U.S. patent number 3,774,522 [Application Number 05/233,453] was granted by the patent office on 1973-11-27 for modular clean room enclosure.
This patent grant is currently assigned to Bio-Dynamics, Inc.. Invention is credited to Robert Claude Marsh.
United States Patent |
3,774,522 |
Marsh |
November 27, 1973 |
**Please see images for:
( Certificate of Correction ) ** |
MODULAR CLEAN ROOM ENCLOSURE
Abstract
A portable, modular room enclosure having an open end providing
horizontal, contaminant-free tunnel type laminar flow for surgery
or the like includes mobile means for generating an air flow
demountably connected to said enclosure, air supply means in the
unit in communication with the air flow generating means for
receiving the air flow and converting it to a contaminant-free
horizontal laminar flow within the enclosure toward the open end,
first and second partitions forming side walls of the enclosure,
wherein each partition is demountably connected at one end to said
air supply means and at least one retractable side panel slidably
mounted on a track connected to each partition wherein the track
and panel are in parallel relation with the partition. By extending
or retracting the side panels the length of each partition may be
selectively changed to accommodate the needs of a surgery theater
or the like.
Inventors: |
Marsh; Robert Claude
(Albuquerque, NM) |
Assignee: |
Bio-Dynamics, Inc. (Castleton,
IN)
|
Family
ID: |
22877315 |
Appl.
No.: |
05/233,453 |
Filed: |
March 10, 1972 |
Current U.S.
Class: |
454/187; 55/509;
600/21; 55/484; 454/251 |
Current CPC
Class: |
A61G
13/108 (20130101); A61G 10/02 (20130101) |
Current International
Class: |
A61G
13/00 (20060101); F24f 009/00 () |
Field of
Search: |
;98/36,33,115SB
;128/1R,1B ;55/DIG.29 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
The Farr DF/48 Clean Booth, Product Data Sheet, May 5, 1965. .
Laminar Flow Clean Room Handbook; Boyd Agnew, Jan. 1966, pages 2,
20 & 40..
|
Primary Examiner: Wayner; William E.
Claims
I claim:
1. A portable modular room enclosure having an open end providing
horizontal contaminant-free tunnel type laminar flow for surgery or
the like comprising:
a. mobile means for generating an air flow demountably connected to
the said enclosure;
b. air supply means in said unit in communication with said air
flow generating means for receiving said air flow and converting
said flow to a contaminant free, horizontal laminar flow within
said enclosure toward said open end;
c. first and second partitions forming side walls of said
enclosure, each partition demountably connected at one end to said
air supply means; and
d. at least one retractable side panel, slidably mounted on a track
connected to each said partition, said track and panel in parallel
relation with said partition for selectively extending the length
of each said partition.
Description
BACKGROUND OF THE INVENTION
The invention relates to a portable clean room and, in particular,
to a surgery isolator as a movable, clean room enclosure providing
a sterile, pathogen-free environment for surgical operations
needing sepsis control.
Infection of surgical wounds and microbial complications in other
hospital treatment areas still persist despite great advances in
antiseptics during the past century. Additionally, modern implant
and transplant surgery and such specialized treatment as
chemotherapy often place fatal significance on hospital acquired
sepsis. Airborne contamination control has always been recognized
as vital in controling cross-infection within the hospital and is
one of the first steps in the overall sanitation program. Recently
the requirements for ultra-clean or sterile assembly environments
in the nuclear or space exploration industries have lead to the
development of "clean rooms" which can virtually eliminate the
environment as a source of airborne infection.
Contemporary clean rooms are permanent structures generally entered
through air lock or the like and, as such, are not compatible with
hospital surgery problems. Operating theaters and surgery rooms
require special equipment, such as X-ray equipment, gas fixtures
and special operating lights. Therefore, a permanent clean room
enclosure is not feasible for a hospital as the requirements for a
clean room will not be needed for every operation. Accordingly
there has developed a need for a portable enclosure for use with
existing ceilings and fixtures in an operating theater which will
provide a clean room environment for operations.
As employed in the present application the term clean room denotes
a facility especially designed to create an atmosphere
substantially free of particles. For this purpose a maximum
particle concentration of 100 particles per cubic foot 0.5 microns
and greater in size, is required. The term laminar flow clean room
as employed in the application is directed to an enclosure or room
formed by a bank of high efficiency particulate air filters on one
entire wall wherein air is introduced to the enclosure through the
filter at a rate of from about 70 to 110 feet per minute.
Conventional high efficiency particulate air (HEPA) filters have a
minimum efficiency of 99.97 percent for particles as small as 0.3
microns in size.
SUMMARY OF THE INVENTION
It is, therefore, a primary object of the invention to provide a
portable, modular enclosure for use in operating theaters or the
like which permits use of existing facilities and permits free
access for operating personnel.
It is another object of the invention to provide a modular clean
room enclosure having externally mounted support equipment to
provide maximum available space within the enclosure.
It is an additional object of the invention to provide a modular
clean room which is readily converted into a conventional operating
theater, as desired.
It is yet another object of the invention to provide a modular
clean room which is freely open to personnel without the need for
air locks or the like.
It is a further object of the invention to provide a portable
surgery isolator whose length may be varied within predetermined
limits in order to adjust to the needs of different operations.
The above and other objects are met in a portable modular room
enclosure having an open end providing horizontal, contaminant
free, tunnel type laminar flow for surgery or the like which
includes mobile means for generating an air flow demountably
connected to the enclosure. Air supply means in the unit is in
communication with the air flow generator and receives the air flow
and converts it to a contaminant-free horizontal laminar flow
toward the open end of the enclosure. First and second partitions
form side walls of the enclosure. Each partition is demountably
connected at one end to the air supply mechanism. At least one
retractable side panel is provided which is slidably mounted on a
track, wherein the track is connected to the partition. The track
and panel are mounted in parallel relation to the partition for
selectively extending the length of the position.
In one embodiment the modular enclosure includes a mounting base
having adjustable leveling feet. First and second air plenums, each
plenum having a side opening and a front opening are adjacently
seated on the mounting base. First and second filter frame supports
are bolted respectively to the first and second air plenums. Each
frame support carries a plurality of individual framed high
efficiency particulate air filters in snap locking engagement with
the filter frame support. Each bank of HEPA filters is protected by
a pair of punched screens latched onto the frame support.
An air tower is provided on each side of the air plenum. Each air
tower is equipped with a prefilter and blower for generating an air
flow into the plenum.
The sides of the portable clean room are formed by a pair of
enclosure panels attached to the side of a filter frame unit and
singly anchored to the ceiling. Each enclosure panel is provided
with a pair of sliding glass door panels suspended from the floor.
The glass door panels permit individual adjustment of the sides of
the isolator module.
If necessary, adjustable ceiling filler panels are provided on each
side enclosure wall and the filter frame support unit to prevent
contaminated air from entering the isolator immediately forward of
the HEPA filter bank.
Substantial significant advantages are obtained by the isolator.
The isolator is readily set up in existing operating theaters
making use of existing ceilings and permitting use of existing
lighting facilities, X-ray facilities, outlets and fixtures. Ready
access through the opened end of the isolator is available without
disturbing the integrity of the clean room environment. All
available space within the clean room enclosure is utilizable as
the mechanical and electrical support equipment remains outside the
enclosure. If a clean room is not needed the sliding glass
sidewalls are retracted into the enclosure panel.
The adjustable ceiling filler panels permit the unit to be set up
in rooms of varying heights within certain limits. Power cords, gas
supply cords and monitoring circuit cords readily pass under the
sliding doors. The transparent side panels permit a large audience
to view the operating theater within the room without the danger of
cross-contamination.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings illustrate a somewhat preferred
embodiment of the invention in which:
FIG. 1 is a top plan view of the modular enclosure or isolator
illustrating the laminar flow of air through the unit;
FIG. 2 is a front view of the unit from the open end of unit toward
the filter bank;
FIG. 3 is a side view of the isolator with the corresponding air
tower removed and diagrammatically illustrating the ceiling anchor
for the side wall;
FIG. 4 is a fragmentary, perspective view of a corner of the
isolator illustrating the adjustable filler panels;
FIG. 5 is an enlarged fragmentary view showing a ceiling hanger
bracket;
FIG. 6 is a partial sectional view of an air tower of the unit
adjacent the side panel of the unit with the retractable glass
sliding panel removed;
FIG. 7 is a perspective view of the isolator with one pair of glass
doors retracted to the side wall;
FIG. 8 is a fragmentary, exploded view illustrating the connections
between the track assembly carrying the sliding glass doors and the
side wall panel; and
FIG. 9 is an exploded view of a filter wall and air supply plenum
of the unit.
DESCRIPTION OF PREFERRED EMBODIMENTS
As illustrated in FIG. 1 modular enclosure or isolator 10 has
associated therewith a pair of air towers 12 for generating an air
flow into the unit. Each air tower is mechanically connected to a
plenum extension panel 14 to provide an air way into the unit. Air
passing through the plenum extensions is received through the side
openings 16 of air plenums 18. Each said air plenum 18 opens into a
bank 20 of high efficiency particulate air filters. Each bank is
protected by a pair of abutting perforated screens 22.
The wall of contaminant-free, laminar flow air represented by the
solid line of arrows 24 in FIG. 1 is bounded and shaped by a pair
of solid stationary partitions 26 connected to the sides of filter
bank 20. One pair of sliding glass door panels 28 is mounted to the
exterior wall of each of the partitions 26. The bottom of the
sliding glass door panels is suspended above the floor to permit
air and power lines and the like to extend under the door panel.
Air also passes over the tops of the door panels as well as from
the end of the isolator 10. The aforesaid air passages are denoted
by arrows in FIG. 1. This ultra clean air gently sweeps across the
enclosure area removing all airborne contaminants generated therein
and also provides a positive barrier against particles from the
surrounding environment.
As particularly illustrated in FIG. 6 air tower 12 is a
self-contained mobile unit carried by a set of adjustable casters
which provide a leveling adjustment to compensate for any possible
uneven floor. Casters 180 are spaced at each corner of the air
tower. Tower 12 is formed from a rectangular shell 182. On the face
of the shell are a pair of elongated hinged corner panels 184 which
provide access for a set of three vertically mounted prefilters
186, one set of prefilters to each panel. A pair of elongated slots
188 on the face of the air tower provides an intake for the
prefilters.
A pair of stacked blowers 30 draw air into the air tower and
exhaust the air into an elongated rectangular discharge orifice 32.
The blowers are shock mounted to reduce vibration.
Air is discharged from the air tower to discharge orifice 32 into a
matched intake orifice 34 in plenum extension panel 14. In order to
provide a positive but detachable mechanical connection between air
tower 12 and plenum extension panel 14 a rotatable mechanical
latching knuckle 36 is provided adjacent discharge orifice 32. The
knuckle is operated by means of crank 38 located on the face of the
air tower. Latch knuckle 36 cooperates with horizontal bar 40 which
is spaced across plenum extension intake orifice 34.
Air tower 12 also contains gauge 42 for measuring air flow velocity
and indicates a malfunction should one or both blowers fail to
operate properly. A ground chain loop 44 below air tower 12
provides a ground to the conductor floor of the operating theater.
In order to provide a more positive and air tight seal between the
air tower and plenum extension panel 14 a resilient, preferably
Neoprene gasket 43 is provided about the periphery of discharge
opening 32. As illustrated in FIGS. 3 and 4 in order to properly
align air towers 12 with plenum extension panels 14 there are
provided a pair of docking stops 46 mounted at the top and bottom
edges of intake orifice 34. As seen in FIG. 4 the stops extend
outwardly from the back edge of the extension panels 14 and engage
the rear panels 48 of air towers 12.
The isolator air supply and filter modules are shown in FIGS. 1, 2,
6, 7 and 9. Air supply module 50 is formed from plenum extension
panels 14 and plenums 18. Filter module 52 is formed from filter
bank 20 and protective screens 22. Air supply module 50 and filter
module 52 are seated on the walls 56 of mounting base 58. Mounting
base 58 is a rectangular frame containing six spaced apart leveling
feet 60 as shown in FIG. 2. After the base has been leveled it is
preferred to employ a rubber or Neoprene gasket to seal the bottom
of the mounting base to the floor. A pair of rectangular air
plenums 18 are seated side to side along the length of mounting
base 58. Each plenum consists of a generally rectangular frame with
a solid rear and open front face. There is provided a side opening
16 in each of the plenum frames to receive air passed from plenum
extension panels 14 which is bolted on to the plenum. Air plenums
18 are each bolted to mounting base 58.
Filter module 52 is formed from a pair of filter frame support
units 64 bolted together side to side as illustrated in FIG. 9. If
necessary a silicone sealant is provided between the bottom of each
filter frame support and the mounting base to provide an air tight
seal therewith.
Each filter frame is divided into three compartments for retaining
framed HEPA filters. For this purpose a spring loaded clamping
mechanism 66 is provided for each compartment. When necessary each
framed HEPA filter may be easily removed from the unit and
replaced. Conventional framed HEPA filters 68 are provided for each
filter frame compartment, wherein each filter is adapted to remove
all particulate matter 0.3 microns and larger with an efficiency of
99.97 percent.
A pair of rectangular perforated screens 22 are latched to the
front of each frame support 64. The perforated screens protect the
HEPA filters and also indicate damage to them. For present purposes
it is preferred to employ perforated aluminum screens having a 30
percent open area. A workable screen contains openings
approximately 0.06 inch in diameter. The screen is preferably about
1/16 inch thick. As shown in FIG. 9 latches 70 are provided on the
upper face of frame support 64 and cooperate with mounting hooks
(not shown on the screen) to anchor the screen to the frame
support. Further, a series of spaced apart tongues 72 are provided
along the base of each frame support to cooperate with tongue
receiving grooves to further anchor the screens.
The screens cooperate with the filter bank to provide a
unidirectional laminar flow pattern directed toward the open end of
the isolator and at preferred velocity of from 70 to 110 and
particularly 90 feet per minute.
The modular side enclosure units 74 are illustrated in FIGS. 3-8.
Each enclosure includes a solid aluminum partition 26 which is
preferably caulked or sealed with a silicone sealant to the floor
of the operating theater. As shown in FIG. 6 each partition is
bolted 76 to a side edge of frame support 64. In order to carry
glass door panels 28 each said partition is provided with a track
assembly 78. FIG. 8 illustrates the mounting of track assembly 78
to partition 26. An elongated stud plate 80 is bolted or screwed to
the outside upper wall of the partition.
Four elongated threaded bolts 82 project horizontally from stud
plate 80. Each track assembly has a complimentary pair of
pre-punched holes for capture by each said bolt. A nut and washer
84 are employed to anchor each bolt on the track assembly.
As illustrated in FIG. 5 track assembly 78 contains four extruded
rectangular compartments. The parallelly aligned bottom
compartments 284 are each provided with a pair of opposed channels
86 adapted to receive the rollers associated with a conventional
sliding door assembly.
For aesthetic purposes it is preferred to employ a pair of closure
plates 88 to cover the track assembly. As shown in FIG. 8 rear
inside closure plate 89 is bolted to partition 26. Outer closure
plate 90 is bolted to track assembly 78.
A second pair of closure plates 92 cover the assembly beyond the
partitions. The ends of closure plates 92 are screwed or bolted to
mating flanges 94 on closure plates 88.
As illustrated in FIGS. 1, 3, 6 and 7 a pair of conventional glass
door panels 28 are hung on track assembly 78. Doors 28 are
preferably suspended about 3 inches off the floor so that operating
room power lines, gas lines and the like may pass safely
thereunder. Each glass door panel assembly has a pair of parallelly
aligned glass doors consisting of inner door 96 and outer door 98.
A bumper 100 is provided to arrest the movement of inner door 96
adjacent plenum extension 14. Bumper 100 faces inner door 96 and is
screwed to partition 26. A similar bumper 102 is screwed to the
outer frame 104 of inner door 96 and serves to arrest the movement
of outer door 98 as it is retracted.
As illustrated in FIG. 6 in order to arrest the movement of inner
door 96 as it is moved from its position of rest adjacent panel 96
and moved towards a furthest extended position, an ENTERLOCK
extrusion wing 106 is provided at the end of partitions 26. A
mating wing is provided on the inside rear edge of inner door 96.
Similarly, an extrusion wing is provided on the forward outer edge
of inner door 96 which is adapted to mate with an extrusion wing on
the inside rear edge of outer door 98. In order to provide a
further positive arrest for the outward movement of the sliding
doors a closure plate is screwed across the ends of the track
assembly (not shown).
In order to prevent scraping of the doors during opening and
retraction a partition mounted roller guide 108 is provided to ease
movement between the inner door and partitions. Similarly, a roller
guide is provided on the lower forward edge 110 at inner door 96 to
prevent scraping between the inner and outer doors.
In order to provide an air tight seal between the ceiling of the
operating room, the air supply module and the side partitions 26
filler panels are employed. Turning now to FIGS. 4 and 7 there is
shown a pair of partition mounted side filler panels 112. Each side
filler panel extends from the rear edge 114 of each plenum 18 to
the forward edge 116 of each partition 26. Each filler panel 112 is
formed from a lower L-shaped bracket bolted to the top of partition
26 and an upper inverted L-shaped bracket 120 which is frictionally
mounted to lower bracket 118 by means of set screws 122. Upper
bracket 120 is adapted to frictionally slide along the outer
surface of lower bracket 118 until the upper bracket engages the
ceiling. At this point set screws 122 are engaged. A pair of
upright extrusions 124 provide mounting brackets for the set
screws.
A Neoprene gasket is provided along the upper ledge of upper
bracket 120 to provide an air tight seal with the ceiling.
In similar fashion an upper 126 and lower 128 filler panel is
provided along the inner edge 130 of frame supports 64. A sealing
gasket is provided along the upper ledge of the upper filler panel
126 of the blankoff.
In order to support the weight of the glass doors in the extended
position it is preferred to employ a track assembly mounted hanger
bolt, as illustrated in FIGS. 3 and 5. For this purpose a bottom
hanger bracket is screwed into the top compartments of track
assembly 78 by means of machine screws 134. An inverted U-shaped
top hanger bracket 136 is slidably engaged along the rear wall 138
of lower bracket 132. For this purpose a pair of complimentary
slots are provided in top and bottom hanger brackets 132, 136. A
pair of screws 13 extend through the mating slots and the height of
top hanger bracket 136 is adjusted by selectively tightening the
nuts on the screws in the desired position.
The top of top hanger bracket 136 contains a slot elongated in
direction perpendicular to the mating slots 137 in the respective
hanger brackets. For mounting purposes a hanger bolt 142 is driven
into the operating room ceiling and permitted to extend the
preselected distance below the ceiling. The hanger bolt is captured
by the slot in top hanger bracket 136 and is engaged thereunder by
a nut.
To assemble the surgery isolator mounting base 58 is moved to a
preselected portion section of the operating theater and, if
necessary caulked or sealed to the floor. Depending on the length
of the track assemblies a hanger bolt 142 is driven into the
ceiling for capture by the respective hanger brackets. Air supply
plenums 18 are bolted to the mounting brackets and plenum
extensions 14 are bolted to the respective ends of plenum 18. With
the air supply module 50 assembled, the filter module is then
erected by bolting the frame support 64 to the air plenums 18. Next
the partitions 26 are bolted to the filter support 64. The
individual HEPA filters 68 are snapped into the respective filter
support compartments and the perforated screens 22 are latched onto
the front of the frame supports. The track assembly and sliding
doors are then bolted to the respective side partitions. To support
the track assembly lower hanger bolt bracket 132 is slid along an
extruded track 144 on track assembly 18. When the hanger bolt 142
is suitably aligned a pair of screws extending through the lower
hanger bolt bracket are tightened locking the bracket onto the
track assembly. The top hanger bracket is vertically adjusted until
the hanger bolt extends through the slot in the top plate and then
a nut is selectively tightened beneath the slot to capture the
hanger bolt.
Next, the side and top mounted ceiling filler panels are vertically
adjusted until they are in sealing engagement with the operating
room ceiling. Silicone sealant is then applied to the juncture
between the top of the frame support unit and mounting base. Next,
air towers 12 are individually aligned with docking stops 46 on
plenum extension 14. After alignment crank 38 on each of the air
towers is actuated and mechanical latch knuckle engages plenum bar
40 locking each respective air tower to the plenum extension.
In general it is preferable to employ strong, rigid but lightweight
metals for the modular units. Aluminum is a preferred material.
Preferably all components are desired to passed through a standard
doorway. If desired an additional air intake may be employed on top
of the air tower.
While the preferred embodiment of the invention has been
illustrated hereinabove it will be obvious to those skilled in that
art that various modifications can be made in materials, size and
mounting arrangements within the spirit of the invention. The
invention is not to be limited except as set forth in the following
claims.
* * * * *