U.S. patent application number 09/833807 was filed with the patent office on 2002-05-02 for assembly.
Invention is credited to Cocker, Neil.
Application Number | 20020050770 09/833807 |
Document ID | / |
Family ID | 9889963 |
Filed Date | 2002-05-02 |
United States Patent
Application |
20020050770 |
Kind Code |
A1 |
Cocker, Neil |
May 2, 2002 |
Assembly
Abstract
The present invention relates to a modular containment assembly
of novel component parts which by virtue of its inherent
versatility is straightforward and inexpensive to assemble whilst
providing improved performance and cleanliness thereby minimising
the potential for product contamination. More particularly, the
component parts are an operator booth and a modular structure
comprising a plurality of unitary frameworks between which (in use)
is induced an airflow.
Inventors: |
Cocker, Neil; (South
Yorkshire, GB) |
Correspondence
Address: |
FACTOR & PARTNERS, LLC
1327 W. WASHINGTON BLVD.
SUITE 5G/H
CHICAGO
IL
60607
US
|
Family ID: |
9889963 |
Appl. No.: |
09/833807 |
Filed: |
April 12, 2001 |
Current U.S.
Class: |
312/107 ;
312/223.3 |
Current CPC
Class: |
F24F 2221/36 20130101;
F24F 3/163 20210101 |
Class at
Publication: |
312/107 ;
312/223.3 |
International
Class: |
A47B 087/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 15, 2000 |
GB |
0009295.7 |
Claims
What is claimed is:
1. A modular containment assembly comprising components between
which in use is induced an airflow, said components being: a
modular structure comprising a plurality of unitary frameworks
stacked to form a network of discrete housings; an operator booth
of box-like configuration having a rear wall positioned adjacent to
the modular structure, wherein the modular structure is adapted at
or near to its lower end to receive the airflow from the operator
booth and at or near to its upper end to transmit the airflow to
the operator booth, and the rear wall of the operator booth is
adapted at or near to its lower end to transmit the airflow to the
modular structure; and means for inducing the airflow downwardly in
the operator booth.
2. A modular containment assembly as claimed in claim 1 further
comprising: a plenum arrangement adjacent to an open ceiling of the
operator booth, wherein the plenum arrangement is capable of
transmitting the airflow from at or near to the upper end of the
modular structure downwardly into the operator booth.
3. A modular containment assembly as claimed in claim 2 wherein the
plenum arrangement comprises one or more plenum chambers.
4. A modular containment assembly as claimed in claim 3 wherein the
or each plenum chamber is adapted to contribute to perfect laminar
flow (PLF).
5. A modular containment assembly as claimed in claim 3 wherein the
or each plenum chamber comprises a base frame having a ladder-like
configuration.
6. A modular containment assembly as claimed in claim 5 wherein the
base frame comprises two elongate side members joined in parallel
spaced apart relationship by a plurality of transverse members.
7. A modular containment assembly as claimed in claim 5 wherein on
the lower face of the base frame is mounted PLF material.
8. A modular containment assembly as claimed in claim 5 wherein a
profiled canopy is secured to the upper face of the base frame.
9. A modular containment assembly as claimed in claim 8 wherein the
profiled canopy has a substantially vertical open end through which
may be transmitted airflow from the modular structure.
10. A modular containment assembly as claimed in claim 9 wherein
the substantially vertical open end is defined by two side walls
joined in substantially parallel spaced apart relationship by an
integral rear wall which curves inwardly away from the open
end.
11. A modular containment assembly as claimed in claim 10 wherein
the substantially vertical open end is fitted with a panel of PLF
material.
12. A modular containment assembly as claimed in claim 1 wherein
the modular structure comprises: an at least partially open front
face at or near to its lower end and adjacent to the rear wall of
the operator booth, wherein the rear wall of the operator booth at
or near to its lower end comprises an elongate gap capable of
transmitting airflow from the operator booth to and through the at
least partially open front face of the modular structure.
13. A modular containment assembly as claimed in claim 12 wherein
the at least partially open front face is adapted to mount a
pre-filter.
14. A modular containment assembly as claimed in claim 1 wherein
each unitary framework is a metal frame construction.
15. A modular containment assembly as claimed in claim 14 wherein
the metal is steel.
16. A modular containment assembly as claimed in claim 1 wherein
one or more of the unitary frameworks is panelled.
17. A modular containment assembly as claimed in claim 16 wherein
the panels are steel panels.
18. A modular containment assembly as claimed in claim 1 wherein
each unitary framework comprises a plurality of struts.
19. A modular containment assembly as claimed in claim 18 wherein
the struts are uniform.
20. A modular containment assembly as claimed in claim 18 wherein
each strut of the unitary framework has a uniform drill
pattern.
21. A modular containment assembly as claimed in claim 1 wherein
one or more of the unitary frameworks is box-like.
22. A modular containment assembly as claimed in claim 1 wherein at
least one unitary framework is adapted to vertically mount a
filter.
23. A modular containment assembly as claimed in claim 22 wherein
the at least one unitary framework is positioned at or near to the
lower end of the modular structure.
24. A modular containment assembly as claimed in claim 1 wherein at
least one unitary framework is adapted to horizontally mount a
filter.
25. A modular containment assembly as claimed in claim 24 wherein
the at least one unitary framework is positioned above the
lowermost unitary framework of the modular structure.
25. A modular containment assembly as claimed in claim 1 wherein at
least one unitary framework is adapted to mount a fan unit.
26. A modular containment assembly as claimed in claim 25 wherein
the at least one unitary framework is positioned at or near to the
upper end of the modular structure.
27. A modular containment assembly as claimed in claim 1 wherein
the means for inducing the airflow comprises a fan unit driven by a
flange mounted inverter controlled motor.
28. A modular containment assembly as claimed in claim 1 wherein
the operator booth comprises individual panels capable of being
locked together.
Description
BACKGROUND ART
[0001] 1. Field of the Invention
[0002] The present invention relates to a novel modular containment
assembly comprising certain components, in particular to a down
flow modular containment assembly, and to the components
themselves.
[0003] 2. Background Art
[0004] In conventional containment assemblies for use in (for
example) handling pharmaceuticals, the air quality in the operator
booth may be controlled using forced ventilation. One category of
forced ventilation is "down flow" in which surrounding air is drawn
downwardly to entrain contaminants to a level below the handling
area (eg to a level below the typical operators breathing zone).
For down flow containment, exhaust is usually carried out at low
level relative to the source of the contaminant.
[0005] Due to the demanding requirements of current Good
Manufacturing Practices exercised within the pharmaceutical
manufacturing industry and to the required containment performance
and operator exposure levels, conventional down flow containment
assemblies are in general complex unitary structures which are
difficult and relatively expensive to assemble.
[0006] The present invention seeks to overcome certain of the
disadvantages of the conventional assemblies by providing a simpler
and more hygienic containment assembly without compromising the
performance of the assembly (ie which meets the strict industrial
operating parameters such as the the Good Manufacturing Practices
of the pharmaceutical industry). In particular, the present
invention provides a modular containment assembly of novel
component parts which by virtue of its inherent versatility is
straightforward and inexpensive to assemble whilst providing
improved performance and cleanliness thereby minimising the
potential for product contamination.
SUMMARY OF THE INVENTION
[0007] Thus viewed from one aspect the present invention provides a
modular containment assembly comprising components between which
(in use) is induced an airflow, said components being:
[0008] a modular structure comprising a plurality of unitary
frameworks stacked to form a network of discrete housings;
[0009] an operator booth of box-like configuration having a rear
wall positioned adjacent to the modular structure, wherein the
modular structure is adapted at or near to its lower end to receive
the airflow from the operator booth and at or near to its upper end
to transmit the airflow to the operator booth, and the rear wall of
the operator booth is adapted at or near to its lower end to
transmit the airflow to the modular structure; and
[0010] means for inducing the airflow downwardly in the operator
booth.
[0011] The versatility of the modular containment assembly of the
invention is such that any of the individual components may be
readily assembled and supplied to a user with the intention of
putting the invention into effect in combination with the other
components which may already be available to the user.
[0012] Typically, the assembly of the invention is adapted so that
air falls in an undisturbed, non-turbulent manner past the region
of the operator booth in which the operator operates ("the operator
breathing zone") at a predetermined velocity. Preferably the
components of the assembly are adapted to attain perfect laminar
flow (PLF) of air. Preferably the modular structure at or near to
its upper end comprises PLF material (eg a PLF screen) through
which the airflow passes to the operator booth.
[0013] A preferred embodiment of the modular containment assembly
of the invention further comprises a plenum arrangement adjacent to
an open ceiling of the operator booth, wherein the plenum
arrangement is capable of transmitting the airflow from at or near
to the upper end of the modular structure downwardly into the
operator booth.
[0014] Preferably the plenum arrangement comprises one or more
plenum chambers. The or each chamber may be generally adapted to
minimise the plenum volume. Preferably the or each plenum chamber
is adapted to contribute to perfect laminar flow (PLF).
[0015] The or each plenum chamber preferably comprises a metal
(preferably steel) base frame coated on two sides with a material
of a preset tension. The base frame provides a specific pressure
drop which may contribute to the perfect laminar flow (PLF). The
base frame conveniently has a ladder-like configuration. For
example, the base frame comprises two elongate side members joined
in parallel spaced apart relationship by a plurality of transverse
members. On the lower face of the base frame there may be mounted
PLF material (eg a PLF screen). Laminar flow light fittings may be
mounted to the lower face of the frame (eg the side members) if
desired.
[0016] A profiled canopy may be secured to the upper face of the
base frame. Preferably the profiled canopy is capable of providing
a smooth and interrupted airflow from the modular structure into
the PLF material. For example, the profiled canopy may have a
substantially vertical open end (eg a substantially square open
end) through which may be transmitted airflow from the modular
structure. The substantially vertical open end may be defined by
two side walls joined in substantially parallel spaced apart
relationship by an integral rear wall which curves inwardly away
from the open end.
[0017] The substantially vertical open end may be fitted with a
liquid seal. For this purpose the ends of the two side walls and
integral rear wall may be provided with a securing flange.
[0018] The substantially vertical open end may fitted with a PLF
panel to advantageously contribute to even distribution of air
across the width and down the length of the plenum chamber.
[0019] The or each plenum chamber may consist of only one external
seal and is advantageously constructed without external sealants
thereby eliminating a source of possible contamination whilst
maintaining the desired level of cleanliness.
[0020] Preferably the or each plenum chamber is detachably mounted
to the ceiling of the operator booth (eg is a plug-in/plug-out
arrangement) which advantageously makes it sufficiently versatile
to be attached to any type of operator booth.
[0021] In a preferred embodiment of the modular containment
assembly of the invention, the modular structure comprises an at
least partially open front face at or near to its lower end and
adjacent to the rear wall of the operator booth, wherein the rear
wall of the operator booth at or near to its lower end comprises an
elongate gap capable of transmitting airflow from the operator
booth to and through the at least partially open front face of the
modular structure. Preferably the at least partially open front
face is adapted to mount a pre-filter (eg by incorporating a filter
retainer panel).
[0022] Although the modular structure may be manufactured from any
suitable metal (such as steel or aluminium), steel is generally
preferred in terms of costs and flexibility to accommodate design
change (eg future developments in filter design or other internal
component design).
[0023] In a preferred embodiment of the modular containment
assembly of the invention, each unitary framework is a metal (eg an
aluminium or steel) frame construction. A frame construction
advantageously minimises the potentially contaminated volume of the
modular structure.
[0024] Each unitary framework provides a discrete housing which may
be tailored to meet the requirements and conform to the size of a
desired internal component. Examples of internal components may
include part of the means for inducing the airflow such as inter
alia one or more filters or a fan unit. For example, one or more
filters may be housed in a lower discrete housing and a fan unit in
an upper discrete housing of the modular structure.
[0025] If desired, one or more of the unitary frameworks may be
panelled. Suitable panels include standard pressed or vacuum formed
filter retainer panels. Such panels may be attached using a
proprietary adhesive tape and adhesive liquid seal to eliminate any
tendency for product entrapment whilst giving overall structural
rigidity. The adhesive tape provides a seal for the panel and the
liquid adhesive seal ensures a substantially leak-free join.
Preferred are sheet metal (eg steel) panels which (when used with a
compatible (eg steel) framework) may be secured in suitable manner
(eg using adhesives, tapes or fasteners).
[0026] Preferably, each unitary framework comprises a plurality of
struts (eg a plurality of horizontal struts and a plurality of
vertical struts). Particularly preferably the struts are uniform
thereby minimising the number of parts which need to be specially
manufactured. For example, the uniform struts may be of standard
dimensions eg standard 500 mm and/or 700 mm lengths may be used to
assemble the unitary framework allowing any operator booth of width
up to 5 metres to be used. Preferably each strut of the unitary
framework has a uniform drill pattern ensuring complete
modularity.
[0027] Each strut of the unitary framework may be fabricated from
metal (eg aluminium or steel) extrusions and joined in a
conventional manner (eg permanently joined with an air tight corner
piece). Preferably the internal joins between struts are flush and
closed to eliminate entrapment areas. Each strut may comprise an
internal elongate flange which provides a means for securing the
unitary framework to an adjacent unitary framework (eg by providing
a surface through which a fastener such as a bolt may pass) and to
act as a seal zone between adjacent unitary frameworks.
[0028] Preferably one or more of the unitary frameworks is box-like
(eg cuboidal or cubic). Adjacent unitary frameworks may be fastened
together to form the modular structure using any conventional
fastener eg bolts and may be of variable dimensions (eg variable
height) as desired.
[0029] A unitary framework may be adapted to vertically mount a
filter such as a pre-filter (eg by incorporating a filter retainer
panel). Such a unitary framework would generally be positioned at
or near to the lower end of the modular structure and may for
example be the lowermost unitary framework of the modular
structure.
[0030] A unitary framework may be adapted to horizontally mount a
filter such as a hepafilter. Such a unitary framework would
generally be positioned above the lowermost unitary framework of
the modular structure.
[0031] A unitary framework may be adapted to mount a fan unit. Such
a unitary framework would generally be positioned at or near to the
upper end of the modular structure and may for example be the
uppermost unitary framework of the modular structure.
[0032] In a preferred embodiment of the modular containment
assembly of the invention, the means for inducing the airflow
comprises a fan unit driven by a flange mounted inverter controlled
motor which ensures smooth drive via a flexible coupling. The fan
motor unit is placed down flow from the filters ensuring that the
unit is only exposed to clean filtered air. The fan unit may be
seated on highly compressed anti-vibration mounts to ensure that no
vibration is passed onto the adjacent parts of the booth.
[0033] Preferably, the operator booth incorporates a clean room
partition system adapted to meet the requirements of the
pharmaceutical industry. Preferably, the operator booth comprises
individual panels capable of being locked together. This
advantageously eliminates the need for fasteners and reduces
assembly time. Preferably, the operator booth is adapted so that
the number of panel joins are minimised (eg 5 or less) and are
hygienically sealed by a thin bead of silicone.
[0034] The panels of the operator booth may be adapted to provide
exceptional noise damping and vibration isolation. The panels may
provide increased rigidity to support an upper mounted plenum
arrangement. The rear wall of the operator booth comprises a
"service band" which may contain inter alia control buttons, the
electrical and gauge piping, inverter and commissioning interface
which permits entire commissioning from the interior of the booth.
For example, the motor mounted inverter may be controlled via a
link from the service band for ease of commissioning and set up.
Preferably the service band has an aerofoil shaped exterior profile
which improves dust capture in the work area by accelerating
airflow over its surface.
[0035] Each component of the modular down flow booth of the
invention is itself independently patentably significant.
[0036] Thus viewed from a further aspect the present invention
provides a modular structure as hereinbefore defined.
[0037] The modular nature of the modular structure makes it easier
and less costly to manufacture than a large, complex unitary
structure (eg a sheet metal fabrication) fulfilling the same
function. The modular structure is extremely rigid and provides a
steady foundation for the attachment of an operator booth. A
preassembled modular structure may be advantageously transported
(eg using a fork-lift transporter) onto a site in ready-to-run
condition so that only internal components (such as filters,
electrical components and piping) need to be added. Alternatively
it may be provided to the user in disassembled form for assembly on
site. The modular structure has the added advantage that the volume
within the network of housings which has the potential to be
contaminated is minimised.
[0038] Viewed from a yet further aspect the present invention
provides a plenum chamber as hereinbefore defined.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] The invention will now be described in a non-limitative
sense with reference to the accompanying Figures in which:
[0040] FIG. 1 illustrates a modular containment assembly in
accordance with an embodiment of the invention;
[0041] FIG. 2 illustrates a modular containment assembly in
accordance with an embodiment of the invention together with
associated down flow (front perspective view);
[0042] FIG. 3 illustrates a modular containment assembly in
accordance with an embodiment of the invention together with
associated down flow (side view);
[0043] FIG. 4 illustrates a disassembled unitary framework of a
modular structure in accordance with an embodiment of the
invention;
[0044] FIG. 5a and 5b illustrate an assembled unitary framework of
a modular structure in accordance with an embodiment of the
invention in (a) unpanelled and (b) panelled form;
[0045] FIG. 6 illustrates a perspective view of a disassembled
plenum chamber of a plenum arrangement of the invention; and
[0046] FIG. 7 illustrates an assembled unitary framework of a
modular structure in accordance with an embodiment of the
invention.
DETAILED DESCRIPTION OF THE DRAWINGS
[0047] With reference to FIG. 1, there is shown (in partially
exposed view) an embodiment of the modular containment assembly of
the invention designated generally by reference numeral 1. The
assembly comprises a rear modular structure comprising a number of
stacked unitary frameworks 2 each having a frame construction
(discussed below). The exposed view of the interior of the operator
booth 3 shows panels 4 which are locked together without the need
for fasteners. The rear wall of the booth 5 incorporates a laminar
flow service band 6 from which the operator can control the
assembly using the control panel 7. In the ceiling region of the
operator booth, there is mounted a plenum arrangement comprising a
number of plenum chambers 8 (discussed below).
[0048] FIGS. 2 and 3 are intended to illustrate in detail the
airflow in the embodiment described in FIG. 1. In the operator
booth, the airflow is directed downwardly to and through an
elongate opening 20 in the lower part of the rear wall 21. In the
lowermost discrete housing 2a of the modular structure, there is
vertically mounted a FP95 pre-filter 31 through which air flows to
a vertically adjacent discrete housing 2b which contains a
horizontally mounted EU13 Gel Seal HEPAfilter 32. In the uppermost
discrete housing 2c, there is provided a fan unit 33 which draws
air into the plenum chamber 8 and through the laminar flow material
downwardly into the operator booth.
[0049] The components of a unitary framework 2 of the modular
structure of the invention are shown in disassembled view in FIG.
4. In this particular case, the unitary framework 2 is adapted to
vertically mount a pre-filter (see 2a in FIGS. 2 and 3). The
unitary framework 2 comprises a plurality of uniform struts
arranged vertically and horizontally to form a regular box-like
framework. Each vertical and horizontal strut is a standard length
R25-9 aluminium extrusion 40 and they are interconnected by means
of air tight P25-3 corner parts 41 which eliminate the need for
screw fixings. One pair of opposing vertical faces are panelled
using a standard panel 42 of universal size. One of the second pair
of opposing vertical faces is provided with a standard pressed or
vacuum formed filter retainer panel 43 capable of retaining a
pre-filter (not shown). Each strut is provided with a standard hole
pitch 44 in an internal flange 45.
[0050] The fully assembled frame construction with struts and
corner pieces is shown unpanelled in FIG. 5a and panelled in FIG.
5b. In order to fix a panel 42, the satin aluminium finish of the
struts 40 may be primed and an acrylic adhesive tape and a
compatible adhesive seal applied. Panels 42 may be bonded into
place whilst the seal is wet leaving no small internal gaps. The
adhesive tape provides an instant bond while the liquid seal sets.
This method of construction is quick, simple and lowers the skill
level required for manufacture.
[0051] FIG. 6 illustrates a disassembled view of a plenum chamber.
A steel frame base 62 has a ladder like configuration coated on two
sides with a material of a preset tension which provides a specific
pressure drop contributing to perfect laminar flow (PLF). The base
frame comprises two elongate side members 67 joined in parallel
spaced apart relationship by a plurality of transverse members 68.
Each side member 67 is adapted to fasten a light fitting at the
position 65.
[0052] A profiled canopy 63 is bonded using a silicone bead seal to
the upper face of the base frame to provide a smooth and
interrupted airflow from the modular structure into a PLF material
64 mounted on the lower face of the base frame. The profiled canopy
has a substantially vertical end 69 defined by two side walls 70
joined in substantially parallel spaced apart relationship by an
integral rear wall 71 which curves inwardly away from the open end.
Compressible foam seal 61 fits over a 25 mm securing spigot 66 at
the ends of the side walls and rear wall and pushes against a flat
bulk head. The compression seal 61 represents the only external
seal of the plenum chamber and is fitted with a PLF panel 80 to
ensure even distribution of air across the width and down the
length of the plenum chamber. The plenum chamber is a clean, sealed
unit ensuring that air which has been filtered to 99.999995% is
uncontaminated upon transmission to the operator booth.
[0053] FIG. 7 illustrates a unitary framework 102 of an embodiment
of the invention which is an alternative to that illustrated in
FIGS. 4 and 5b. In this case, the unitary framework 102 comprises a
plurality of unfirm steel struts arranged vertically and
horizontally (for example 103 and 104) to form a regular box-like
framework. Bonded to three faces of the unitary framework are steel
panels 105a, 105b and 105c. The unpanelled front face 105d is
capable of retaining a pre-filter (not shown). This unitary
framework 102 advantageously has no gaps.
* * * * *