cycle.
The end-opening pressure vessel design was given to the team for further development and testing. After
initial meetings and reading through the previous semesters report, the team developed conceptual designs and
ideas about how to improve the current design. Additional research was performed on potential seals, end cap
design, conducting pressure testing, and adhesives. After the team ran an initial hydraulic oil pressure testing
of last semester’s design, many design changes were considered. The initial test showed the design
weaknesses and where the team should focus more attention. The ring-like seal was replaced with a fully
covered seal with a small hole drilled in the center that will be glued to the top end cap. The seal material was
also changed from the butyl rubber seal recommended from the previous semester to a silicone pie pan seal.
The butyl rubber seal was researched and found to emit hazardous gases during its initial heating cycle. Other
seals such as EPDM and a silicone baking sheet were also researched and tested through pressure tests. The
results of these tests will be discussed in the Results section of this report.
The type of wood for the end caps from the previous team was Caribbean Pine. The wood was researched to
be locally available in Nicaragua without environmental concerns of deforestation that some third-world
countries are experiencing. The top end cap proved to be unable to be sealed effectively in hydraulic pressure
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testing. The team then moved to a new design utilizing an aluminum top end cap in which pipe threads could
be machined into a thin aluminum plate to prevent leakage. Research showed that at this Nicaragua location, a
metal shop was available to support this machining. The aluminum plate adds significant cost to the system
but is necessary for the pressure vessel to contain the steam and control the pressure.
Additional research was performed to conduct effective pressure testing. Labview programs were written and
strain gage application and theory was researched to improve the knowledge base of the team and gather
accurate data. Adhesives were also researched to glue the silicone pie pan to the bottom of the aluminum end
cap. Contact cement was found to be ineffective at adhering to the surfaces and silicone based adhesives were
researched to achieve results desired.
2.2 Pressure Release Valve Research
The pressure relief system that is required for a standard pressure cooker was researched in order to gain
knowledge on the overall purpose and operation of a pressure release valve. It was discovered that there are
various types of valves, as well as several operations of the valves. The three most common valve types
researched were: check/spring valves, weighted valves and ball valves. After thorough research of the
mechanical operations and the ease at which they could be duplicated, a weighted valve was chosen as the
desired pressure regulator valve. It was the one that could most readily be manufactured from off the shelf
products and would be intuitive to operate. A check valve was researched, and it was determined that the
safest way to ensure a vacuum did not occur was to purchase a pre-fabricated check valve.
The main purpose of a pressure regulator valve is to act as a control valve and our system requires a controlled
15psi of internal pressure. It is initially sealed, allowing no air to enter or escape the can, until the inside
pressure reaches the force at which the weight will begin to move. The weight will begin to move and jostle
allowing any excess pressure above the desired amount to escape. Should the pressure in the autoclave for
some unforeseen reason increase to a pressure much greater than 15psi, for example 25psi, the weight will lift
off of the outlet valve and release the pressure from the can emphatically.
A third purpose of outlet valves is safety. In most pressure cookers and autoclaves there is a safety valve
which will blow out, allowing for an instant release of pressure. This particular type of valve, while very
important in the operation of a pressure cooker was believed to be impractical for this specific application.
The seal of the solar autoclave is an inherent safety valve, in that the seal will break when the pressure exceeds
30psi. This type of seal is common in today's pressure cookers and research suggests that it is replacing the
older blow out grommet safety valve. A secondary purpose of the regulator is to act as a safety valve that will
blow off the weight for pressures that exceed 25psi.
Research was conducted on spring valves and their operations. However, due to the complexity of the spring
and determining the spring force, it was concluded that it would not be practical for the Nicaragua application.
It is not known conclusively if any of the local people would be able to perform the calculations, nor where
they could purchase materials to construct the spring valve. Consideration was given to importing the part in
from the United States. However, further research suggested given that cost is one of the main factors in this
project that the part would be too expensive.
The most productive research came from the weekly trips to Lowes and Home Depot and speaking with their
employees. The experts in the Design Clinic also provided insight into the operation of the various valves and
assisted with the construction in a few of the iterations.
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2.3 Sterilization Indicator Research
Work completed in the previous semester, including background research, the conceptualization of various
ideas, and early prototyping of a phase change material design were the starting point for the work done this
semester. The recommendations provided at the end of the semester’s worth of work identified the key areas
the team needed to pursue while working toward the final design of the sterilization indicator. After a phase
change material design was chosen last semester, research for the sterilization indicator has primarily revolved
around phase change materials. Research information that has been used this semester includes melting
temperatures of different phase change materials, material properties of different types of materials such as
acrylic and lexan, and the bonding strengths and properties of glue.
Acrylic was chosen as the material used to manufacture the hourglass because in comparison to lexan it is
more transparent, it has a higher temperature tolerance, and it has a slightly better thermal conductivity. Also,
Polywax©2000 was chosen as the phase change material because its melting temperature is theoretically stated
to be 121°C. The advantage of a phase change material is its ability to quickly change from liquid to solid
over a small temperature change. Lastly, IPS Weld-On adhesive was chosen as the glue since it is designed to
be able to hold together acrylic surfaces under high temperatures given at least 24 hours of curing time.
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3.0 Specifications
3.1 Functional Requirements
The functional requirement for this project is to design and develop a turn-key solar autoclave system to
sterilize medical instruments using only solar energy as an energy source. The system will include the solar
cooker, pressure vessel, pressure relief valve, and sterilization indicator.
3.2 Design Requirements
The autoclave must:

• Satisfy the required conditions to destroy bacillus subtillis spores.
• Require no fuels or electricity to operate and must be easily constructed using commonly available
tools and processes known to the locals (such as using hammers, drills, etc).
The pressure vessel must:
• Be limited to 65.3cm x 64.3cm x 18.7cm; however, must be large enough to accommodate the trays
that the medical instruments are place on, as well as the sterilization indicator and the larger
instruments.
The sterilization indicator must:
• Be able to verify that the sterilization process was or was not successful and is complete.
• Not indicate any false positives for any thermal cycle that lasts less than 10 minutes and also must not
interfere with the operation of the solar autoclave or solar cooker.
• Fit inside the solar autoclave, while leaving room for the instruments.
• Be environmentally and biologically safe to handle without protection.
• Cost less than $10.00 per unit if it is reusable or less than $0.01 per unit and constructible on-site if
non-reusable.
• Conform to Nicaraguan importation laws if non-reusable.
All project tasks must:
• Be constructed using materials locally available in Nicaragua, except the sterilization indicator.
• To try to meet minimize cost, the overall cost of parts must be minimized as long as safety is not
compromised.
3.3 Design Criteria
Using the Innovation and Design Clinic manual as a guide, we chose ten criteria that we felt were the most
important consideration in our design of the sterilization indicator.
• Customer: As with any new design, the first concern is the customer.
• Environment: Neither the autoclave nor the indicator must be environmentally and biologically
(unsafe?) safe for the user and the constructor.
• Safety: Due to the nature of the sterilization process, warning labels are required to be placed on the
solar autoclave to warn of the potential hazards involving steam and high temperature.
• Ease of Use: Also, for the autoclave and the indicator, simplicity is the key. Both should be intuitively
easy to use.
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• Maintenance: The construction and repairs of the solar autoclave should be uncomplicated. The
indicator may not be easy to repair if constructed of material not available locally in Nicaragua;
however, it should be intuitively easy to use.
3.4 Deliverables
Throughout this project there have been administrative, engineering and business deliverables that were
required.
Administrative Deliverables:
• Project Proposal: The project proposal was one of the first administrative deliverables to be completed.
The project proposal was submitted to Dr. Margaret Pinnell and provided the project's functional and
design requirements, deliverables and the Gantt Chart.
• Weekly Status Reports: Each week, weekly status reports provided updates showing the week's
progress, group activities from the week and immediate future project plans.
• Oral Presentation: After the generation of conceptual designs for the pressure vessel, an oral
presentation was given, allowing the sponsors, mentors, group members and design clinic faculty to
provide feedback on the prospective designs.
• Interim Briefing: During the middle of the semester, there was an interim briefing with the primary
mentor and design clinic faculty.
• Final Report and Oral Presentation: The final administrative deliverable is the final report and final
oral presentation, which are to be completed by the end of the semester.
Engineering Deliverables:
• Analyze Recommendations: The first engineering deliverable was to weigh the recommendations from
previous project efforts and determine what project items need revised.
• Improve the Pressure Vessel Design: After analyzing the previous group's recommendations, make
changes to the pressure vessel design.
• Determine the Autoclave’s Structural Integrity: Through pressure testing with strain gages, the
structural limitations of the autoclave is determined.
• Determine the Indicator's Structural Integrity: Through temperature testing with the autoclave and the
oven, the indicator's durability in high-temperature environments is determined.
• Verify System Performance: Once complete, the system’s sterilization capabilities are verifyied using
bacillus subtillis cultures.
• Create Final Drawings, Assembly Instructions, and Parts List: Upon verification of the system’s
performance, final drawings, assembly instructions, and parts lists are created.
• Detailed Cost Estimate: A final deliverable is creating a detailed cost estimate for materials and
construction per autoclave.
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4.0 Procedure
This section illustrates how the design process was performed by the ETHOS team following the Product
Realization Process (PRP) from the Design Manual. The Gantt chart in Figure 4.1, continued onto Figure 4.2
and also included in Appendix C, illustrates the timeline followed. The black bars indicate the estimated
duration of each activity, and the yellow bars indicate the actual duration of activity. It can be seen that while
most tasks were completed within the intended timeframe, some activities ran over due to complexity and
issues that arose during prototyping and feasibility testing.
4.1 Establish Need
The need for the solar autoclave was initially established during ETHOS trips in the summers of 2006 and
2007. Interviews conducted among healthcare facilities throughout Nicaragua indicated that the need for a
solar autoclave was the most urgent in small rural clinics without electricity. Of these there is nearly a
thousand. The need for the sterilization indicator was brought to the attention of the original solar autoclave
group during a presentation to the Ministry of Health in Nicaragua. The need for an indicator to verify
sterilization is a necessary component to the overall system of the solar autoclave. During this semester, the
solar autoclave with sterilization indicator is to be completed and sent to Nicaragua for further testing.
4.2 Proposal and Specifications
The proposal and specifications from the solar autoclave project in the fall of 2008, MEE-432L, and the
sterilization indicator project also in the fall of 2008, ECE/MEE-431L, were modified to incorporate the new
discoveries and decisions that had been made through the course of the semester. The modifications were
mostly an affirmation of which designs would be pursued, as well as an endeavor to incorporate the two
individual projects, solar autoclave and sterilization indicator, into one more definitive project. The team met
with the sponsors at the start of the semester in order to begin making the necessary modifications to the solar
autoclave design from the previous semester and to make various decisions about how to complete the project
within the given time frame. The sterilization indicator was only modified slightly in design, by incorporating
a vent hole.
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ETHOSGantt Chart
Task (Person)
Establish Need (ALL)
Identify Project & Team
Develop Questions for Spons
Meet Sponsor
Figure 4.1 - Gantt Chart
Functional Requirements
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Improved Pressure Vessel (
Compile Conceptual Design
Research Components
Create Embodiment Design
Engineering Calculations
Assemble Components Lis

Figure 4.2 - Gantt Chart (Continued)
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4.3 Research
The research findings, combined with the previous work by both the solar autoclave team and the sterilization
indicator team, allowed the team to focus on completing the pressure vessel and the sterilization indicator in
order to have a complete solar autoclave unit for testing this summer in Nicaragua. In order to further develop
the pressure vessel design, research was conducted on pressure vessels, valve types and operations, pressure
relief devices, abundance and availability of materials needed in the construction of the solar autoclave and
sterilization methods.
4.4 Conceptual Design and Decision Analysis
Six conceptual designs were drawn, four for the pressure vessel and two for the sterilization indicator. The
designs incorporated the team’s prior research, previous developments of the prior semester's team and
conversations with the sponsors and advisors, including Lori Hanna and Dan Hensel from the previous
autoclave projects. The team then came together and went through a decision analysis in order to determine
the final design for both portions of the project. It was found that no one pressure vessel design was superior
and instead the group as a whole came up with a final design that integrated improvements that were felt to
have the most positive impact on improving the pressure vessel.
4.5 Embodiment Design
With the completion of the decision analysis and a final design drawn up by the group, the team split into
three separate entities to concentrate on the three pressing areas of the project: sterilization indicator, pressure
vessel improvements and testing. As testing began on the original pressure vessel, improvements were made
along the way that had not been considered during the design stage, such as trading the threaded rods in for 10
inch bolts and replacing one wood end cap for an aluminum end block.
4.6 Initial Calculations and Testing
Initial calculations were performed on the original can design to determine feasibility. Even though it had
previously been determined that the can would be able to withstand a pressure greater than the ASME
standards of 45 psi, the sponsors were skeptical. Therefore, a pressure test was conducted on utilizing
hydraulic oil. During this phase, the testing team took the opportunity to begin to improve the pressure vessel.
The pressure vessel improvement team supplied various sealants that were researched and determined to be
adequate for the functions required for the solar autoclave. These various sealants were tested during the
hydraulic oil pressure tests.
4.7 Engineering Calculations
The maximum stresses on the can were determined during the previous group's work. Through initial
feasibility testing, these stresses were experimentally measured and tabulated. Calculations were also
performed for the pressure outlet valve to determine the theoretical weight required to seal in pressure and
regulate the system. For the sterilization indicator, calculations were done to determine the thickness of the
hour glass container, the amount of material, the size of the aperture and the slope of the sides of the container.
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4.8 Final Design
Based on feedback from the sponsors and advisors during an oral presentation, the team continued with the
feasibility testing of the can and began to look at alternative methods for the sterilization indicator. As well, it
was determined at this time that a check valve would be required in addition to the pressure regulator valve in
order to prevent a vacuum from forming in the can. The outlet team gathered parts from Lowes and Home
Depot and began to make various prototypes for testing. The sterilization indicator team began the new design
of a bi-metallic strip indicator with a solar photocell as the source of power. The testing team began to do
more strain gauge testing and oven temperature testing. Individual components of the solar autoclave were
improved upon based on research conducted, deliberations among the team and through the feedback of the
sponsors and advisors.
4.9 Prototype Fabrication
The prototype pressure vessel from the previous semester was redesigned throughout the entire process.
Design iterations were made as new information was discovered through testing and conversations with
advisors. Each improvement was tested as the fabrication process went in order to determine its effectiveness
in the overall system. If an improvement was found to be faulty or less than desirable, the team would resort
back to the previous design that was functional.
4.10 Prototype Testing/Data Analysis
The Final Design Prototype, an end-opening cylinder design made with a coffee can, one wooden end block,
one aluminum end block and 10 inch bolts, was tested. Strain data was taken and visual observations were
made in order to confirm the strength of the design under pressure. The prototype outlet valves were each
thoroughly tested with compressed air in the design lab. Improvements were made during the testing to try and
overcome any complications that arose. Prototype sterilization indicators were fabricated and tested in an
available electric autoclave to determine their functionality.
4.11 Cost Estimation
Using the direct costs of the materials purchased for the prototypes and improvements, as well as production
costs estimations gathered from the previous work completed in Nicaragua, a cost estimate was developed.
This gives the estimated cost per unit for the solar autoclave and the sterilization indicator.
4.12. Final Presentation
The final presentation was developed with the cooperation of the entire team. Each team member was
responsible for certain portions, given his or her roles throughout the process. The presentation was
completed with the objective to convey all the information that had been gathered over the semester as well as
to exhibit the final solar autoclave design unit with improved and completed pressure vessel and verified
sterilization indicator.
4.13 Final Report
The final report is an accumulation of the work conducted this semester. It will include the background,
research, embodiment designs, tests and results as well as recommendations and conclusions.
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5.0 Embodiment Design
After the decision analysis and brainstorming session, refer to section 4.4, the group decided on a final design
that incorporated elements believed to better enhance the functionality of the solar autoclave. The sterilization
indicator design was already in place from last semester's work, as a precaution it was determined that a
second back-up indicator should be designed.
5.1 Pressure Vessel
The original solar autoclave design consisted of a 34.5 ounce coffee can measuring 7" tall and 6" in diameter.
The can is open on one end. Both ends of the can were capped with 8"x8"x2" pine end blocks. The caps were
held in place with 12" threaded rods and wing nuts. The sealant utilized prior to this semester was butyl
rubber. From the team's final conceptual design and the brainstorming session, we incorporated new
modifications to the existing solar autoclave design from last semester. It was determined that the wood end
block on the open end of the coffee can would be replaced with an aluminum block, 8"x8"x1/2", to prevent the
seeping of moisture into the wood. The 12" threaded rods were replaced with 10 inch hex bolts, allowing for
the autoclave to have only stationary end block (the wood end block on the closed end). Various sealants were
tested in order to determine the best possible seal for the pressure vessel. The outlet valve was researched and
several prototypes were constructed for testing. It was determined that the overall dimensions of the pressure
vessel would be no larger than originally specified. The current design dimensions are 8"x8"18". Figure 5.1
shows the pressure vessel complete and Figure 5.2 shows a blown apart image of the pressure vessel and the
components.
Figure 5.1
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Figure 5.2
5.2 Outlet Valve
The outlet valve consists of 1/2" copper pipe, a 1/2" T-fitting, a 1/2" male couple, a 3/4" to 1/2" male
reduction couple, a 3/4" check valve, a vent pipe from a pressure cooker with a weighted regulator, and a 1/2"
copper end cap. A 1/4" hole is drilled into the top of the 1/2" end cap and the vent pipe is securely fastened
through the hole. Three pieces of copper pipe are cut and affixed to the three T-bracket openings. The check
valve and the reduction couple are screwed together with pipe tape. The right side of the T-bracket is soldered
to the reduction couple. The copper end cap with the vent pipe is soldered to the top of the T-bracket and the
1/2" male couple is soldered to the left side of the T-bracket. Figure 5.3 shows the complete outlet valve.
Weighted Regulator
Check Valve
Copper Pipe Vent Pipe

Copper End Cap
Male copper
Male copper connector Copper T-fitting connector
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Figure 5.3
5.3 Sterilization Indicator
For the sterilization indicator, the physical design is focused on how it can passively indicate whether or not
conditions for sterilization have been met. To avoid pressurization of the indicator’s interior, end caps with
holes were created to allow pressure to escape. In
order to prevent leaking, a plug cap was designed
that is removable such that both ends of the
indicator can be used. Also, the inside of the
indicator is sloped to help the liquid wax flow to
the bottom. The slope is very shallow; however, it
is steep enough to facilitate movement.
Intended to be a reliable and sustainable indicator,

the phase-change material hourglass has an
undeniable appeal. Its simplicity in operation
makes it an attractive solution to the sterilization
indication problem. However, it became clear that
the hourglass approach has its faults and some of
these faults may be fatal for its use in this
application. In order to prepare for this possible
pitfall, a second embodiment design was created
for an electronic sterilization indicator.
Figure 5.4
This electronic indicator was originally proposed during the first semester of sterilization indicator design but
was forgone for the hourglass design. Similar to the passive material-based hourglass, the electronic indicator
passively determines the temperature and, once the temperature exceeds 121°Celsius, a timer is activated.
After the timer reaches 15 minutes, a light is activated to indicate that the conditions have been met. Its
temperature sensor is a PTC thermistor that would need to be inserted into the pressure vessel through a sealed
hole. A thermistor functions as a resistor that correspondingly changes its resistance with temperature. As the
temperature increases, for a PTC thermistor, the resistance increases.
Aside from the thermistor, the rest of the electronics need to be outside of the pressure vessel such that the
power source, a small photovoltaic cell array, can be powered. Similar to the cell arrays found on solar
calculators, some cell arrays can provide 5V and upwards of 100mA while being reasonably sized. Once the
circuit is connected and organized on a protoboard, it can be mounted onto one of the sides of the pressure
vessel such that it will be easily seen.
The electronic indicator's theory of operation is very simple. Once the temperature reaches 121°Celsius, the
thermistor's resistance will increase to a predicted resistance. Since the thermistor is in a voltage divider for
biasing a transistor, the voltage at the base of the transistor will increase until the transistor is activated.
Voltage at the emitter will be seen by a CN555 timer's enable pin. With voltage at the enable pin, the timer
will begin to create pulses that have a period of 3.5 seconds. The output of the timer connects to the trigger of
a counter and, once started, the counter will count up 256, which is 10000000. Once this value is reached, an
LED will be attached to the 28 pin and will be activated. Thus, the LED will be activated once the 15 minutes
at 121°Celsius has been reached.
20
6.0 Calculations
Calculations are performed to attempt to predict how long it will take for the material to melt under a given set
of circumstances. These calculations are shown and explained in this section.
6.1.1 Variables
t = Thickness; T1=Temperature of outside plastic; Tw=Temperature of Inner Surface; tm=time interval;

hsf= latent heat of fusion; p=density; V=volume; k=thermal conductivity of hourglass, A=Surface area.
6.1.2 Calculations and Equations
(6.1)
(6.2)
(6.3)
(6.4)
(6.5)
(6.6)
External Temperature as a function of Indicator Height and Diameter
135
Z Axis: Required Temperature (C)
130
125
120
115
3
2.5 6
2 5
1.5 4
1 3
2
0.5 1
Y Axis: Indicator Diameter (cm) X Axis: Indicator Height (cm)
Figure 6.1 - External Temperature as a Function of Indicator Height and Diameter
21
As can be seen in Figure 6.1, a range of different heights and diameters will melt the necessary amount of
Polywax® 2000 in 15 minutes at 121° Celsius. By inspection, the plot is very intuitive; in order to have a
constant melting temperature over various dimensions (each contour), one dimension will have to decrease as
the other increases. That is why the height decreases as the diameter increases and vice-versa. Since the
hourglass’s phase and encasement material has been selected, these are the only remaining variables.
Once the plot was created, it was used to determine the dimensions of the initial prototypes.
6.1. 3 Analysis
From Equation 1, the melting time can be calculated through the ratio of the product of the wax’s mass, latent
heat of fusion, and the thickness of the hourglass over the product of the hourglass’s surface area, thermal
conductivity, and the temperature difference between the wax and the external temperature. Using the same
variables, the required external temperature can be calculated for a given time and initial conditions by using a
rearranged version of Equation 6.5 – Equation 6.6.
From Equation 2, the required temperature outside the indicator can be calculated through the ratio of the
product of the wax’s mass, latent heat of fusion, and wall thickness over the product of the hourglass’s surface
area, thermal conductivity, and the time. This is then added to the initial temperature of the system.
The assumptions made in the equations were accepted because a certain amount of prototype testing was
needed. This testing proved how the assumptions affected the final design. These assumptions include even
heating of the phase change material, the phase change material has reached melting temperature at the
beginning of the 15 minutes, and the slope in the hourglass can be approximated by averaging it with the rest
of the container.
6.2 Pressure Release Valve
Once it was concluded that weighted valve design would be utilized, calculations were done to determine the
amount of weight required to maintain 15 psi and up to 18 psi. The simple Newtonian law of F=W/A was
used, where F is the force of the pressure in psi, W is the weight required in pounds to keep the seal on the
regulator intact and A is the cross sectional area of the outlet valve on which the weight will rest.
6.3 Water Amount
The question of how much water is required to create enough steam for the entire sterilization cycle is a
problem worked on by the team. Calculations were performed by the previous semester’s group and these
were used to provide a starting point for our group when performing oven testing. These calculations can be
seen in Appendix. The amount of water needed is a very important calculation and experimental problem to
test because too much water would cause for a longer heating up time and not enough water will result in no
steam creation and a lack of pressure.
22
7.0 Prototype Development and Testing
There were many prototypes developed throughout the semester of the pressure vessel, pressure relief valve,
and sterilization indicator. Feasibility tests were performed to check the designs and to ensure they worked
properly. The development of effective testing methods and data capturing techniques of the three main
components of the solar autoclave was a large portion of time spent on this project, and results of these tests
proved very valuable to further the design.
7.1 Pressure Vessel Structural and Seal Testing
Verification of the previous team’s data was necessary for further advancement of the design and sealing of
the system. Three different sealant types were put into testing to determine the most feasible and favorable.
The pressure vessel was modified after our first test to allow for quicker setup and testing. To test the system
and the sealants, hydraulic oil was pumped into the vessel at a controlled rate until the seal broke and the
design reached its maximum pressure
The previous design utilized a 34.5 ounce can served as the pressure vessel with two end caps held together by
threaded rods and 8 wing nuts. To ensure a better seal and less stress on the end caps, threaded bolts were used
in conjunction with machined aluminum end plates. To pump fluid into the system and gauge pressure, an
assembly was made as shown in Figure 7.1.
The can had 6 strain gauges applied to measure various strains on the can when put under pressure. 2 gauges
were places on the bottom of the can, 2 were placed in the vertical axis of the can to measure longitudinal
stress and the last 2 strain gauges were placed along the middle of the can to measure the hoop stress. See
Figures 7.2 and 7.3
The tests began by placing the vessel into a bin, to allow capture of any leaking oil, with the front plate and
valve assembly removed. The strain gauges were then wired into the strain gage measuring equipment and
were ordered in a manner to allow identification of where the strain gages were placed. The can was then
filled with hydraulic fluid until it was near the rim, as shown in Figure 7.4. The front plate and assembly was
then placed onto the can and then tightened down by hand and then by a wrench.
Once completely sealed, hydraulic oil was pumped in at a slow rate and measurements were taking every 5
psi. Readings were taken on the stresses and then the pumping continued. The seal proved to be the failure
point of all systems and as such, the maximum pressure and strains were recorded once the seal gave.
After testing, strain gauge data was analyzed and verified the ability of the can to hold the pressures. In
addition the maximal pressures and seal failures were compared to determine the best type of seal. The
following table details the maximal pressures and strain measurements for each sealant type.
23
Figure 7.1 - Valve Assembly with Hydraulic Pump Attached
Figure 7.2 - Strain Gages - Side of Can
24
Figure 7.3 - Strain Gages - Bottom of Can
Figure 7.4 - Pouring Hydraulic Oil into Can
25
Figure 7.5 - Hydraulic Oil Pressure Test Setup
7.1.1 Temperature Testing
Upon completion of the initial air pressure testing, the system underwent temperature testing to see if the
proper temperature could be attained in a reasonable amount of time. A 1/8” hole was drilled into the
aluminum end cap to allow a K-type thermometer to be inserted directed into the can. Epoxy was used to seal
up and enclose the hole. Another K-type thermometer was attached to the outside of the can so that the end
would measure the ambient air temperature.
Water was added to the can and then sealed in the same manner as the oil pressure tests. Based off of
calculations, one cup of water was required to create the pressure needed to sterilize the medical equipment.
A tube was connected to the vessel through the valve assembly to allow the gauging of pressure inside of the
can. At first, a thick plastic tube was utilized but failed under the high temperature, shown in Figures 7.7 and
7.8. A thin copper tube system was attached in place of the plastic tube as shown in Figure 7.9.
At periodic intervals, temperatures were read off from the ambient air temperature and the internal
temperature. The maximum temperature allowed for the ambient air temperature was set at 160°Celsius. This
temperature simulated the maximum temperatures reached by the solar autoclave.
26
Figure 7.7 - Temperature Test Setup with Plastic Tubing
Figure 7.8 - Melted Plastic Tubing
27
Figure 7.9 - Temperature Test Setup with Copper Tubing
7.1.2 Air Pressure Testing
Initially, air pressure tests were done to check the leak rate of the system and conclude the design was safe for
oven testing. Also, due to a lack of pressure readings from the temperature testing, further air pressure tests
were conducted to find leak locations. The pressure vessel was attached to an air outlet with a pressure
regulator to allow pressurization of the system at a controlled rate. A sheet of Plexiglas was placed beside the
system to provide a safe barrier in case of catastrophic failure of the system, detailed in Figure 7.10.
The pressure vessel was sealed in the same manner as the other tests. The air pressure was increased and
brought up to around 15psi. Then it was cut off so that a calculation of the leaking rate could be determined.
By making an accurate calculation, a comparison could be made to determine the required water needed in the
system to hold 15psi for the required time frame. The leaking rate was high and it was found that the threads
of the system were bleeding pressure.
Figure 7.10 - Air Pressure Testing with Plexiglas Shield
28
Materials were purchased from Lowes and Home Depot once it was determined that there is a Home Depot in
Nicaragua where materials can be purchased. All materials are off the shelf products. The original thought
was that off the shelf products would be easier to obtain in Nicaragua and therefore the purchase and
construction of the outlet valve could be completed in Nicaragua by the clinics. Parts were chosen from the
plumbing section and the hardware section. Two different designs were constructed using two different sizes
for a total of four designs.
7.2.1 End Cap as Regulator
Research into pressure regulator valves led to a weighted valve design for the outlet valve of the solar
autoclave. The initial design was a copper pipe from the aluminum end block with a vent to release the
pressure out of the can. In order to build and maintain pressure, it was decided that an end cap with a load
attached (weight) would suffice as the weighted valve. A 1/2" copper pipe was utilized and a 1/2" end cap
with weights was attached. First holes were drilled in the end cap to allow for excess pressure to escape. The
1/2" cap with holes is shown as Figure 7.11. The cap had a plate attached to it to hang the weights from. This
is shown in Figure 7.12. The theory was that as the pressure builds in the can, the force begins to push on the
weighted cap on the vent pipe. The cap would remain in place and sealed up to the 15psi threshold. It was
desired that the valve would regulate the pressure, meaning that as the pressure increased above 15psi, the cap
would slightly raise up, allowing the excess pressure to escape through the drilled holes. When the excess
pressure was relieved, the cap would slide back into position, again forming a seal to keep the pressure in the
can at 15psi. Utilizing the calculations performed previously, for a 1/2" outlet valve, 3 lbs would be required
for 15psi. Since we wanted the system to maintain pressure at 15psi and the cap to remain intact at this
pressure, we began testing the cap design with 3.5 pounds and gradually increased the weight. The cap was
designed to maintain a seal for a pressure of 20psi. The outlet valve concept is shown as Figure 7.13.
Figure 7.11
29
Figure 7.12
Figure 7.13
During a team meeting, it was brought to the pressure vessel improvement team's attention that the 5 pounds
required for 20psi on the 1/2" weighted valve may be enough to actually tip the solar autoclave over. It was
decided that the outlet valve could be reduced to 1/4" outlet via a reduction couple. This in turn would result
in a weight requirement of only 1 pound. Figure 7.14 is resultant end cap design. A soup can was used to hold
the weight under the end cap. It was thought that wet sand or water could be placed in the can to a specified
line that indicated one pound.
30
Figure 7.14
Feasibility testing on both end cap designs with various weights proved to be unreliable in maintaining a seal,
as well as the proper blow off pressure. It was determined at that time to move on to a second design concept.
7.2.2 Nut and Bolt Fixture as Regulator
Through research it was found that some pressure regulators actually have a cylindrical weight that is
physically in the outlet valve. This concept was adapted by using a nut, bolt and rubber gasket to simulate the
design seen in the research. Figure 7.15 and 7.16 show the two nut and bolt configurations that were
prototyped. The first is for the 1/2" outlet valve and the second is the for the 1/4" outlet valve. A proper seal
was not obtained in initial test runs and therefore aquarium sealant was utilized to try and make a better seal
on the vent pipe. This sealant is shown on only the smaller nut and bolt, Figure 7.16.
31
Figure 7.15
Figure 7.16
The weight was held in the same manner as the first two designs, with a metal plate and soup can. Figure 7.17
is the pressure regulator system for the nut and bolt configuration.
32
Figure 7.17
While the concept seemed to have some merit, it did not maintain a seal for even low pressures and the design
was abandoned for a weighted outlet valve off an existing pressure cooker. At this point in the semester, it
was decided that while the idea of constructing a pressure regulator from off the shelf material was appealing,
it was not realizable given the materials purchased of the shelf were not sufficient for creating a high-quality
seal which resulted in a lack of maintaining pressure.
7.2.3 Safety Valves
During the interim meeting, it was suggested that a safety valve be incorporated into the design through a
separate hole in the aluminum end cap. Plastic and galvanized steel 1/2" nipples were utilized along with
varying sizes of rubber plugs. The various safety valves were constructed and tested. Figure 7.18, 7.19, and
7.20 show the various designs that were tested.
33
Figure 7.18
Figure 7.19
Figure 7.20
34
A major factor in the functionality of the safety valve was the force at which the plugs were inserted into the
shafts. When a mallet was used, the plug would not budge. If only human brute force was utilized, then it was
not consistent on when the plug would pop. At this same time, the sealants were being tested and it was found
that none of the sealants that were being considered could withstand more that 30-35 psi. It was decided at
this point that this would act as the safety valve, similar to modern pressure cookers. While the safety valve
plug design was feasible given a prescribed force on each use, there is no way to verify that this exact force
could be accomplished by the nurses in Nicaragua.
7.2.4 Check Valve valvula de descarga
The check valve was required to prevent a vacuum from forming inside the can. Research into check valves
showed that Home Depot had a check valve for less than $10. It was decided that one could not be fabricated
from off the shelf parts for less than this. Also, the check valve was known to work. Figure 7.21 is a picture
of the check valve purchased for the solar autoclave. This is a 3/4" check valve and the piping from the end
block was 1/2", therefore a reduction couple had to be soldered to the copper pipes.
Figure 7.21
35
The sterilization indicator’s prototype development process began with the choice of materials and
verification of concept. A suitable housing material was identified as extruded acrylic from USPlastic and a
good phase-change material was identified as Polywax© 2000. In
addition to being a good fit for the requirements, Polywax© 2000 was
readily available.
The first test that was performed was creating tubes out of the
acrylic and sealing phase-change material inside. The prototypes were
applied to a fast high-temperature cycle. Basically, this kind of cycle
quickly heats up to the maximum temperature of 121° Celsius and
holds that temperature for 15 minutes. It then rapidly depressurizes
and cools down. So, the focus of this specific test was to see whether
or not enough heat would conduct through the housing to melt the
Polywax© 2000, so the length and the amount of Polywax©2000 Figure 7.22 - Initial test to verify heat transfer.
in each tube were arbitrary. Figure 1 shows the experimental
setup for this test. Although only a small amount of the material melted, the test revealed a major flaw with the
design that was not previously considered: pressurization of the contents. As the interior of the indicator heats
up, the fixed mass of air heats up. Thus, a heated fixed mass of air in a fixed volume results in a large pressure
being exerted on the walls of the indicator. It was seen with this initial test that the end caps sprung leaks. We
concluded that a method for venting the indicators was needed.
Designing the vented indicators was decided to be important enough to have the
team apply the decision analysis process to the designs. The concept that was
widely accepted as being a good solution was to have a single hole drilled
through the top and bottom of the indicator. Whenever the indicator is in
operation, a removable plug will be placed into the bottom such that no wax will
leak out; however, the top will still be open in order to allow venting. As
prototypes for this concept were being fabricated through UDRI, a weight-driven
indicator concept was designed, fabricated, and tested.
Figure 7.23 - Airless design. To try to avoid the venting issues presented by the other design, a quick
prototype was created to test an airless indicator. The concept, shown in Figure
2, is to have a cylinder completely filled with Polywax©2000 and a washer
suspended in the solidified wax. The theory of operation was that it would indicate
sterilization when the washer dropped to the other end of the indicator, showing
that all of the contents melted. Three of these were created of various size, 0.75cm,
1cm, and 1.25cm tall. They were put into the autoclave in a similar experimental
setup as Figure 1 and were exposed to a fast high-temperature thermal cycle. The
results were surprising. Two of the three indicators had a sealing failure while the
other indicator bulged indicating that it still had a large amount of internal pressure.
Figure 7.24 - One of the These prototypes shows how important it is to take into consideration the thermal
failed airless indicators. expansion of the phase-change material as it changes from solid to liquid.
Initially, three vented indicators were machined according to the concept shown
in Figure 4. One-half of each indicator contained the Polywax© 2000 while the other half remained empty.
Once the Polywax© 2000 melts, it is intended to travel through the material aperture and into the second
chamber. Only when all of the material has been transported to the other side of the indicator can the cycle can
36
be considered complete. These were machined to be 0.75inches, 1 inch, and 1.25 inches tall. Similar to the
other tests, they were initially applied to a fast high-temperature thermal cycle.
The results of this test were very encouraging. Although the
expansion of the solid material into its liquid state was seen through having
material flowing out of the top venting hole, some material did flow down
into the empty half of the indicator and was held there by the stopper. Thus,
the next prototypes require the top chamber to be only half filled and to find
the necessary amount of material to melt over a thermal cycle.
To accomplish this, a test grid was created that had indicators of
various sizes and amounts of Polywax© 2000. So, six indicators of the kind
shown in Figure 4 were made and once filled with their appropriate amounts
of material, were tested under a slow high-temperature thermal cycle. The
slow high-temperature thermal cycle slowly increases the temperature from Figure 7.25 - Vented Sterilization
ambient to 200° Fahrenheit holds the temperature at around 225° Fahrenheit Indicator Concept
for 20 minutes. Once those twenty minutes have elapsed, the temperature is then increased to 250° Fahrenheit
and held at 250° for 15 minutes. The chamber is then quickly cooled and the test is complete. Such a cycle is
intended to replicate the conditions that would be found inside the solar autoclave.
37
8.0 Results
Research and testing performed in previous semesters allowed the team to continue in the current semester to
improve the open-ended cylinder design for the solar autoclave. Conceptualization from the previous
semester led the team to continue the phase-change material indicator design. Re-evaluating the
recommendations left from last semester as well as developing new conceptual designs for both products led
to testing of the new ideas. The team performed cycles of testing, implementing improvements at each phase.
At the conclusion of the testing the final design contained an aluminum end plate, a new sealant, a pressure
release valve, and easy-to-access assembly. The final design of the sterilization indicator was vented in a
simple way to ensure stability and to make it easier to use but was found to be unreliable as a final design.
8.1 Pressure Vessel
Extensive testing has been performed this semester in an effort to develop a final working system. The
research performed at the beginning of the semester and the recommendations left from the groups that
worked on the project in the previous semesters have allowed us to pursue defined projects. The team worked
to improve upon the open-ended cylinder design for the solar autoclave. Testing was performed on the
pressure vessel through hydraulic oil structural testing, air pressure testing, and oven testing. The results of
the tests examined the structural integrity of the design as well as its ability to heat and gain pressure. After
the final testing on the pressure vessel was completed, conclusions and recommendations were drawn as to
how to improve the design further and how to continue testing.
8.1.1 Pressure Seal and Structural Testing
The seal and structural testing phase developed as a need to check the structural integrity of the design and
determine which seal was the most effective. Conclusions drawn from this series of tests were that the can
will safely be able to withstand the pressures of the sterilization cycle. The sealant located between the can
lip and the top end cap was proved to be an effective safety relief at 32-40 psi through failure. The silicone
pie pan was selected as the most desired seal as it performed the best and is proven to be safe at oven
temperatures. The final conclusion drawn from the hydraulic oil testing was that it would be safe to start air
pressure testing.
8.1.2 Air Pressure Testing
The results of the air pressure testing concluded that the 10 psi of pressure were lost over a 10 minute period.
After the ten minutes, the system steadied at 5 psi and did not lose further pressure. This test proved that the
current design is not completely air tight and that there might be difficulty getting the pressure up to 15 psi and
maintaining this pressure. The air pressure testing also concluded that the design was safe to start oven
testing.
8.1.3 Oven Testing
Oven testing was performed to simulate the environment that the pressure vessel and relief valve will
experience when placed in the solar autoclave. Six oven tests were performed and measurements taken. The
chart below shows the recorded temperatures of the oven and inside of pressure vessel during the test. Many
38
conclusions were drawn from this testing phase of simulated heating. First, all the system component were
able to withstand the high temperatures of the oven, including the wooden end cap. The pine wood was the
cause for concern because of the evaporation of its moisture content which could result in cracking.
From oven testing, the temperature of 121°C was determined to be reachable in the pressure vessel given
simulated oven temperatures of 150°C over a time period of approximately 50 minutes. With copper piping to
the outside of the oven, no pressure was able to be recorded from the gage, but steam could be seen leaving the
manually triggered outlet. Water and steam leaks were visible with the setup.
The final oven test resulted in the pressure vessel incorporating the relief valve. During this test, the inner can
temperature steadied at 109°C, which from steam tables pressure would be about 8 psi. The removal of the
pressure relief valve resulted in 30 seconds of steam out of the vessel.
Figure 8.1 – Oven Testing of Solar Autoclave
The pressure vessel system completed at the end of last semester that was improved upon did not include a
release valve that is necessary to an autoclave. An effort was made to develop a valve that could be
manufactured by the same people who will manufacture the pressure vessel. Unfortunately, due to
unreliability in these manufactured parts, it was determined that this would not be possible. A commercial
vent pipe and weighted regulator were purchased and implemented in our final design. Also for safety
concerns a check valve has been included to prevent a lower pressure vacuum inside of the pressure vessel.
39
8.2.1 Verification of Final Design
The improved pressure vessel required a pressure release/regulator valve, as well as a check valve and a safety
valve. A reasonable effort was made to manufacture an outlet valve from off the shelf components that could
be easily assembled by the solar autoclave construction team in Nicaragua. Due to the randomness and
unreliability of the off the shelf copper components, it was decided that this design be abandoned for a more
reliable pre-fabricated outlet valve and check valve.
The outlet valve obtained from a commercial pressure cooker is fabricated with more precision than the
copper caps and copper piping. The copper pipes, couples and cap were soldered together and used in the final
design as part of the overall structure. The testing on the final outlet valve and check valve design proved
successful in forced air tests. It was determined that the jiggler for the vent pipe would activate at 15 psi. It
was desired to have an outlet valve that would maintain the pressure at 15 psi; therefore weight was added to
increase the psi at which the outlet valve would regulate. Various weights were added and the nominal
additional weight found was to be 0.015 lbs, which results in a total weighted regulator of 0.215 lbs. This
weight will jiggle at 16 psi, therefore maintaining and regulating 15 psi. Without the addition of the 0.015 lbs,
the jiggler maintained pressure at 14 psi, by jiggling at 15 psi. This additional weight is critical to sustain the
required 15 psi in order to sterilize the medical instruments. Table 8.1 shows the experimental testing
completed on the final outlet valve/check valve.
Table 8.1
Force (Weight) Required to Maintain

Pressure for Fabricated Vent Pipe
Total
Additional Weight
Weight (lb) (lb) σ (psi)
0.000 0.2000 15
0.005 0.2050 15
0.010 0.2100 15
0.015 0.2150 16
0.035 0.2350 18
The safety valve for the overall system was addressed and it was concluded that the sealant of the solar
autoclave, in addition to the weighted regulator was adequate as a safety valve. The silicone sealant was tested
and verified to break its seal at 30-35 psi. The known operating levels of the solar cooker, from previous
experiments conducted during the summer of ***, conveyed that the autoclave would not be able to reach or
sustain elevated pressures above what the sealant would break down at. It was also concluded that the drilling
of an additional passage in the aluminum end block would result in a weakness in the integrity of the block.
The check valve was incorporated into the system in order to prevent a vacuum from forming in the solar
autoclave during the cool-down cycle. The swing check valve will stabilize the pressure inside the can to that
of the pressure outside the can. The testing results of the check valve prove that it is operating correctly and
will prevent the can from collapsing in on itself, as is the case with a vacuum.
40
The sterilization indicator testing performed during this semester has provided the team with insight into the
nature of phase change material. The failure of the airless, sealed approach provided a better understanding of
the expansion properties. The vented, hourglass design proved to be functional but relies on an extensive
heating procedure. Also, the current vented design relies on an end cap to prevent leakage and therefore also
will need to be placed on a flat, stable and dry surface during the entire process. These factors, while not
ruling out the design, have made the final design not a reliable indication device. The electrical embodiment
design appears to be a much more reliable approach to the problem. The following sterilization indicator
section details the findings after testing.
After comparing the two embodiment designs on paper, the simplicity of the hourglass is still appealing;
however, disadvantages to its design became apparent after testing. First, the amount of heat required to
increase the indicator's temperature is very large and may inhibit the autoclave's ability to produce steam.
Second, the phase-change material is very slow and will not be able to respond to rapid changes in
temperature. Also, it requires a rather large amount of flat space in the pressure vessel to operate. Additional
considerations will have to be made to ensure that the pressure vessel does not become rocked or bumped such
as to not disturb the indicator. If the pressure vessel uses its top-loading design and then needs to be set onto
its side, this indicator will be very difficult to keep upright.
The electronic indicator has its appeals as well. It has a much smaller thermal footprint and does not interfere
with the contents of the vessel. There will be no trouble in disassembling or reassembling the pressure vessel
with the electronics. It also will operate more responsively to temperature variations, unlike the hourglass.
Also, the electronics will operate more predictably than the hourglass as there is a sense of uncertainty related
to the operation of the hourglass. However, there will be a much larger cost in creating an electronic indicator
than a phase-change hourglass. Also, the electronic indicator may be more fragile and susceptible to damage
than the hourglass.
Being the more developed concept, the hourglass design was chosen to be refined and, unfortunately, not
enough time remained to complete any additional work on the electronic indicator. By the end of the semester,
it was determined that the amount of inconsistencies and unknowns related to the hourglass indicator will keep
us from recommending it for implementation. It is currently not a reliable indication device. If future effort
will be placed in developing a sustainable indication device, it is recommended that the electronic indicator be
developed. The benefits from the electronic indicator outweigh its flaws and, when compared to how the
hourglass's flaws outweigh its benefits, the electronic indicator clearly is the better choice.
41
9.0 Manufacturing Instructions & Nicaragua Test Plans
9.1 Manufacturing Procedure – Pressure Vessel

9.1.1 Materials
a. Tin plated steel can (coffee can), 6” diameter x 7” long
b. Pine board, 1-1/2” x 8” x 8”
c. Four (4) threaded bolts, 3/8” x 10” long
d. Plumber’s Tape, 1/4" wide [is there an alternative? This acts as a sealant to the threads. Makes
it water tight].
e. Eight (8) 3/8" flat washer
f. Four (4) wing nuts, 3/8” thread
g. Aluminum Plate, 8” x 8” x ½” [could possibly be thinner]
h. Silicone pie plate
• Pressure Relief Valve System parts [complex systems. We need to find a place that sells
plumbing systems. If was difficult for Daniel to find a place that sells piping]
i. Copper pipe – ½” diameter x 9”
j. Copper end cap – ½” diameter
k. Copper T-bracket – ½”
l. Check Valve – ¾”
Pressure gauge.
9.1.2 Tools
a. 12 inch (min.) ruler
b. Pencil
c. Sharp pointed marker
d. Power drill
e. Hand saw
f. 1/4" drill bit
g. 1/2" drill bit
h. 5/16” drill bit
i. Adjustable wrench
j. Medium-sized locking pliers (min. 3/8” jaw opening)
k. Utility knife or a box cutter
l. Soldering Tools
m. Hack Saw
9.1.3 Procedure
i. Forming the wooden block:
1. Using the hand saw, cut the pine board into two equal sections, 8 inch by 8 inch
square.
2. The cap needs to be drilled to accommodate the threaded rods. Make one mark
in each corner of the block, one-half inch from the adjacent faces, as shown in
Figure 9.1
42
Figure 9.1 - Marking the Corner Holes
3. Fit the 1/2 inch drill bit into the power drill and plug in the drill, if necessary.
Make sure to secure the drill bit firmly.
4. Drill one hole at each of the four marks made. It is very important that these
holes be as near perpendicular to the surface as possible. Clear the holes of any
splintered wood.
5. Cap should now look as shown in Figure 9.2.
Figure 9.2 - Cap after Drilling Holes
ii. Adding the valve assembly:

1. Cut a 3” long piece of copper tubing and solder with a ½” male adapter.
2. Solder a ½” T-bracket onto the assembly.
3. Cut two (2) 3” long pieces of copper tubing and solder to the other sides of the
T-bracket.
4. Using a ¼” drill bit, drill a hole into the copper end cap.
5. Assemble outlet valve through the cap.
6. Solder cap to top of the pipe of the assembly.
7. Solder the ¾” male adapter reduction to ½”.
43
8. Couple to the right side of the t-bracket.
9. Using plumber’s tape and attach the check valve. IMPORTANT: Make sure the
Arrow on the side of the check valve points towards the pressure vessel.
iii. Creating the seals:

1. Lay the silicon pan out on a flat, firm surface--preferably on a cutting board.
2. Cut off any sides to silicon so that you have a flat piece.
3. Using the ruler and a marker, make a rough circle of 8” diameter putting marks
down at each measurement including the center.
4. Using the marks as a guide, use the shears or the utility knife to cut out the
silicon.
5. Using the utility knife or sharp object, pierce a hole into the center of the silicon.
iv. Producing the metal end cap

1. Cut out an 8” x 8” block of aluminum, if not already done.
2. Using the marker, mark locations ½” from corner. See Figure 9.2
3. Using a ½” drill bit, drill at each mark the entire way thru.
4. Mark the center of the plate with the marker by measuring 4” from both sides.
5. Drill a ½” pipe threaded (NPT) hole into the center of the plate.
v. Applying the seal to the metal end cap

1. Take metal cap and apply a coat of silicon glue.
2. Place the silicon cutout onto the glued side, making sure that the center hole is
aligned with the center hole.
vi. Assembling the Solar Autoclave

1. Place wood cap on-end, on a flat surface.
2. Place 1 washer on each bolt and insert the bolts into the holes of the wooden
cap.
3. Place the current assembly on a flat surface, allowing the bolts to be upright.
4. Place the 6 inch diameter can on the upper face of the wood cap, in between the
threaded rods. The closed end of the can should be facing the wood.
5. Slide the instrument tray into the can.
6. Place aluminum cap and sealant onto the can, allowing the bolts to go through
the machined holes.
7. Once Cap A is settled onto the can, slide a flat washer down each end of the
threaded rod followed by a wing nut.
8. Adjust the can such that it is centered on the silicone seal, and then tighten the
wing nuts down by hand.
9. The Solar Autoclave should now look as shown in Figure 9.3
44
Figure 9.3 - Assembled Autoclave and Valve Assembly
9.2 Manufacturing Procedure – Sterilization Indicator
To machine a phase change hourglass indicator, perform the following steps

assuming that d equals 1":
1.) Drill a 1/8" hole as deep as the desired indicator is tall (h) into the center
of the acrylic rod. Continue to drill an additional 1/8" deep.
2.) Cut two 1/16" cross-sectional slices from the newly drilled rod. These
two slices will be the vented caps for the indicator.
3.) Cross-sectionally cut the acrylic rod once at length "h" from the end of
the rod. This resulting piece will be the indicator.
4.) Bore out a 7/8"-wide hole into the newly cut piece a distance of
(h/2+1/32)".
5.) Repeat step 4 on the other end of the indicator. If completed successfully, Figure 9.4
there should be a 1/16"-thick partition in the center of the indicator.
6.) To create the plugging cap, insert the rod into a lathe and lathe-down 1/8" of the rod until a 1/8" wide plug
is created.
7.) Cross-section the rod 1/16" below the base of the 1/8"-tall plug. This will produce the cap.
45
8.) Apply a thin coat of IPS Weld-On glue onto one of the caps with a hole as well as onto the edge of one of
the ends of the hourglass. Firmly press the cap onto the hourglass and maintain pressure between the cap and
the hourglass with a c-clamp. Let sit for 48 hours.
9.) Insert the plug cap into the hole of the newly capped indicator. Melt an amount of Polywax2000 and pour it
into the open end of the indicator.
10.) Repeat step 8 for the last open end of the indicator.
11.) Heat the indicator in an oven at 125 Celsius for 30 minutes. This should transfer all of the phase-change
material into one end of the indicator.
12.) The indicator is complete.
9.3 Nicaragua Test Plans
After completion of the team’s final testing on campus, the test plans for Nicaragua have been developed to
guide the team heading to Nicaragua this summer. The proposed testing is very similar to tests performed on
campus with integration of the solar box cooker. The supplies to conduct these tests will be made available to
the team and recommendations of testing procedures follow.
Solar Autoclave Testing:
Supplies:
All materials and tools listed in manufacturing instructions

Pressure Gage
Copper Piping
Sleeves
Connecting inserts for copper piping
Manual triggering outlet
T-valve
Thermocouples
Multimeter
Aluminum plate with hole for thermocouples
Procedure:
The Nicaraguan test plans are to perform the same oven testing procedure, but use the solar autoclave as the
heating source. The pressure vessel design should be built according to the manufacturing instructions and the
aluminum plate should have a small hole be drilled in it to allow for a thermocouple to be inserted into the
system. Use epoxy to seal the hole and keep the thermocouple in place right above the water level.
The silicone seal should then be glued to the aluminum top end can using the high temperature silicone
sealant. A small slice or hole in the silicone pie pan will need to be made to let the thermocouple wire into the
inside of the can. A t-valve should be tightened into the top end cap to attach both the pressure relief valve
and the copper piping to the outside air. The copper piping setup with pressure gage and pressure relief valve
46
will be intact on arrival and should be connected to the T-valve. The pressure relief valve cap should point
vertically when the can sits on one of its sides to ensure of its performance.
After the pressure vessel is constructed, the solar box cooker should be placed under the sunlight to achieve its
maximum temperatures. An open container of water should be placed in the cooker to begin heating the
system. Once the water is boiling, approximately one cup of the water should be poured into the coffee can.
The system should then be tightened down using the wing nuts. The bolt heads should be held with a wrench
and the wing nuts tightened down as much as possible by hand.
Another thermocouple should be tied to a bolt on the pressure vessel to capture the actual oven temperature.
The thermocouples can then be connected to the multimeter, which should be set up to read temperature in
Celsius. The pressure vessel should be inserted into the solar box cooker and the copper piping guided out of
the box cooker. The system is then ready to begin testing to check the pressures and temperatures of the
pressure vessel.
It is recommended that the temperatures and pressures be recorded every five minutes of the heating process.
The oven temperature, can temperature, and can pressure should be monitored checked for any abnormal
trends. Oven testing took almost an hour to achieve sterilization temperature, so the solar autoclave may take
a considerable amount of time to heat up.
When taking the pressure vessel out of the oven, extreme caution should be kept as the contents will be very
hot and take a long time to cool down. If no pressures are recorded, the copper piping setup can be checked
for leaking and re-soldered to prevent the leak. The test could also be run with just the pressure relief valve
removing the T-valve. This test would only provide for temperature readings, but the pressure can be
calculated from steam tables.
47
10.0 Cost Estimation
The design requirements of the solar autoclave and the sterilization indicator included the cost to manufacture
said products. The solar autoclave was to be low cost both in materials in production. The sterilization
indicator was set to a cost of $0.01 for non-reusable and $10 for reusable per unit for materials and
manufacturing. The cost of a low end pressure cooker runs approximately $19.95 for a 4 quart model and a
upwards of $97.98 for a 23 quart model. These figures will be used to make a comparison between the final
designed solar autoclave and a pressure cooker from Wal-Mart (which has a several hundred stores in
Nicaragua). The final design cost estimate including the sterilization indicator was found to be $211.16 and
can be located at the bottom of Table 10.1.
48
Item
Direct Labor (Press
Assemblers
Skilled Laborers
Overhead
Total Direct
Direct Materials (P
49
11.0 Conclusions
There were three main components that were designed and tested this semester for our project. The solar
autoclave was taken from a previous pressure vessel prototype and improved, the sterilization indicator was
taken from an embodiment design and finalized and the pressure release valve was developed to add to the
pressure vessel. During this the Product Realization Process (PRP) was followed. The solar autoclave was
improved in many areas including the components used in the final design, for example the seal, and the
assembly process. The structural integrity of the final design was verified and shown to be pressure stable
prior to the inclusion of the pressure release valve. Ultimately, the autoclave system takes an extensive
amount of time to heat in a normal home oven under warm, stable conditions. Therefore it is likely that the
conditions in a solar cooker in Nicaragua will also lead to a very lengthy time to reach the necessary
temperature. The pressure release valve developed for the autoclave was initially designed and built with
components that could be easily found off the shelf. Unfortunately, it was determined that they were not
manufactured within the necessary tolerances to allow them to be consistently used in a final design.
Therefore we purchased an outlet valve and a check valve that work reliably. Also, in our final design the seal
of the pressure vessel functions as a secondary safety system as it has been shown to fail between 32 and
40psi. The vented, hourglass design of the sterilization indicator has been shown to require a lengthy heating
time before it is ready to indicate the critical temperature across time. Like any phase change material, it
requires a substantial amount of energy to change from solid to liquid and this will require a lot of input
energy. The current design requires an end cap in the bottom to keep the material within the bottom chamber.
This creates a requirement that the device be placed on a flat, stable and dry surface in order to work and be
prepared to be flipped over for the following test. Currently it is not a reliable indicator for the sterilization
process.
50
12.0 Recommendations
The final design has been verified through extensive testing, but further investigation will involve testing the
entire autoclave system to verify sterilization. Additional oven tests should be run to verify that the system is
reaching and holding the desired pressure using reliable gages. If the 15psi internal pressure is not being
reached, then the design needs to be reevaluated and the seals of all the parts will need to be improved. The
entire system including the solar cooker, the pressure vessel, sterilization indicator, and pressure release valve
must be tested together and verified to work in the Nicaraguan climate. We have provided test plans for the
next trip to Nicaragua. The phase change sterilization indicator needs further testing before it will be suitable
for use. The indicator should be tested within the solar autoclave, once it has been verified, to ensure that both
parts work together accordingly. The electronic indicator embodiment design is preferred over the phase
change indicator at this point for its simplicity and the fact that it will not require a lengthy heating time. Also
thermal-set polymers should be investigated more. Information on thermal-set polymers are included in the
Appendix. The amount of water needs to be studied using various amounts to make sure that the optimum
level is being used. In addition, further testing must be conducted to verify endurance of the design across its
lifespan for safety and maintenance purposes. The financial cost of the entire system also needs to be further
considered to keep production costs at a minimum. The price difference for certain components in Nicaragua,
and potentially other developing countries, may result in significantly lower prices. Also, the tray used within
the solar autoclave can only be 6.5” by 6”. We are recommending the use of chicken wire, but specifically not
using galvanized steel as it can corrode toxic contents into the water used. The tray must be chosen such that
it will avoid burning the users or the users must be effectively taught to not touch it until it cools.
51
13.0 References
1. Megyesy, Eugene F. Pressure Vessel Handbook. Tenth Edition. Pressure Vessel Publishing, Inc. Tulsa,
OK. ©1995.
2. Zappe, R. W. Valve Selection Handbook. Fourth Edition. Gulf Publishing Company, Houston, TX.©
1999.
3. Malek, Mohammad A. Pressure Relief Devices. McGraw-Hill Publishing, New York, NY. ©2006.
4. Young, Warren C. Roark’s Formulas for Stress and Strain. Sixth Edition. McGraw-Hill, New York.
©1989.
5. Green, David W., Winandy Jerrold E., Kretschmann, David E., Mechanical Properties of Wood. Wood
handbook—Wood as an engineering material
6. Michael Vaughen, Manager of Central Supply, Akron Children's Hospital.

Michael served as a contact for obtaining medical instruments to be tested.
7. Jim Seemore, Manager of Sterilization Department, Akron Children's Hospital.

Jim helped the design team .
8. Doepker, Philip E. “The Design Project. The Application of the Product Realization Process.”
University of Dayton
9. HALA. Lexan Data Sheet. Raw data. Dec. 2005.
10. Hanna, Lori, Daniel Hensel, and Pete Kolis. Solar Autoclave/Solar Cooker Technical Report. Tech.No.
Summer 2008.
11. Hanna, Lori, Daniel Hensel, Matt Pinger, Adam Ryba, and Chris Weiss. Solar Autoclave. Vers. Final. 24
Apr. 2008. University of Dayton. 7 Oct. 2008.
12. Incropera, Frank P. Introduction to Heat Transfer. Wiley. 2001. Fourth edition.
This book was used as a reference to perform the heat transfer calculations through the housing units.
13. Kerr, Barbara P., and James Scott. “Use of the Solar Panel Cooker for Medical Pressure Steam
Sterilization.” Tech.No. Kerr-Cole Sustainable Living Center.
This document provides their methodology for sterilization indication, which turns out to be different
from our own.
14. Lemieux, P. "Destruction of Spores on BDR in a Commercial Autoclave." Applied and Environmental
Microbiology.
15. "Periodic Table-Melting Point." 2006. Sept. 2008

<http://www.chemicalelements.com/show/meltingpoint.html>.
52
16. Colavito, C.J. Solar Cooker Box Construction Manual. Nicaragua: Grupo Fenix, 2008.
17. http://www.nationsencyclopedia.com/Americas/Nicaragua-CLIMATE.html.
This site was used to find climate data in Nicaragua.
18. http://www.csgnetwork.com/emctablecalc.html.
This site was used to determine humidity content in the Nicaraguan Climate.
19. http://products.asminternational.org/hbk/index.jsp.
This site provided fracture mechanics information for steels.
20. http://www.memagazine.org/backissues/membersonly/february2000/features/code/code.html.
An article on boiler pressure vessel codes.
21. http://www.a-sp.org/Standards/chapters/assembly/B.pdf.
This is the global stock sizing for different metals.
22. http://www.worldsteel.org/pictures/programfiles/WSIF07web%20v7.pdf
This .PDF summarizes the global steel production for the world in 2007.
23. http://american.edu/ted/NICARAG.HTM.
Different woods found in Nicaragua.
24. http://web.worldbank.org/WBSITE/EXTERNAL/COUNTRIES/LACEXT/NICARAGUAEXTN/0,,cont
entMDK:21792497~pagePK:141137~piPK:141127~theSitePK:258689,00.html.
An article discussing the need in Nicaragua to grow forests.
25. http://www.elarbol.nl/boseng.html
This site discusses the different types of wood available in Nicaragua.
26. http://www.usaid.gov/our_work/environment/forestry/features_aug2004a.html
This article talks about the forests in Nicaragua.
27. http://www.vollrathco.com/catalog_product.jsp?id=4485&cid=133
A site for steel cylinders for cooking purposes.
28. http://www.narang.com/autoclave_sterilizers/autoclave_pressure_steam_sterilizers.php
This is general information about autoclaves and their abilities
29. http://www.cancentral.com/index.cfm
The main site for the Can Manufacturers Institute (CMI).
30. http://www.webcastgroup.com/client/start.asp?wid=0870727051764
A video explaining the process of how cans are made.
53
31. http://www.ecplaza.net/tradeleads/seller/4274700/pneumatic_cylinder_tube.html
Neumatic Cylinder Tube.
32. http://www.arlon-std.com/Library/Guides/Outgassing%20of%20Silicone%20Elastomers.pdf
This is a technical document discussing the outgassing of silicone.
33. http://www.ee.ualberta.ca/~schmaus/vacf/outgas.html
This is a table that shows the amount of outgassing that occurs on different materials.
34. http://www.spiraxsarco.com/resources/steam-engineering-tutorials/steam-engineering-principles-and-
heat-transfer.asp
This site gives excellent information on the different properties of steam.
35. www.dofmaster.com/steam.html
This is a steam and water calculator to determine how much water to use inside the pressure vessel.
36. http://www.csgnetwork.com/emctablecalc.html
This site is a wood and moisture content calculator.
37. http://www.asrc.cestm.albany.edu/perez/2003-2004/map.pdf
This is a paper mapping the intensity of solar radiation around the world.
38. http://www.saluddelsol.org/
Research into solar autoclave, background and purpose.
39. http://www.vpico.com
This site gave information on steam sterilization cycles in healthcare facilities and how they use
biological indicators.
40. http://www.wikipedia.org/wiki/sterilization
This site gave a broad overview of all sterilization practices.
41. http://www.bag-healthcare.com
This site provided all the different types of biological indicators for sterilization processes
42. http://www.globalspec.com/
Engineering search web-site. Utilized for further research into materials.
43. http://www.usplastics.com
Utilized to order materials.
44. http://www.tapplastics.com
Utilized to order materials.
45. http://www.grupofenix.org/
Research into solar cookers, solar autoclaves, and conditions in Nicaragua
46. http://missvickie.com/
Miss Vicky's Pressure Cooker Website --This website has a lot of great information on pressure cookers
and how they operate, as well as comparative analysis of older traditional cookers to today's modern
cookers. The operation of the various valves and seals are explained in an easy to understand manner.
47. http://en.wikipedia.org/wiki/Pressure_cooking
Pressure cooking - Wikipedia, the free encyclopedia --This website was utilized as a resource for the
definition and function of the various valves. It aided in deciphering between a PRV and PSV, as well as
the difference in a regulator valve versus a relief valve.
54
48. http://www.sms.si.edu/IRLspec/Pinus_elliot.htm
Smithsonian Marine Station at Fort Pierce --This website was utilized to determine the properties of the
Caribbean pine that is to be used for the stationary end cap. It was determined from this site that the pine
is abundant and will make a proper functioning end cap for the solar autoclave.
49. http://www.solarcooker-at-cantinawest.com/homemade_solar_ovens.html
Homemade solar ovens - Best materials and supplies --The team utilized this website to determine the
availability of materials and resources in Nicaragua. No costs were found from the site.
50. http://walmart-centroamerica.com/nuestras_tiendas_nicaragua.htm
Central Americas Wal-mart website --This website was used to determine the proximity of Wal-mart to
the clinics, as well as the availability of the materials used in the construction of the autoclave.
51. 3M. "3M Comply (SteriGage) Steam and EO Chemical Integrators." 3M Infection Prevention
Solutions . 3M Corporation. 30 Oct. 2008
http://solutions.3m.com/wps/portal/3m/en_us/ip/infectionprevention/solutions/sterilization-assurance/
This site provided inspiration for one of the conceptual designs.
52. Diack. "Diack Control (for 250 F) VAC Control (For 272 F)." ZapConnect . 30 Oct. 2008.
http://www.zapconnect.com/products/index.cfm/fuseaction/products_display_detail/eregnum/1824234/o
wner_operator_number/1824234/product_code/joj/1824234.html
This site provided material properties for their phase change material.
55
Appendix Table of Contents
Appendix A Design Project Agreement
Appendix B Contact Information
Appendix C Project Proposal
Appendix D Weekly Status Reports
Appendix E Final Gantt Chart
Appendix F First Oral Presentation
Appendix G Second Oral Presentation
Appendix H Final Oral Presentation
Appendix I Meeting Minutes
Appendix J Individual Conceptual Designs
Appendix K Decision Analysis Sheets (Team)
Appendix L Embodiment Designs
Appendix M Learn, Lead and Serve Grant Application
Appendix N Miscellaneous Calculations & MATLAB Code
Appendix O Miscellaneous Engineering Drawings
Appendix P Project Expenses
Appendix Q Purchase Receipts
Appendix R Miscellaneous Research
Appendix S Structural & Sealant Test Data
Appendix T Oven Test Data
Appendix U Project Description Form
Appendix V Solar Autoclave Final Report
Appendix W Solar Autoclave Technical Report
Appendix X Design of a Sterilization Indicator
Appendix Y Rough Draft – Graded – John Hageman
Appendix Z Rough Draft – Graded – Don Schenk
56

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Solar Autoclave with Sterilization Indicator

ECE/MEE 432L, Design and Manufacturing Clinic

2.1 Pressure Vessel Research

2.2 Pressure Release Valve Research

3.1 Functional Requirements

3.2 Design Requirements

The autoclave must:

3.3 Design Criteria

4.1 Establish Need

4.2 Proposal and Specifications

Establish Need (ALL)

Identify Project & Team

Develop Questions for Spons

Compile Conceptual Design

Create Embodiment Design

Assemble Components Lis

4.4 Conceptual Design and Decision Analysis

4.5 Embodiment Design

4.6 Initial Calculations and Testing

4.7 Engineering Calculations

4.9 Prototype Fabrication

4.10 Prototype Testing/Data Analysis

4.11 Cost Estimation

4.12. Final Presentation

4.13 Final Report

5.1 Pressure Vessel

5.2 Outlet Valve

Copper Pipe Vent Pipe

Intended to be a reliable and sustainable indicator,

6.1 Sterilization Indicator

t = Thickness; T1=Temperature of outside plastic; Tw=Temperature of Inner Surface; tm=time interval;

6.1.2 Calculations and Equations

External Temperature as a function of Indicator Height and Diameter

Figure 6.1 - External Temperature as a Function of Indicator Height and Diameter

6.2 Pressure Release Valve

6.3 Water Amount

7.1 Pressure Vessel Structural and Seal Testing

Figure 7.2 - Strain Gages - Side of Can

Figure 7.4 - Pouring Hydraulic Oil into Can

7.1.1 Temperature Testing

Figure 7.8 - Melted Plastic Tubing

7.1.2 Air Pressure Testing

Figure 7.10 - Air Pressure Testing with Plexiglas Shield

7.2.1 End Cap as Regulator

7.2.2 Nut and Bolt Fixture as Regulator

7.2.3 Safety Valves

7.2.4 Check Valve valvula de descarga

8.1 Pressure Vessel

8.1.1 Pressure Seal and Structural Testing

8.1.2 Air Pressure Testing

8.1.3 Oven Testing

Figure 8.1 – Oven Testing of Solar Autoclave

8.2 Pressure Release Valve

Force (Weight) Required to Maintain

9.1 Manufacturing Procedure – Pressure Vessel

Figure 9.2 - Cap after Drilling Holes

ii. Adding the valve assembly:

iii. Creating the seals:

iv. Producing the metal end cap

v. Applying the seal to the metal end cap

vi. Assembling the Solar Autoclave

9.2 Manufacturing Procedure – Sterilization Indicator

To machine a phase change hourglass indicator, perform the following steps