Method for connecting modular mobile rooms
10161147 ยท 2018-12-25
Assignee
Inventors
Cpc classification
E04B1/34384
FIXED CONSTRUCTIONS
E04H5/02
FIXED CONSTRUCTIONS
International classification
E04H1/00
FIXED CONSTRUCTIONS
E04H3/08
FIXED CONSTRUCTIONS
Abstract
A method and a connector unit for connecting two or more structures wherein at least one of the two or more structures being connected is a mobile structure validatable for pharmaceutical manufacturing or patient care. The connector unit comprises of an alignment system, a sealing, and a fixation system. The method for using the connector unit comprises of aligning the two or more structures to dock the two or more structures together, sealing the two or more structures, or one or more structures and an environment air tight with a seal or a sealing system, and affixing the two or more structures together to prevent relative movement of the two or more structures, or breakage of the seal or seal system.
Claims
1. A method for connecting two structures with a connector unit, the method comprising: obtaining a first mobile structure and a second mobile structure wherein the first mobile structure has a first wall having a first opening, and wherein the second mobile structure has a second wall having a second opening that is adapted to be connected to the first opening in the first wall of the first mobile structure; placing the first and second mobile structures together by moving the first wall of the first mobile structure and the second wall of the second mobile structure together into contact with each other and aligning the first opening in the first wall of the first mobile structure with the second opening in the second wall of the second mobile structure in a same movement that moves the walls of the first mobile structure and second mobile structure together; wherein the aligning is carried out by aligning a first alignment structure that is formed on the first wall of the first mobile structure and a second alignment structure that is formed on the second wall of the second mobile structure, wherein a shape of the second alignment structure is complementary to and fits a shape of the first alignment structure or wherein a shape of the first alignment structure is complementary to and fits a shape of the second alignment structure; sealing the aligned openings between the first and second mobile structures from an environment with an air tight seal or an air tight sealing system; and affixing the first and second mobile structures together in contact with each other to prevent relative movement of the first and second mobile structures, or breakage of the air tight seal or the air tight sealing system, wherein the first and second mobile structures form a connected unit that is mobile.
2. The method of claim 1, wherein the first and second mobile structures are each selected from the group consisting of a pharmaceutical manufacturing unit, a patient care unit, a cleanroom, an isolation cubicle, a containment cubicle, a pod, a module, a unit, a building, a corridor, a hallway, a mobile structure and an access structure.
3. The method of claim 1, wherein a connection between the first and second mobile structures can be disconnected, separated, and then reattached.
4. The method of claim 1, wherein the air tight seal or air tight sealing system that seals the aligned openings between the first and second mobile structures from the environment is reversible.
5. The method of claim 1, wherein air tight seal or air tight sealing system that seals the aligned openings between the first and second mobile structures from the environment is selected from the group consisting of an induction sealing, cap sealing, adhesive sealant, bodok seal, Bridgman seal, compression seal fitting, diaphragm seal, ferrofluidic seal, a gasket, flange gasket, o-ring, o-ring boss seal, glass-ceramic-to-metal seals, piston ring, hose coupling, hermetic seal, hydrostatic seal, hydrodynamic seal, labyrinth seal, face seal, plug, radial shaft seal, siphon trap, split mechanical seal, wiper seal, dry gas seal, and exitex seal.
6. The method of claim 1, wherein the step of affixing the first and second mobile structures together comprises a method of using a device selected from the group consisting of a clamp, a spring load, a bolt, a magnetic coupling, a bayonet coupling, or a lock.
7. The method of claim 1, wherein the air tight seal or the air tight sealing system surrounds the aligned openings between the first and second mobile structures to provide a hermetic seal.
8. A method for connecting two mobile cleanroom structures with a connector unit, the method comprising: obtaining a first mobile structure and a second mobile structure wherein the first mobile structure has a first wall having a first opening that is adapted to be connected to another opening, and wherein the second mobile structure has a second wall having a second opening that is adapted to be connected to the first opening in the first wall of the first mobile structure; and placing the first and second mobile structures together by moving the first wall of the first mobile structure and the second wall of the second mobile structure together into contact with each other and using an alignment system to align the opening of the first mobile structure and the opening of the second mobile structure together in a same movement that moves the walls of the first mobile structure and second mobile structure together; wherein the alignment system comprises a first alignment structure that is formed on the first wall of the first mobile structure and a second alignment structure that is formed on the second wall of the second mobile structure, and wherein a shape of the second alignment structure is complementary to and fits a shape of the first alignment structure or wherein a shape of the first alignment structure is complementary to and fits a shape of the second alignment structure, wherein the first and second mobile structures form a connected unit that is mobile.
9. The method of claim 8 further comprising the steps of: sealing the aligned openings between the first and second mobile structures from an environment with an air tight seal or an air tight sealing system; and affixing the first and second mobile structures together in contact with each other to prevent relative movement of the first and second mobile structures, or breakage of the air tight seal or the air tight sealing system.
10. The method of claim 9, wherein the first and second mobile structures are each selected from the group consisting of a pharmaceutical manufacturing unit, a patient care unit, a cleanroom, an isolation cubicle, a containment cubicle, a pod, a module, a unit, a building, a corridor, a hallway, a mobile structure, and an access structure.
11. The method of claim 9, wherein the connection between the first and second mobile structures can be disconnected, separated, and then reattached.
12. The method of claim 9, wherein the air tight seal or air tight sealing system that seals the aligned openings between the first and second mobile structures from the environment is reversible.
13. The method of claim 9, wherein air tight seal or air tight sealing system that seals the aligned openings between the first and second mobile structures from the environment is selected from the group consisting of an induction sealing, cap sealing, adhesive sealant, bodok seal, Bridgman seal, compression seal fitting, diaphragm seal, ferrofluidic seal, a gasket, flange gasket, o-ring, o-ring boss seal, glass-ceramic-to-metal seals, piston ring, hose coupling, hermetic seal, hydrostatic seal, hydrodynamic seal, labyrinth seal, face seal, plug, radial shaft seal, siphon trap, split mechanical seal, wiper seal, dry gas seal, and exitex seal.
14. The method of claim 9, wherein the step of affixing the first and second mobile structures together comprises a method of using a device selected from the group consisting of a clamp, a spring load, a bolt, a magnetic coupling, a bayonet coupling, or a lock.
15. The method of claim 9, wherein the air tight seal or the air tight sealing system surrounds the aligned openings between the first and second mobile structures to provide a hermetic seal.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) For a more complete understanding of the features and advantages of the present invention, reference is now made to the detailed description of the invention along with the accompanying figures and in which:
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DETAILED DESCRIPTION OF THE INVENTION
(7) While the making and using of various embodiments of the present invention are discussed in detail below, it should be appreciated that the present invention provides many applicable inventive concepts that can be embodied in a wide variety of specific contexts. The specific embodiments discussed herein are merely illustrative of specific ways to make and use the invention and do not limit the scope of the invention.
(8) To facilitate the understanding of this invention, a number of terms are defined below. Terms defined herein have meanings as commonly understood by a person of ordinary skill in the areas relevant to the present invention. Terms such as a, an and the are not intended to refer to only a singular entity, but include the general class of which a specific example may be used for illustration. The terminology herein is used to describe specific embodiments of the invention, but their usage does not delimit the invention, except as outlined in the claims.
(9) The present invention is a connector unit for connecting two or more structures wherein at least one of the two or more structures being connected is a mobile structure validatable for pharmaceutical manufacturing or patient care.
(10) The present invention can be used with a modular pharmaceutical facility for the production of, e.g., vaccines and includes all the necessary quality control, quality assurance, and lot release functions. The end product can be made within the same or an adjacent module vaccine filled in bulk vials, suitable for distribution, and compliant with all FDA current Good Manufacturing Practices (cGMP) guidelines. The following terms are used interchangeably modular unit, structure, unit or module to describe a unitary structure that includes at least one portion that is a sealable, working area or cleanroom in which one or more functions or processes are conducted that require a controlled working environment and a mechanical service room or area (which may be closed or open) and that support the clean room and provides redundant services to the cleanroom, e.g., air-handling, electrical, water, waste water, waste disposal, chiller and/or heated water, gas, control units and sensors, security. These services will generally be connected to a source of the service that uses universal connectors, which are those commonly used as fittings in industry (e.g., 110 or 220 volt connections, -1 inch liquid or gas connections, wired or wireless connections to an intra, extra or internet and the like).
(11) As used herein, the terms validation and pre-validation are intended to encompass all documented processes or acts undertaken to demonstrate that a procedure, a process or an activity will consistently yield an expected result or outcome. Validation often includes qualification of equipment and systems. Validation is a key required component of Good Manufacturing Practices (GMP) and other regulatory requirements. For example, in the pharmaceutical industry, validation of a facility and the process within it is done prior to obtaining regulatory approval for the commercial manufacture and sale of the pharmaceutical product. Validation activities in the pharmaceutical industry may also include trial runs (pre-validation) before performing the actual validation to set validation limits, critical manufacturing controls, alert limits, etc. and to assess the potential outcome of the actual validation run. Validations routinely performed are cleaning validation, process validation, analytical method validation, computer system validation, qualifying systems and equipment including: design qualification (DQ), component qualification (CQ), installation qualification (IQ), operational qualification (OQ), and process qualification (PQ).
(12) The skilled artisan will recognize that though the connector units, structures, facilities or units described in the instant invention are validatable, they may not be validated or required to be validated for certain uses and applications, particularly for non-human use or manufacture of products for non-human consumption (for e.g. veterinary applications, agriculture applications, pesticide manufacture, etc.).
(13) The connector unit of the present invention can be used to form a suite or be part of multiple-modular unit facility, can include specific enclosed spaces for the manufacture, fermentation, growth (e.g., in a bioreactor) of the composition requiring an FDA approved, GMP or cGMP facility that includes, e.g., lights, controlled GMP areas consistent with USDA, CDC, FDA or regulations for foreign equivalents, including clean room conditions, purification, chromatography, bulk or individual vial filling, that can be arranged within, e.g., a standard factory or facility with a clearance sufficiently high to accommodate the units within. In one example, the modular units can be placed within a building shell that includes standard electrical connections, water, wastewater, air handling to which the units are connected. The present invention requires no pre-assembly or re-assembly of the multiple units as each can function independently and can be used for multiple purposes.
(14) For example, a complete manufacturing facility can be built, within hours to days, from pre-assembled, pre-approved modular units that include all the equipment necessary for the desired function(s) for that unit within a manufacturing plant using the connector units of the present invention. These flexible-by-design GMP modular units allow for the design of production facilities for the rapid deployment and re-deployment of units based on the design needs. For example, one modular unit may include a self-contained bioreactor, the necessary liquid handling devices, refrigerators, tissue culture hoods and microbiology testing equipment, basic laboratory equipment (pipettors, sterile pipette tips, growth media, petri dishes, incubators and other general lab supplies), that has been tested and prevalidated to be compliant with the cGMPs or other regulatory body compliance requirements or in compliance with applicable codes, statutes, ordinances, regulations or equivalents. A modular unit for protein isolation, adjacent to but completely independent from the bioreactor unit, can be positioned and in communication with the bioreactor unit such that the materials manufactured in the bioreactor are rapidly and easily transferred to the protein isolation unit that has, pre-approved and validated protein separation units, e.g., centrifuges, liquid chromatography columns, spectrophotometers, polyacrylamide gel electrophoresis (PAGE) units and bulk packaging units. Next, the bulk protein may be transferred to a packaging unit that includes all the equipment necessary to fill individual doses of the protein, small molecule or other agent that is being manufactured.
(15) By connecting the individual modules, the present invention provides for the rapid exchange and continuous manufacture of product in case that one part of the manufacturing process must be changed or revalidated (e.g., in the case of the manufacture of a different biological or the detection of contamination) without the need to re-certify the entire facility. The addition of more modular units, connected by the connector unit(s) of the present invention, also allows for very rapid scale-up that can be customized for short periods of time. For example, a plant can receive the addition of modular units for scaling-up for a short period of time, the manufacture and isolation of a vaccine for a short period of time and the redeployment of those units elsewhere upon completion of the production run. In fact, the present invention can be used in existing manufacturing facilities for short-term expansion of manufacturing capacity without the need for revalidation of the new manufacturing capacity or the expensive, long-term installation of an additional production line that will only be used for a short period of time.
(16) The connector units of the present invention can be used to connect modular units to stand-alone facilities and/or module units, which may be placed within and/or outside an existing structure. One example of such a structure is an empty facility or building. One such building could be of standard, pre-cast concrete construction, flat slab with smooth floors, concrete tilt wall, double T precast ceiling and having steel or other walls. In one non-limiting example, the walls can be epoxy coated for improved cleanability). Within the building, the modular units provide the dedicated wet laboratory, growth, bioprocess and purification units necessary for manufacture. These units are simply lifted into position (e.g., pushed on air bearings, casters, pallets), connected to a power source and, if necessary, a water and/or a wastewater supply.
(17) The present invention allows the designer to have the ability to connect one functioning modular unit to one or more additional functioning modules without disrupting the function or compliance of the original modular unit(s). Furthermore, the designer also has the ability to disconnect one functioning module from one or more additional functioning modules without disrupting the function or compliance of the original modular unit(s).
(18) The connector units taught herein can integrate into modular units to improve energy efficiency by connecting into an efficient energy recovery system that allows for energy recapture at a rate much higher than can be expected with existing methods throughout the connector unit(s) and the modular unit(s). The intake and exhaust of the redundant HVAC systems of the connector and modular unit(s) can be connected to the central HVAC of the building thereby enhancing the energy efficiency of both units. For example, the modular units of the present invention can be placed inside of a second environment (a building with ambient temperature or less humidity), which having the modular unit interact dynamically with that second environment. In this manner of operation, the modular unit can use ambient air that does not need to be treated by a large and expensive external air handling unit.
(19) Another vast improvement over existing designs is the ability of the modular units to service multiple clients with a single cluster of modular units in a single contiguous manner through the connector units. For example, a biotechnology research park or similar entrepreneurial facility could host various different companies, each having their own production facility or modular unit. One distinct advantage of using the modular units is that each completely selfcontained modular unit can contain an individual hazardous waste, spills, etc., without affecting any other structures (within a process flow or affecting an adjacent production facility, e.g., when a facility has various manufacturing lines or different companies).
(20) When the modular unit needs to be connected to a source of water, the incoming water could be purified in an adjacent modular unit that could service various different production lines or the module itself could include a water purification unit. The modular unit of the present invention has the advantage that the redundant air handling units, electrical panels and even the water filtration units can be in the portion of the modular unit that is adjacent the clean room and can be serviced without service personnel having to enter the clean room area. When handling wastewater, the modular unit can include sump pumps to eliminate waste. Furthermore, the bag in/bag out filters connected to the air-handling units can also be changed without the need to enter the cleanroom area. These separate externally accessible portions of the modular units allow for maintenance and maintenance personnel to service the unit without the need to gown-up and enter the clean room area.
(21) Duplicate processes and equipment for air handling, exhaust, etc., with automatic fault tolerance/failover allows the user, e.g., from an external panel or via the internet, to switch-over from a first system to a second system if sensors within the modular unit sense a problem with a component in the first system or as part of regular maintenance.
(22) Another feature of the connector units of the present invention is the ability to use utility and other connection devices (e.g., plugs and fittings) that are well-known to maintenance personnel. For example, the modular units can use standard quick connectors for chilled water, electricity, etc. that allow the user to hot swap the modular units externally. One advantage of the present invention is that it can take advantage of existing building infrastructure, e.g., mechanical equipment such as boilers, clean steam generator and compressors that can easily be connected to the units. The building's existing maintenance facilities and personnel can provide maintenance and service to the units and environmental service compliance from outside the clean room space via the mechanical are of the unit that is separate from the clean room space.
(23) The connector units of the present invention can be made from, for example, a welded aluminum frame, with an all aluminum wall structure of materials and coatings that are cleanable in the drug production environment and are compliant with the cGMP's as described by the USDA, CDC, FDA or equivalent regulatory agency. Stainless steel fixtures and surfaces may also be used when necessary, but could add more weight to the unit if a weight limit exists.
(24) The connection of the connector unit, e.g., within the clean room portion of the modular unit or even the maintenance portion of the modular unit, can be controlled and monitored externally using standard network information systems and remote systems monitoring.
(25) Moreover, modular or connector units can be outfitted with air bearings, so that the modular units can be moved easily to other areas to be reconfigured in near real time to support necessary processes and surge capabilities without disturbing ongoing operations.
(26) Each connector unit can be preassembled with a final documentation package that can include: the design, structural, mechanical, and electrical drawings, system dossiers, installation qualification and operational qualification plan and executed documents, maintenance logs, and pro-forma quality assurance documents including basic standard operating procedures for connecting into modular units and/or fixed facilities. These may be provided in hard copy, or provided via a display panel within the modular unit or externally (including within the maintenance bay) that is electronic and can include the necessary passcode/password protection.
(27) Space pressure can be monitored, e.g., the pressure in the connector units and/or modular unit(s) to which they are connected. If the pressure drops to 0.0 water column (WC) or below, an alarm can be sent to the BAS. When an alarm is sent to the BAS, the system can call pre-programmed emergency telephone numbers and/or communication electronically via text or email.
(28) Additional Points that can be monitored in the connector unit include, e.g., a static pressure blowout sensor in communication with the air handling units (AHU's) For example, the BAS can determine if there is a belt failure in either of the AHU's or EF's by using, e.g., an amp sensor that monitors the change in amp draw on the motor. Another sensor can be a pitot tube in the supply air duct and exhaust air duct that monitors static pressure connected to the BAS. Also, gravity dampers, automatic dampers and damper end switches and the controls can also be connected to and monitored by the BAS.
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(33) One embodiment is a single layer, rounded rectangular seal 60 that is placed between surfaces 44a and 46a. The seal can positioned opposite of the seal 60 shown by placing the seal on surface 46a instead of 44a (not depicted). Alternatively, the seal 60 can enter a groove 61 in surface 46a, with the volume of the seal 60 being equal to or greater than the volume of the groove 61 in surface 46a. The groove 61 and seals 60 can be positioned on either surface 44a or 46a, can be alternated, and can also surround the openings between cleanroom 16 and corridor 20.
(34) Another embodiment is a double layer, thinner rounded seal 62 on surface 44b, which fits into grooves 63 on surface 46b or can contact surface 46b directly. Seal 62 and grooves 63 can be positioned vice versa with the seal on surface 46b instead, and the grooves 63 on surface 44b. The groove 63 and seals 62 can be positioned on either surface 44b or 46b, can be alternated, and can also surround the openings between cleanroom 16 and corridor 20.
(35) Another embodiment is a trapezoidal shaped seal 64 between surfaces 44c and 46c wherein the seal would be thicker against one surface (or vice versa). The seal 64 can be positioned on surface 46c instead of 44c. Likewise, the seal 64 shown herein is not limited to a specific surface, but can be on surface 46c with the thicker lining against surface 44c. As with the embodiment described above, the seal 64 can enter the grooves 65 or directly contact the surface 46b (or vice versa). The groove 65 and seals 64 can be positioned on either surface 44c or 46c, can be alternated, and can also surround the openings between cleanroom 16 and corridor 20.
(36) The fourth embodiment shows a single layer wider rounded seal 66 between surface 44d and 46d. Again, The seal 66 can be on surface 46d instead of 44d. As with the embodiment described above, the seal 68 can enter the grooves 67 or directly contact the surface 46b (or vice versa). The groove 67 and seals 66 can be positioned on either surface 44d or 46d, can be alternated, and can also surround the openings between cleanroom 16 and corridor 20. The seal or seal system of the connector unit between the structures shall be reversible allowing the two structures to be undocked and separated when necessary. The seal system needs to not allow any air leaks, and must be able to stay intact for a prolonged period of time. There are multiple other designs available for the seal or seal system between the two or more structures, or one or more structures and the environment. The seal system designs for the connector unit can include at least one of induction sealing, cap sealing, adhesive sealant, bodok seal, Bridgman seal, compression seal fitting, diaphragm seal, ferrofluidic seal, a gasket, flange gasket, o-ring, o-ring boss seal, glass-ceramic-to-metal seals, piston ring, hose coupling, hermetic seal, hydrostatic seal, hydrodynamic seal, labyrinth seal, face seal, plug, radial shaft seal, siphon trap, split mechanical seal, wiper seal, dry gas seal, or exitex seal.
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(38) It is contemplated that any embodiment discussed in this specification can be implemented with respect to any method, kit, reagent, or composition of the invention, and vice versa. Furthermore, compositions of the invention can be used to achieve methods of the invention.
(39) It will be understood that particular embodiments described herein are shown by way of illustration and not as limitations of the invention. The principal features of this invention can be employed in various embodiments without departing from the scope of the invention. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, numerous equivalents to the specific procedures described herein. Such equivalents are considered to be within the scope of this invention and are covered by the claims.
(40) All publications and patent applications mentioned in the specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.
(41) The use of the word a or an when used in conjunction with the term comprising in the claims and/or the specification may mean one, but it is also consistent with the meaning of one or more, at least one, and one or more than one. The use of the term or in the claims is used to mean and/or unless explicitly indicated to refer to alternatives only or the alternatives are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and and/or. Throughout this application, the term about is used to indicate that a value includes the inherent variation of error for the device, the method being employed to determine the value, or the variation that exists among the study subjects.
(42) As used in this specification and claim(s), the words comprising (and any form of comprising, such as comprise and comprises), having (and any form of having, such as have and has), including (and any form of including, such as includes and include) or containing (and any form of containing, such as contains and contain) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.
(43) The term or combinations thereof as used herein refers to all permutations and combinations of the listed items preceding the term. For example, A, B, C, or combinations thereof is intended to include at least one of: A, B, C, AB, AC, BC, or ABC, and if order is important in a particular context, also BA, CA, CB, CBA, BCA, ACB, BAC, or CAB. Continuing with this example, expressly included are combinations that contain repeats of one or more item or term, such as BB, AAA, AB, BBC, AAABCCCC, CBBAAA, CABABB, and so forth. The skilled artisan will understand that typically there is no limit on the number of items or terms in any combination, unless otherwise apparent from the context. In certain embodiments, the present invention may also include methods and compositions in which the transition phrase consisting essentially of or consisting of may also be used.
(44) As used herein, words of approximation such as, without limitation, about, substantial or substantially refers to a condition that when so modified is understood to not necessarily be absolute or perfect but would be considered close enough to those of ordinary skill in the art to warrant designating the condition as being present. The extent to which the description may vary will depend on how great a change can be instituted and still have one of ordinary skilled in the art recognize the modified feature as still having the required characteristics and capabilities of the unmodified feature. In general, but subject to the preceding discussion, a numerical value herein that is modified by a word of approximation such as about may vary from the stated value by at least 1, 2, 3, 4, 5, 6, 7, 10, 12 or 15%.
(45) All of the compositions and/or methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While the compositions and methods of this invention have been described in terms of preferred embodiments, it will be apparent to those of skill in the art that variations may be applied to the compositions and/or methods and in the steps or in the sequence of steps of the method described herein without departing from the concept, spirit and scope of the invention. All such similar substitutes and modifications apparent to those skilled in the art are deemed to be within the spirit, scope and concept of the invention as defined by the appended claims.
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