Modular, self-contained, mobile clean room

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Solution Overview

Problem

Existing mobile modular plants for biotechnological production lack integrated systems for sterile environments, efficient power supply, and flexible deployment options, making them inefficient and cumbersome for pharmaceutical manufacturing and medical treatment applications.

Innovation Solution

A modular, self-contained cleanroom system with integrated air handling, redundant power sources, fire suppression, and IT systems, allowing for rapid deployment and validation, and enabling connection to external utilities without requiring facility integration, along with external maintenance capabilities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If mobile modular plants are used for biotechnological production, then mobility and flexibility are improved, but integration of sterile environments, power supply, and support systems becomes insufficient

Engineering Contradiction:

Improvemobility and flexibilityVSAvoidintegration of sterile environments, power supply, and support systems

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system is divided into separate functional modules: a cleanroom module for sterile operations, a mechanical system room module for support equipment, and corridor connector modules for linkage. Each module can be independently transported, assembled, and configured based on specific application requirements, maintaining mobility while integrating complex functions through modular architecture.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple previously separate systems (cleanroom environment control, power supply with redundant sources, fire suppression, IT systems, and mechanical support) are merged into an integrated modular plant system where components communicate and coordinate through standardized interfaces, reducing overall system complexity while maintaining comprehensive functionality.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If traditional facility integration is required for utility connections, then system reliability is improved, but deployment time and complexity increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoiddeployment time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Utility connections (power, water, HVAC, fire suppression) are pre-integrated and pre-tested within each modular unit during manufacturing. The modules arrive at the deployment site ready-to-connect with pre-configured interfaces, eliminating the need for complex on-site integration work while maintaining reliable system performance through factory-controlled quality assurance.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Each modular unit is self-contained with internal redundancy (dual power sources, integrated fire suppression, autonomous HVAC control) that allows the module to operate independently or in coordination with other modules without requiring constant external facility support, reducing deployment complexity while ensuring continuous reliable operation.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If cleanrooms require extensive validation and integration testing, then regulatory compliance is improved, but setup time and cost increase

Engineering Contradiction:

Improveregulatory complianceVSAvoidsetup time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The cleanroom system is segmented into standardized modular units with pre-defined validation protocols for each module type. This segmentation allows for modular validation where each unit can be validated independently according to regulatory standards (GMP, ISO), reducing overall validation time compared to validating a custom-integrated facility while maintaining full compliance through documented modular validation procedures.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If mobile modular plants lack integrated support systems, then mobility is improved, but operational efficiency and reliability deteriorate

Engineering Contradiction:

ImprovemobilityVSAvoidoperational efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The modular plant incorporates universal multi-functional support systems that serve multiple purposes: the mechanical system room provides HVAC support, power distribution, and equipment housing; corridor connectors enable both physical linkage and utility transmission; and the integrated IT system provides monitoring, control, and data management across all modules. This multi-functionality maintains mobility while achieving high operational efficiency through coordinated system integration.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12350660B2Modular, self-contained, mobile clean room

Publication Date: 2025.07.08 G CON MANUFACTURING INC

AI summary

Biosafety units, methods of making and sealing the same are disclosed herein. The present invention includes a unitary structure able to be validated for pharmaceutical manufacturing comprising: at least one controlled air, sealable, sterilizable cleanroom; a mechanical system room adjacent to and separate from the cleanroom comprising: one or more air handling units that provide conditioned air to the cleanroom; and one or more power busses that provide power to electrical outlets in the cleanroom from two sources, wherein the at least two power supplies are connectable to one or more external electrical power sources; an integrated fire suppression system integral to the cleanroom; and one or more corridor connectors, wherein a corridor can be attached at the corridor connector.