GB2346627A

GB2346627A - Partition seal

Info

Publication number: GB2346627A
Application number: GB9903303A
Authority: GB
Inventors: Trevor Ian Drummond
Original assignee: Individual
Current assignee: Individual
Priority date: 1999-02-12
Filing date: 1999-02-12
Publication date: 2000-08-16
Anticipated expiration: 2019-02-12
Also published as: GB2346627B; GB9903303D0

Abstract

A method of sealing a joint between two panels 5. A compressible gasket 6 is held in place and compressed by a stud 5 inserted into a resilient clip 8. The clip 8 has inwardly facing protrusions to engage the stud 5 The gasket may be flush with the edge of the stud 5 or recessed from the edge of the stud 5 to form a channel into which a sealant can be inserted. By adapting the form of the stud and clip the seal may be formed on the top surface of two abutting panels along the joint fig.1A, along the ends of the two panels and flush with the outside surfaces (fig 3 not shown), or at the intersection of a corner (fig 2 not shown) e.g between wall and ceiling. A door comprising front and rear panels which are hermetically sealed is also disclosed.

Description

PARTITION SEAL The present invention relates to seals for sealing joints between modular wall and/or ceiling partitions in cleanroom or other controlled environments. The invention also relates to methods of providing a smooth impervious seal between individual modules that are used to construct cleanrooms.

Cleanroom environments are designed for work with hazardous substances and organisms, sterile and aseptic products, medical devices, etc. An essential feature of their design is that there are no cavities or voids which may harbour spilled fluids or solid materials, or in which microorganisms may grow. Cleanrooms are also used in the microelectronics industry to prevent the accumulation of dust and other small particles that may interfere with the construction and function of small and fragile microelectronic components.

Cleanroom systems are designed to provide controlled environments in which unwanted substances are contained and/or excluded. They are normally constructed using modular wall and ceiling partition systems, designed so as to allow the modular assembly of a range of cleanroom sizes and designs using only a small number of basic components. The modules of the partitions are conventionally erected using mechanical fixing systems such as clamps, camlocks, bolts and screws.

In cleanroom areas, all exposed surfaces should be smooth, impervious and unbroken in order to minimise the shedding or accumulation of particles or microorganisms and to allow the repeated application of cleaning agents and disinfectants where necessary. To prevent the accumulation of dust and to facilitate cleaning, there should be no inaccessible recesses or air voids, since these areas provide a perfect environment for the accumulation of particles or microorganisms.

After erection, the joints between the partition modules are conventionally sealed using a manually applied sealant such as silicone, to ensure the integrity of the sealed structure. Since this sealant must be manually applied to the joints (for example, using an applicator gun), this extends the installation time and increases the cost of construction. Furthermore, using manually applied sealant, it is not generally possible to achieve a neat seal, meaning that the finished structure is often not aesthetically appealing.

A further major problem is that the use of sealant creates a permanent sealed joint. Once the joint is sealed, it is not possible to access services installed behind the partition structure without the provision of hatches or removable panels. The provision of any such hatches or panels results in additional ledges and potential leak paths through the partitioned structure.

Furthermore, each time a hatch or panel is removed, the sealant must be reapplied in order to ensure the integrity of the seal. In some instances, it may not be possible to establish optimum locations for access hatches at the time of installation, since it is not then known where or how often access may be required.

There is thus a great need for a system of sealing the joints between partition modules in cleanroom environments, which does not require the application of sealant to the joints and that is easy to dismantle and reassemble.

According to the present invention there is provided a seal device for sealing a joint between two partition surfaces, comprising at least one compressible gasket and attachment means, wherein the attachment means act during use to compress continuously the gasket such that the gasket provides a seal between the partition surfaces.

When in place, the device of the invention provides a smooth, impervious and unbroken join between modules of a partition wall or ceiling, or between wall and ceiling modules. The compressed gasket prevents the entry of particles or microorganisms into the joint between the modules, so removing the need for the application of a separate sealant. Preferably, the gasket is non-porous.

The device may have a cap portion and an attachment portion. The cap portion may have projecting flanges that overlap the edges of the modules that are to be joined together. The flanges of the cap portion should overlap the edges of the modules to a sufficient degree to ensure that the gasket seals the join along the entire length of the module. This overlap should be sufficiently great to compensate for any warping or inconsistency along the length of the module. Preferably, the flanges overlap the modules by at least 0. 5cm, more preferably by at least 1 cm.

If there are three or four modules to be joined in one plane, for example at the juncture of four wall modules, further flanges may extend in appropriate directions. If there are three modules to be joined, for example, between a ceiling module and two wall partitions, a third flange should extend in a direction perpendicular to the other flanges so as to overlap the joint in the third plane.

If included, the cap portion is preferably substantially flat to ensure that the device protrudes minimally from the surface of the partition. However, modifications of this design may be made as required. For example, the top of the cap portion may be curved so as not to present any sharp edges along the length of the wall. This will facilitate cleaning of the partition.

On the underside of each flange of the cap portion there is provided at least one compressible gasket. In general, a gasket will be provided for each partition module that is to be joined ; for example, to join two wall modules, a gasket will be provided on each of two flanges.

The gasket may be constructed from any suitable compressible material. Preferably, however, the gasket is constructed from a non-porous material such as silicone, neoprene or butyl.

Further, the gasket is preferably constructed from a material which can withstand the cleaning processes to be used. Most preferably, the gasket is constructed from silicone material.

The thickness of the gasket will depend on the material from which the gasket is constructed.

However, ordinarily, the gasket will be of approximately 3mm thickness in its non-compressed form.

The gaskets may be positioned so as to be flush with the edges of the flanges of the cap portion. In this aspect of the invention, there is no need to apply sealant. However, if sealant is required, for example, to conform to required construction standards, this may be applied at the edge of the seal device against the compressed gasket.

In an alternate embodiment of the invention, the gasket is positioned so as to be set back from the edge of the flange, so that when the device is fixed in place, a channel is formed between the flange and the external surface of the partition module. Sealant may then be expressed into this channel, if required. A neat seal can result, yet the sealant can be readily removed from the channel at any time, if required.

Any attachment means may be used that acts to exert a continuous compressive force on the gasket when the device of the invention is fixed in place. Preferably, the attachment means comprises a stud that may be fitted into a retaining clip. In a preferred embodiment of the invention, the attachment means comprises a stud that may be push-fitted into a retaining clip.

The stud may be extruded. The retaining clip may be present as an integral part of one or both partition modules, or may be a separate component. The retaining clip may be positioned behind the external face of a module, in which case the clip should be fixed in place behind or may be biased against the external face of the module so as to hold the device tightly in place when attached over a joint. In this fashion, a continuous force thus acts to compress the device against the external surface of the partition modules, so ensuring that the gasket is permanently compressed and forms a tight seal. This compressive force may also assist in holding the partition modules in place without the need for additional fixings.

Other attachment means will be known to those of skill in the art. For example, the attachment means may comprise a threaded stud such that the device may be screwed in place using a nut biased against the back surface of the external face of the modules. In this embodiment of the invention, a washer may be used to provide a surface for biasing against the back surface of the module. The retaining clip may also be attached to, or may be an integral part of, a stud or structural support section that allows attachment of the clip to the module or to other structures.

The retaining clip may also be fixed to a retainer, such as an extruded cove retainer (see Figure 2).

The gasket is preferably compressed by at least 5% when the device is fitted in place. This degree of compression should be sufficient to prevent any air passages under the gasket, so providing a continuous tight seal. This degree of compressive force is easily attained using an arrangement of panel clips or using a stud and retaining clip attachment known to fit the device in place.

The device of the invention may also be designed for application over a comer joint. In this aspect of the invention, the cap portion should preferably have flexible flanges, allowing the cap portion to flex into a curved shape so as to form a cove between two walls or between a ceiling and a wall (see Figure 2). Gaskets are provided on the underside of each end of the flanges. When the device is fixed in place, for example, using a retaining clip attached to a cove retainer, the ends of the cap portion are biased against the external surfaces of the partition modules, so compressing the gasket to the required degree and so forming a continuous tight seal.

According to a further aspect of the invention, a gasket may be provided on the external face of a partition module rather than on the clip or cap portion of the seal. The gasket should be positioned so as to abut or to be proximal to the edge of the module. In this embodiment of the invention, a device may be compressed onto the gasket, so sealing the joint in the same way as if the gasket were positioned on the underside of the sealing cap, as described above.

According to a further aspect of the invention, there is provided a module for a partition wall, ceiling or floor in a cleanroom environment comprising a compressible gasket on an end surface of the module such that when compressed onto a second module, the joint between the modules is sealed. This aspect of the invention removes the need for a separate sealing material to be applied to the joint; when the module is compressed against an adjacent module, the gasket is compressed and forms a seal between the modules.

The gasket may be provided on the end surface of one or of both modules to be joined. In order to provide the necessary compressive force, the modules must be pulled together in some way, for example, using panel clip assemblies (see Figure 3). Such assemblies may allow push fitting of the modules together, or the modules may be fixed together manually, for example, using camlocks, bolts or screws. The system of attachment should be sufficiently strong to compress the modules together continuously with sufficient pressure for the gasket to be compressed along the full length of the module.

In this aspect of the invention, the gasket may be positioned so as to be flush with the external face of the partition module. Accordingly, when the modules are compressed together, the joint is free of any cavities. In an alternative embodiment of this aspect of the invention, the gasket may be set back from the external face of the module, so that when two modules are compressed together, the end of the gasket and the walls of the modules define a channel. This channel may then be filed with sealant to give a flush join between the modules. This embodiment of the invention will be preferred in cases where cleanroom building regulations or construction standards stipulate the compulsory use of sealant. The gasket should be of similar (or the same) material, compressibility and dimensions as described above.

According to a further aspect of the invention, there is a provided a partition wall or ceiling for a cleanroom comprising a module or a seal device as described above.

The present invention also provides a door comprising a front panel, a rear panel and a seal device as herein described, wherein the seal device provides a hermetic seal between the front and rear panels.

According to a still further aspect of the invention, there is provided a method of sealing a joint between two or more partition modules in a cleanroom comprising applying compressive force onto a compressible gasket located between said partition modules.

According to a still further aspect of the invention, there is provided a method of sealing a joint between two or more partition modules in a cleanroom comprising applying compressive force to a sealing device placed over the joint between said modules, wherein a compressible gasket is located between said device and the surfaces of said partition modules.

The invention will now be described by way of example. However, as will be clear to the skilled artisan, modifications may be made without departing from the scope of the invention.

In the drawings: Figure 1A is a cross-sectional view of a seal device fixed in place over a joint in a single-sided partition wall.

Figure 1B is a cross-sectional view of two seal devices fixed in place over the joints in a doublesided partition wall.

Figure 2 is a cross-sectional diagram showing a seal device fixed in place over the comer joint between a wall and a ceiling partition module.

Figure 3 is a cross-sectional diagram showing two wall modules of a partition fixed together.

With reference to Figures 1A and B of the drawings, a device (1) of the first embodiment of the invention comprises a cap (2) and an extruded stud (3). The cap comprises two flanges (4) which overlap and press against external faces of partition modules (5). The cap is flat along its outside surface. The width of the cap is approximately 5 cm.

Two non-porous compressible gaskets (6) are positioned on the underside of the flanges (4). The gaskets are constructed from silicone material. The depth of the gaskets is approximately 3mm.

The extruded stud (3) extends from the centre of the cap, and forms a bulb (7) towards its distal end. The stud (3) is held by a retaining clip (8), by virtue of the bulb (7) of the stud (3) bearing against ears (9) of the retaining clip. The ears (9) of the retaining clip (8) are biased towards each other and are designed so that when the stud is in place, a continuous force acts to pull the stud (3) inwardly. The device (1) can be push-fitted into the retaining clip (8).

The retaining clip (8) is held within an extruded aluminium support (10). The support (10) presents a surface against which the rear surfaces of the partition modules (5) bear, so that when the stud (3) and retaining clip (8) are fitted together, a continuous compressive force is exerted on the gaskets (6) between the underside of flanges (4) and external surfaces of the modules (5). In this way, the partition modules (5) are held in position without the need for additional fixings.

The profile of the bulb (7) of the stud (4) is designed so that it co-operates with the ears (9) of retaining clip (8) so as to generate a degree of compressive force sufficient to compress the gaskets (6) by at least approximately 5%. This generates a tight seal between the seal device (1) and the external faces of the modules (5).

In Figure 1B, a second seal device (11) and retaining clip (12) arrangement forms a seal over the joint between rear facing partition modules. One partition wall may thus be used to separate two compartments of a cleanroom environment. Aluminium support (13) is adapted to accommodate second retaining clip (12) and acts to space apart the partition modules to the required extent, for example to allow the fitting of cables and pipes between wall surfaces.

In a second embodiment shown in Figure 2, a seal device forms a seal over the joint between a ceiling module (15) and a wall module (16). The retaining clip (8) is attached to an extruded cove retainer (17) that is itself fixed rigidly to both ceiling (15) and wall (16) modules. The coving (14), which is preferably rigid aluminium, is held pressed against the partition modules through retention of the stud (3) between the ears of retaining clip (8). The flanges (18) of the coving (14) thus exert a compressive force on gaskets (20) between ends (21) and the external faces of the ceiling (15) and wall (16) modules. In an alternative embodiment, the flanges are constructed from plastics material and are resiliently flexible to exert a continuous compressive force on the gaskets (20).

The profile of the bulb (7) of stud (3) is designed so that it co-operates with the ears (9) of retaining clip (8) to generate the required degree of continuous compressive force on the gaskets (20), even after installation. This generates a tight seal between the seal device and the external faces of the modules (15,16). Coving (14) can be push-fitted in place.

Gaskets (20) are of depth of approximately lmm when compressed. Flanges (18) are each of about 8cm in length.

In a third embodiment shown in Figure 3, a cross-section is shown of two wall modules (22,23) of a partition between which gaskets (27) are compressed. The wall modules are held together by a panel clip assembly that comprises an extruded stud (24) and a retaining clip (25). The ears (26) of the retaining clip (25) are bent apart by the stud (24). The ears are resiliently biased towards each other, meaning that when the stud is fitted in place, a compressive force is generated that biases the stud inwards and therefore pulls the modules (22,23) together. The profile of the bulb (7) of the stud (4) is designed so that it co-operates with the ears (9) of retaining clip (8) so as to generate a degree of compressive force sufficient to compress the gaskets (6) by approximately 5%. The ears are made sufficiently rigid to generate the required degree of force. This generates a tight seal between the seal device (1) and the external faces of the modules (5). The wall modules (22,23) can be push-fitted together.

In the embodiment shown in Figure 3, the gaskets are set back from the external faces of the wall modules (22,23) so that channels (28) of predetermined width and depth are formed between the gasket and ends of the modules. The end of the gasket defines the channel.

Silicone sealant (29) is expressed into the channels (28) using a manual applicator gun to provide a second seal.

It will of course be understood that the present invention has been described above purely by way of example, and that modifications of detail can be made without departing from the scope of the invention.

Claims

CLAIMS 1. A seal device for sealing a joint between two partition surfaces, comprising at least one compressible gasket and attachment means, wherein the attachment means act during use to compress continuously the gasket such that the gasket provides a seal between the partition surfaces.
2. A seal device according to claim 1, wherein a cap portion carries the or each gasket on its underside.
3. A device according to claim 2, wherein said gasket is flush with an edge of said cap portion.
4. A device according to claim 2, wherein said gasket is set back from the edge of said cap portion such that when the device is fixed in place, a channel is provided between the cap portion and the partition surfaces.
5. A device according to any one of claims 2-4, wherein said cap portion comprises a coving to allow sealing of a corner joint between a wall partition and a ceiling or floor partition when the device is fixed in place.
6. A device according to claim 5, wherein the coving is substantially rigid.
7. A device according to any one of the preceding claims, wherein said gasket is compressed by at least 5% when the device is fitted in place.
8. A device according to any one of the preceding claims, wherein said gasket comprises non porous material.
9. A device according to any one of the preceding claims, wherein said compressible gasket comprises silicone, neoprene or butyl material.
10. A device according to any one of the preceding claims, wherein said gasket is of at least 3mm thickness when not compressed.
11. A device according to any one of the preceding claims, wherein said attachment means comprises a stud adapted for fixing into a retaining clip.
12. A device according to claim 11, wherein said stud is adapted to be push-fitted in to the retaining clip.
13. A device according to claim 11, wherein said retaining clip has inwardly facing ears which apply a continuous force to the stud in use.
14. A seal device substantially as hereinbefore described with reference to and as shown in Figures 1A and 1B, Figure 2 or Figure 3 of the accompanying drawings.
15. A module for a partition wall, ceiling or floor in a cleanroom comprising a compressible gasket on an end surface of the module such that when said gasket is compressed onto a second module, the joint between the modules is sealed.
16. A module according to claim 15, wherein said gasket is flush with the external face of said module.
17. A module according to claim 15, wherein said gasket is set back from the external face of said module such that when compressed onto a second module, a channel is provided between the external face of said modules and said gasket.
18. A partition for a clean room comprising a module according to any one of claims 15-17.
19. A partition according to claim 18, wherein said compressive force between said modules is provided by a panel clip assembly.
20. A partition for a cleanroom comprising at least two wall, ceiling or floor modules in which the joint between said modules is sealed using a device according to any one of claims 1- 14.
21. A door comprising a front panel, a rear panel and a seal device according to any one of claims 1 to 14, wherein the seal device provides a hermetic seal between the front and rear panels.
22. A partition for a cleanroom comprising at least two wall, ceiling or floor modules wherein a compressible gasket is provided on the external surface of each module such that a sealing cap may link said modules and seal the joint between said modules when a compressive force is applied to said cap.
23. A method of sealing the joint between two or more partition modules in a cleanroom comprising applying compressive force onto a non-porous compressible gasket located between said partition modules.
24. A method of sealing the joint between two or more partition modules in a cleanroom comprising applying compressive force to a sealing device placed over the joint between said modules, wherein a non-porous compressible gasket is located between said device and the external faces of said partition modules.