Modular panel system and a wall installation method

Abstract

The present invention relates to the construction industry, and in particular to laboratories, hospitals, food production areas and other places where asepsis is required. Specifically, it relates to a modular construction system based on self-supporting panels, which have post-formed exterior surfaces and are complemented with corner components of similar construction to build hermetic, waterproof and insulating walls that have smooth surfaces. For this, there is a modular system of panels for forming aseptic spaces within an enclosure and a method of installing a clean room wall by means of a modular system of panels to form aseptic spaces inside an enclosure.

Claims

1. A modular system of panels for forming aseptic spaces within an enclosure, comprising a rectangular parallelepiped type panel with two side covers, wherein each panel includes a flat wall surface that extends into a curved-concave surface at an upper edge of the panel and then continues in a counter-curve that joins an upper surface, where each side cover is half of a post-formed cover of plastic material and comprises a perimeter profile that has a perimeter groove centered and continuous along an outer edge, wherein the halves of the post-formed cover are joined by an inner surface to the perimeter profile, exposing the perimeter groove on an edge of the panel, wherein the perimeter groove has an upper groove on the upper surface of the panel, a bottom groove on a lower edge of the panel, and a side groove on a side of the panel, wherein the upper groove slides the panel with respect to an upper guide profile fixed in a ceiling of the enclosure; wherein the system further comprises: at least one intermediate support profile assembled on a support profile fixed to a floor of the enclosure by means of fasteners to slide the panel on the bottom groove on a projection on an upper edge of the intermediate support profile, while sliding with respect to the upper guide profile; at least one connection profile with a central projection that assembles with the side groove for interleaved mounting of panels; a concave curvature profile assembled on a curve support profile fixed to each side of the support profile to configure a concave and tangential curvature to the floor of the enclosure; and a corner encounter part, which includes a concave corner post-formed cover, a convex corner post-formed cover, a set of edge profiles with a cross-section equal to the perimeter profile that join the corner post-formed covers by a side, upper, and bottom edge with the panels through connection profiles.

2. The modular system of panels of claim 1, further comprising a floor cover that extends to adhere on the concave curvature profile and on a portion of the intermediate support profiles, so that an edge of the floor cover establishes a continuous surface with the flat wall surface of each panel.

3. The modular system of panels of claim 1, wherein the connection profile comprises a flexible strip with a raised edge and the central projection extends along the flexible strip and symmetrically with respect to the plane of the flexible strip.

4. The modular system of panels of claim 3, wherein the central projection has a shape complementary to the side grooves of the panels, which allows tight assembly between the panels to be joined.

5. The modular system of panels of claim 3, wherein the flexible strip has a width less than a distance between the flat wall surfaces and a height of the raised edge is equal to an optimum spacing between adjacent panels to form a sealed joint by subsequent application of a joint sealing product.

6. The modular system of panels of claim 1, wherein between the side covers and the perimeter profile an interior space for insulation is defined that comprises a filling material suitable for at least one of thermal, acoustic, or fire insulation.

7. The modular system of panels of claim 1, wherein the plastic material of each half of the post-formed cover comprises at least one or more of acrylonitrile butadiene styrene (ABS), polymethylmethacrylate (PMMA), glass fibers or carbon dipped in thermostable resins.

8. The modular system of panels of claim 1, wherein for electrical, water, oxygen, gas, and compressed air installations, the system includes at least one panel provided with at least one rectangular hole located on the flat wall surface and a tube that extends upwards from an inside of the at least one rectangular hole and projects beyond the upper surface of the panel through the perimeter profile.

9. The modular system of panels of claim 1, wherein at least one panel has a large rectangular opening therethrough for a frame and a door, which starts at the lower edge of the panel defining an internal lateral edge and an internal upper edge, wherein the intermediate support profile, the support profile, the concave curvature profile, and the curve support profile connected to a bottom of the panel are cut to allow the large rectangular opening to extend to the floor, and the frame and the door are fixed in the large rectangular opening, where the frame and the door have a thickness equal to the panel.

10. The modular system of panels of claim 1, wherein at least one panel has a closed rectangular opening in an interior area of the panel for a frame and a window, and the frame and the window are fixed in the closed rectangular opening, where the window has a window surface in the same plane as the flat wall surface of the panel.

11. The modular system of panels of claim 1, further comprising a panel crossing part, which includes four concave corner post-formed covers, a set of edge profiles with a cross section equal to the perimeter profile that join the concave corner post-formed covers by an adjacent side, upper and lower edge with panels that converge at a junction through connection profiles.

12. A method of installing a clean room wall by means of a modular system of panels to form aseptic spaces inside an enclosure, comprising the steps of: a) fixing an upper guide profile to a ceiling of the enclosure with fasteners; b) fixing a support profile without a cover to a floor of the enclosure and assembling an intermediate support profile; c) positioning a panel by sliding the panel between an upper groove and the upper guide profile and between a bottom groove and a projection on an upper edge of the intermediate support profile; d) intercalating a connection profile with a central projection with a side groove on a side of each panel; e) fixing a curve support profile on each side of the support profile and assembling a concave curvature profile; and f) extending a floor cover and adhering the floor cover to the concave curvature profile and on a portion of the intermediate support profile that remains visible, so that an edge of the floor cover establishes a continuous surface with a flat wall surface of each panel.

13. The method of claim 12, wherein the step of intercalating a connection profile with each panel comprises tightly assembling the central projection of the connection profile and the side groove of each panel, so that a raised edge of a flexible strip of the connection profile is fully fitted between lateral edge surfaces of adjacent panels defining optimal spacing between adjacent panels.

14. The method of claim 13, further comprising the step of: g) applying a joint sealing product in the optimal spacing between adjacent panels to form a sealed joint.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a better explanation of the invention, a description will be made of a preferred embodiment, in relation to the illustrative and non-restrictive figures, wherein:

(2) FIG. 1 shows a vertical sectional view of the panel mounted with its complementary components according to the present invention.

(3) FIG. 2 shows a detailed view of the previous view, illustrating the assembly between the panel and the intermediate support profile.

(4) FIGS. 3A and 3B show, respectively, perspective and sectional views along line A-A of a mold for post-forming a half cover to cover a panel.

(5) FIG. 4 shows an exploded perspective view of the panel, in its monolithic portion.

(6) FIG. 5 shows a perspective view of the panel, in its monolithic portion.

(7) FIGS. 6A and 6B show, respectively, assembly and exploded view of the horizontal section of a joint between adjacent panels according to the present invention.

(8) FIG. 7 shows a perspective view from below of a convex corner post-formed cover, where the dotted lines indicate zones of curvature change without joints.

(9) FIG. 8 shows a view similar to the previous one for a concave corner post-shaped cover.

(10) FIG. 9 shows a perspective view from below of the junction of three post-formed cover halves in different planes and interspersed with a concave corner post-formed cover (indicated by arrow A) and a convex corner post-formed cover (indicated by arrow B).

(11) FIG. 10 depicts the termination of a concave corner of a clean room at the sky level according to the present invention, where the dotted lines indicate zones of curvature change without joints.

(12) FIG. 11 depicts the termination of a concave corner of a clean room at the sky level obtained by prior art technology.

(13) FIG. 12 is an exploded vertical view showing the bottom edge of the panel and the profiles that allow it to be fixed to the floor and incorporate the concave curves in the encounter with the floor.

DETAILED DESCRIPTION OF THE INVENTION

(14) In an important aspect of the invention, post-formed covers for the main surfaces of the panels are included, where said covers have sterile and waterproofing characteristics and that by their smooth shape allow them to be washable and sterilizable. Wherein, the post-forming of the covers implies that their configuration is achieved through the application of heat and pressure on a sheet against a mold. The material in which the covers are manufactured is generally plastic, compatible with post-forming process and with the hygiene requirements of the clean room, considering, but not limited to, materials such as acrylonitrile butadiene styrene (ABS), polymethyl methacrylate (PMMA), glass or carbon fibers bathed in thermosetting resins.

(15) Hereinafter, the panel (1) is identified as the upper portion of the modular panel, which is integral or monolithic. The panel (1) has a rectangular parallelepiped shape, with larger faces corresponding, each, to a flat wall surface (2) that extends into a curved-concave surface (4) upon reaching the upper edges of the panel (1). The curved-concave surfaces (4) define arcs of protruding curvature of cross section corresponding to a quarter of circumference and end in a small convex counter-curvature. Said counter-curvature in turn connects to the panel upper edge surface (3).

(16) In FIG. 1, in a cross-sectional view, the present modular panel installed between the sky and the floor of an enclosure is shown. Which, to form the interior walls of a clean room, of a defined height, includes the panel (1) mounted together with support profiles (8a, 8b, 9b), concave curvature profiles (9a) and the upper guide profile (7). FIG. 2 shows the assembly between the panel (1) and the intermediate support perimeter profile (1b), in addition to the encounter between the flat wall surface (2) on each side of the panel and the floor cover (11).

(17) An advantageous feature of this configuration is that the same panel is used for enclosures of different heights, which is achieved by varying the height of the intermediate support profile (8a), which can be manufactured in a range of sizes, and even resized before transporting to the assembly site, to cover a wide spectrum of total panel height.

(18) All profiles must be made of a material that resists the mechanical stresses and hygiene requirements of the clean room, considering but not limited to materials such as aluminum and PVC.

(19) The panel (1) is developed in an industrialized manner and then transported together with the profiles mentioned above to the assembly site. During the work, elements of fastening of the state of the art are used, whose positions are indicated in FIG. 1, without the need for dimensional adjustments or application of paints or coatings, beyond the sealing of joints between adjacent panels.

(20) In particular, the elaboration of the panel (1), with reference to FIGS. 3A, 3B and 4, is carried out by means of a procedure that includes the post-forming of shells using a mold such as FIGS. 3A and 3B. The plastic material used in the process must allow adequate levels of mechanical resistance and surface finish to a clean room. Subsequently, said post-formed shells are roughed so as to preserve the surfaces corresponding to the flat portion (2′), the upper edge portion (3′) and the curved-concave portion (4′), and the corresponding ones can also be preserved to the lateral edge portions (5) of the mold, thereby obtaining a half cover (1a) for each main face of the panel (1).

(21) In the exploded view of FIG. 4, the component parts of the panel (1) are presented, which from the upper level to the lower level correspond to: a cover half (1a), the filler material (1c), the perimeter profile (1b) and another half of cover (1a) in the opposite direction to the first. Once the panel (1) is assembled, the filler material (1c) is confined within the perimeter profile (1b) and between both cover halves (1a). The filling material of the panel depends on the insulation requirements and may include without restriction any materials such as polyurethane, aluminum honeycomb and mineral wool.

(22) The perspective view of the panel (1) presented in FIG. 5 shows that the lateral edge surface (5) and the upper edge surface (3) reveal at least part of the perimeter profile (1b), and in particular grooved grooves. In effect, the panel (1) has said groove that extends through the sections indicated as upper (6a), bottom (6b) and lateral groove (6c) along the corresponding edge surfaces.

(23) The upper (6a) and bottom (6b) grooved grooves are arranged so that during assembly a panel (1) can slide between the upper guide profile (7) and the projections on the upper edge of the intermediate support profile (8a).

(24) On the other hand, with reference to FIGS. 6A and 6B, each lateral grooved groove (6c) allows the fitting with a central projection (12c) of a connection profile (12) to join adjacent panels.

(25) The preferred embodiment of the connection profile (12), presented more clearly in FIG. 6A, comprises a flexible strip (12a) having raised edges (12b) and central projections (12c) that extend along the flexible strip and symmetrically with respect to the plane of it. In addition, the width of the flexible strip (12a) is smaller than the separation distance of the flat wall surfaces (2) of the panel (1) and the thickness or height of its raised edges (12b) is equal to the spacing required to form an optimal sealed joint (13) between adjacent panels. That is, the dimension of the raised edges (for example, the diameter in case of being circular), is equal to the required spacing between panels to offer optimal conditions for the subsequent application of a product for sealing joints, for example, silicone liquid, or other product appropriate to the sanitary requirements of the use of the clean room.

(26) As for the corner encounters, a monolithic corner with a concave and a convex side is defined, which similarly to the panel (1), has a post-formed concave corner and convex corner covers and an edge profile laterals of cross section equal to the perimeter profile (1b) formed in perpendicular planes that includes a central groove identical to that of the panel (1). In this way, the union with the panels (1) follows the methodology set forth above, which uses the connection profile (12) and subsequent formation of a sealed joint (13).

(27) FIG. 7 shows a post-shaped convex corner cover in a lower perspective. Note that, as in the case of the panel (1), this cover includes widening with curvature when it reaches each upper edge, and in the encounter of said widening, it presents a transition with a variable radius of curvature.

(28) Similarly, a concave corner post-shaped cover is shown in FIG. 8. The one that also has widening with curvature when it reaches each upper edge, but this case in the encounter of the planes has a spherical curvature surface. Note that in FIGS. 7 and 8 the dotted lines indicate zones of change of curvature without joints.

(29) To present the previous corners in context, FIG. 9 is included, which also shows a bottom perspective view, and includes three panel covers in different interleaved planes with a post-shaped concave corner cover (indicated by arrow A) and a post-shaped convex corner cover (indicated by arrow B). We have included arrows A and B to clarify the view since otherwise misinterpretations may occur due to the optics.

(30) The following two figures seek to highlight the advantages of surface termination of the present technology with respect to the traditional solution in which the curvatures are resolved in the cleanroom industry when the panels are straight. For this purpose, the comparison of the number of junction lines exposed in a concave corner at the sky level is made.

(31) FIG. 10 represents a concave corner obtained by the present technology, which incorporates a concave monolithic corner spliced with panels mounted on each side, and where the dotted lines indicate zones of curvature change without joints. The arrows emphasize the location of the 4 lines or joints, of which those vertically oriented are sealed during the assembly process.

(32) On the other hand, FIG. 11 represents the termination of a concave corner of a clean room at the sky level, obtained by means of prior art technology, in which four pieces with concave surfaces converge at the corner of the corner, generating nine lines or joints that are emphasized by arrows.

(33) Finally, FIG. 12 is an exploded view that will allow to describe more clearly the assembly process of the modular panel, in particular of the profiles that allow positioning the lower edge of the panel (1) with respect to the floor and incorporate the concave curvature widening in the encounter with the floor.

(34) Consistent with the foregoing, an embodiment of the present invention relates to a modular system of panels for forming aseptic spaces within an enclosure, which comprises a rectangular parallelepiped type panel with two side covers, in which each includes a flat wall surface (2) that extends on a curved-concave surface (4′) when it reaches the upper edge of the panel and that after a counter-curve joins the upper edge surface (3), in which the panel has a upper grooved groove (6a) on its upper edge to slide the panel (1) with respect to a top guide profile (7) fixed in the sky of the enclosure, where each side panel (1) cover is a half of post-formed cover (1a) of plastic material and in which the panel (1) comprises a perimeter profile (1b) that has grooved grooves (6a, 6b, 6c) centered and continuous by its outer edges, in which the halves of post-formed cover (1a) are joined by their inner surfaces to the perimeter profile (1b), leaving exposed the grooved grooves (6a, 6b, 6c) centered and continuous by their outer edges, in which the halves of post-formed cover (1a) are joined by their inner surfaces to the perimeter profile (1b), exposing the grooved grooves (6a, 6b, 6c) on the edges of the panel (1); and because the system further comprises: at least one intermediate support profile (8a) that is assembled on a support profile (8b) fixed to the floor by means of fasteners (10) to slide the panel (1) with its bottom grooved groove (6b) of the lower edge on projections on the upper edge of the intermediate support profile (8a), while sliding with respect to the upper guide profile (7); at least one connection profile (12) with central projections (12c) that assemble with the grooved grooves on the sides of each panel (1) for interleaved mounting; concave curvature profiles (9a) that are assembled on curve support profiles (9b) fixed to each side of the support profile (8b) to configure a concave and tangential curvature to the floor of the enclosure; and parts of corner encounters, in which each corner encounter part includes a concave corner post-formed cover (15), a convex corner post-formed cover (14), a set of edge profiles with cross-section equal to the perimeter profile (1b) that join both post-formed covers (14, 15) by their lateral, upper and lower edges for joining with the panels (1) through connection profiles (12).

(35) The system further comprises a floor cover (11) of the enclosure that extends to adhere on the concave curvature profiles (9a) and on a portion of the intermediate support profiles (8a), so that the edge of the floor cover (11) establishes a continuous surface with each flat wall surface (2) of each panel.

(36) In addition, the connection profile (12) comprises a flexible strip (12a) with its raised edges (12b) and central projections (12c) for assembly that extend along the flexible strip and symmetrically with respect to the plane of the flexible strip.

(37) In particular, the central projections (12c) have a complementary shape to the grooved grooves (6a, 6b, 6c) of the panels, and allow tight assembly with the lateral grooved grooves (6c) on the side edges of the panels to be joined.

(38) Following the above, the flexible strip (12a) has a width less than the separation distance of the flat wall surfaces (2) and the height of its raised edges (12b) is equal to the optimum spacing between adjacent panels to form a sealed joint (13) by the subsequent application of a joint sealing product.

(39) In addition, the system is such that between the side covers and the perimeter profile (1b) an interior space for insulation is defined which comprises a filling material suitable for thermal, acoustic, fire insulation, among others, as required.

(40) In another aspect of the system, the plastic material in which each half of post-formed cover (1a) is manufactured comprises one or more materials chosen from: acrylonitrile butadiene styrene (ABS), polymethylmethacrylate (PMMA), glass fibers or carbon dipped in thermostable resins.

(41) Optionally, the system comprises, for electrical installations, water, oxygen, gas and compressed air includes at least one panel (1) provided with at least one rectangular hole located on a flat wall surface (2) and a tube that extends towards from the inside of said at least one rectangular hole and projecting beyond the upper edge of the panel through the perimeter profile (1b).

(42) Optionally, the system comprises, at least one panel (1) has a large rectangular opening that crosses it and starts at the lower edge of the panel defining internal lateral and upper edges, in which the profiles (8a, 8b, 9a, 9b) that they are connected to the bottom of said panel (1) are cut to allow the rectangular opening to extend to the floor, and a frame with at least one door that fits and is fixed in the extended rectangular opening, where said frame and door have a thickness just like the panel.

(43) Optionally the system comprises, at least one panel (1) with a closed rectangular opening that crosses it in an interior area of the panel, and a frame with a window that fits and is fixed in the closed rectangular opening, where said window has its window surfaces in the same plane of each flat wall surface (2) of the panel.

(44) In another aspect, the system further comprises a panel crossing part, which includes four concave post-formed corner covers (15), a set of edge profiles with cross section equal to the perimeter profile (1b) that join the post-formed covers (15) by its adjacent side edges, upper and lower, for joining with panels (1) that converge at a junction through connection profiles (12).

(45) With respect to the method of installing a clean room wall by means of a modular system of panels to form aseptic spaces inside an enclosure, according to any of the embodiments described above, the steps of: a) fixing an upper guide profile (7) are included to the sky of the enclosure by means of fasteners (10); b) fix a support profile (8b) to the floor without a cover and assemble an intermediate support profile (8a); c) position a panel (1) by sliding between the upper grooved groove (6a) and the upper guide profile (7) and between the bottom grooved groove (6b) and projections on the upper edge of the intermediate support profile (8a); d) intersperse mount a connection profile (12) with each panel (1), so that a tight assembly is established between one of the central projections (12c) of each connection profile (12) and one of the lateral grooved grooves (6c) of each panel (1), and so that the raised edges (12b) of the flexible strip (12a) of each connection profile (12) are fully fitted between the lateral edge surfaces (5) of adjacent panels; e) fix curve support profiles (9b) on each side of the support profiles (8b) and assemble concave curvature profiles (9a); f) extend the floor cover (11) and adhere it on the concave curvature profiles (9a) and on a portion of the intermediate support profiles (8a) that remains visible, so that the edge of the floor cover (11) establish a continuous surface with the flat wall surfaces (2) of each panel.

(46) Furthermore, the step of intercalating a connection profile (12) with each panel (1) is carried out in such a way that a tight assembly is established between one of the central projections (12c) of each connection profile (12) and one of the lateral grooved grooves (6c) of each panel (1), and so that the raised edges (12b) of the flexible strip (12a) of each connection profile (12) are fully fitted between the lateral edge surfaces (5) of adjacent panels defining an optimal spacing slot between adjacent panels.

(47) Next, the method comprises the step of applying a joint sealing product in the optimal spacing groove between adjacent panels to form the sealed joint (13).

PARTS LIST

(48) 1 panel (monolithic) 1a half of post-formed cover 1b perimeter profile 1c filler material 2 flat wall surface 2′ flat portion (of the mold) 3 upper edge surface 3′ upper edge portion (of the mold) 4 curved-concave surface (top edge) 4′ curved-concave portion (of the mold) 5 lateral edge surfaces 5′ lateral edge portions (of the mold) 6a upper grooved groove 6b bottom grooved groove 6c lateral grooved groove 7 upper guide profile 8a intermediate support profile (with a guide projection) 8b support profile 9a concave curvature profile 9b curve support profile 10 fasteners 11 floor cover 12 connection profile 12th flexible strip 12b raised edges 12c central projections 13 sealed joint 14 convex corner post-formed cover 15 concave corner post-formed cover