JP6748686B2 - Module, modularized facility, and method of constructing modularized facility - Google Patents

Description

The present invention relates to, for example, a module in which devices and equipment are installed in advance, a modularized facility in which a plurality of the modules are carried into a building, and a method of constructing the modularized facility.

In recent years, clean rooms have been adopted in semiconductor manufacturing factories, food manufacturing factories, pharmaceutical manufacturing factories, operating rooms in hospitals, and the like. The clean room is a room that maintains a high degree of cleanliness and is maintained at a constant temperature and humidity, and is configured so that dust, particles, bacteria, etc. from the outside do not enter.

Conventionally, as a clean room facility including such a clean room, a facility in which a clean room is partitioned by a partition unit is known (for example, refer to Patent Document 1). According to this clean room facility, it is possible to provide a clean room which has a high degree of freedom in layout design and divides a large space.
However, in the above-mentioned clean room facility, there is a problem that the construction period becomes long when a new clean room facility is constructed because it requires the work of assembling the partition units in the building.
In order to solve such a problem, it is possible to arrange a module manufactured in advance in a factory in a building under construction. As such a technique, a modular unit including a clean room and a maintenance room is known (for example, see Patent Document 2). By using this modular unit, it is possible to shorten the work period because the work on site can be reduced.

JP, 2011-257019, A Japanese Patent Publication No. 2017-532470

By the way, in Japan, when the above-mentioned modular unit is transported to the site, there are legal restrictions such as the Road Traffic Law. Specifically, dimensional regulations must be met to transport modular units manufactured in Japan to the construction site by land. If the limit is exceeded, it is necessary to apply to the competent authorities, and there is also a limit to the size range outside the limit where the application is permitted.
An object of the present invention is to provide a module that can be easily transported, a modularized facility that can be installed in a short period of time using the module, and a method for constructing the modularized facility.

The module of the present invention is
A multi-layered module having a rigid frame structure,
A main chamber module in which a space to be a main chamber is formed in a lower layer, and an air supply chamber module in which a space to be an air supply chamber for supplying air to the main chamber is formed in an uppermost layer,
The length of the module in the long side direction is 5 m or more and 12 m or less, and the length in the short side direction is 2 m or more and 2.5 m or less,
Said main chamber height modules than 2m 3m or less, the height of the air supply chamber module Ri der least 1.5m below 0.8 m,
The main chamber module is
The floor,
An indoor suction port that is disposed above the floor surface and is separated from the floor surface on the floor surface side of the main chamber module, and that sucks air in the main chamber.
Equipped with
The air supply chamber module,
An outside air intake filter unit for supplying outside air to the main chamber,
A fan filter unit for cleaning the outside air supplied to the main chamber,
An air conditioner for adjusting at least one of temperature and humidity of the main chamber,
Module comprising: a.
With a module of such a size, it is not necessary to apply for a special vehicle passage permit in advance, so the labor of transportation can be reduced and the road can be easily transported.
Further, by providing such equipment, a clean room can be accurately constructed in the building.

In addition, the module of the present invention,
It is characterized in that it comprises one or two layers of the main chamber module and one layer of the air supply chamber module.
As described above, since the module is composed of the main chamber module and the air supply chamber module, an optimal module for a clean room can be realized.

In addition, the modularized facility of the present invention,
A modular facility in which the module of the present invention is arranged,
A layout of the building area is formed using the module in which the equipment is installed in advance,
The device does not straddle between the adjacent modules.
In this way, by installing the device in a module so as not to straddle between adjacent modules, each module can be handled as a unit and layout in a building can be facilitated.

In addition, the modularized facility of the present invention,
The module is arranged in the existing building.
As described above, the module according to the present invention is not limited to a newly built building, and can be placed in an existing building.

In addition, the modularized facility of the present invention,
It is characterized in that the module having a size corresponding to a space between columns in the existing building is arranged.
For example, if the existing building has a ramen structure with a minimum lower RC structure or SRC structure, the span between columns will be small, so it is possible to eliminate wasted space by arranging a custom-sized module between columns. it can.

In addition, the modularized facility of the present invention,
The module forms a clean room provided in the modularized facility.
Since the module of the present invention has a high degree of freedom in layout design, it is suitable for forming a clean room.

In addition, the modularized facility of the present invention,
In the building or the existing building, a bio-drug culture area, a bio-drug refinement area, and a drug preparation area are arranged in different layers.
Thus, by arranging the bio-drug substance culture area and the bio-drug substance purification area on different floors, it is possible to achieve a good balance with the area of the preparation area.

In addition, the modularized facility of the present invention,
Each layer of said building, characterized in that the additional area for expending the module is formed.
As a result, when the process is changed due to the progress of development or the like, the modules can be efficiently added.

In addition, the construction method of the modularized facility of the present invention,
A method for constructing a modularized facility, wherein the module of the present invention is placed in a building,
A manufacturing process of assembling the module structure in a factory and installing the equipment,
A transfer step of transferring the module in which the device manufactured in the manufacturing step is installed in the building,
A method of constructing a modularized facility, comprising a carrying-in step of carrying in the module in a predetermined layout in the building.
The module according to the present invention in such a process by arranging the building, it is possible to construction a modular facility in a short construction period.
In addition, the construction method of the modularized facility of the present invention,
A method for constructing a modularized facility, wherein the module of the present invention is placed in a building,
A device is installed, and a transfer process of transferring the module, which has been placed in another existing facility, to the building,
And a loading step of loading the module in a predetermined layout in the building.
Since the module of the present invention has high versatility, it can be reused in this way.

In addition, the construction method of the modularized facility of the present invention,
The equipment is installed in each main chamber module so as not to straddle between the adjacent modules when performing the layout.
In this way, by installing the device in a module so as not to straddle between adjacent modules, each module can be handled as a unit and layout in a building can be facilitated.

In addition, the construction method of the modularized facility of the present invention,
The module is transferred to a construction site of the building in the transfer step.
That is, when building a new building, the modules are transported from the factory to the construction site.

In addition, the construction method of the modularized facility of the present invention,
In the carrying-in step, the module is carried into the existing building.
As described above, the module according to the present invention is not limited to a newly built building, and can be placed in an existing building.

According to the present invention, it is possible to provide a modularized facility that can be constructed in a short construction period using a module that is easily transported, and a method for constructing a modularized facility.

It is a perspective exploded view and a perspective view showing a module concerning an embodiment. It is a schematic diagram which shows the layout of the building of the modularization facility which concerns on embodiment. It is a layout diagram showing a combination pattern of modules in the building of the modularized facility according to the embodiment. FIG. 6 is a perspective view showing a case where a brace is temporarily provided in the module according to the embodiment. FIG. 3 is a perspective view showing a case where the main chamber module has a plurality of layers in the module according to the embodiment. It is a figure which shows the procedure of carrying in a module in the building of the modularization facility which concerns on embodiment. It is a figure which shows the air conditioning equipment in the modularized facility which concerns on embodiment. It is a conceptual diagram of the air conditioning equipment arrange|positioned in the building of the modularization facility which concerns on embodiment. It is a figure which shows the span between the pillars in the building of the existing modularized facility.

Hereinafter, a module according to an embodiment of the present invention will be described with reference to the drawings. 1A is a perspective exploded view showing a module according to the embodiment, and FIG. 1B is a perspective view showing the module according to the embodiment. As shown in FIGS. 1A and 1B, the module 2 is composed of a rectangular parallelepiped rigid-frame structure and has two layers. The module 2 also includes a main chamber module 6 in which a main chamber 4 is formed in a lower layer, and an air supply chamber module 10 in which an air supply chamber 8 for supplying air to the main chamber 4 is formed in an upper layer. The module 2 is applied to a clean room, and is used to configure a process room used in a process of manufacturing biopharmaceuticals, a work room for other work, and a changing room.

The frames forming the structure of the module 2 are each made of steel such as H-section steel, groove-section steel, or mountain-section steel. In this way, by making the structure a rigid frame structure using a universal steel material, it becomes easy to install partitions and install equipment. Further, the floors of the main chamber module 6 and the air supply chamber module 10 are laid with iron plates, and finishes such as coating floor finish and PVC sheet. As a result, the weight of the module 2 can be reduced as compared with the floor having a concrete structure, and the module 2 can be easily transported.

The length X in the long side direction of the module 2 is 5 m or more and 12 m or less, and the length Y in the short side direction is 2 m or more and 2.5 m or less. The height H1 of the main chamber module 6 is 2 m or more and 3 m or less, and the height H2 of the air supply chamber module 10 is 0.8 m or more and 1.5 m or less. Both the lengths X and Y are external dimensions.

Here, when the module 2 is loaded on the bed of a truck and is transported by road on the road, the maximum size at the time of traffic is defined by laws such as the Road Traffic Law. It is possible to pass over the maximum size by applying for special vehicle passage permission (special vehicle) in advance, but in this case, it is necessary to conduct a preliminary survey of the transportation route and a large number of modules continuously. The time and cost of transportation greatly increase due to transportation and the need to arrange guided vehicles during transportation.

In this respect, by limiting the size of the module 2 to the above-mentioned size, it is not necessary to apply to the competent authority in advance, so that the labor and cost of transportation can be reduced. In addition, it will be easy to relocate or reuse the module 2 to another domestic site in the future.

Next, the modularization facility according to the embodiment will be described by taking as an example the case where the modularization facility is a biopharmaceutical manufacturing facility. FIG. 2 is a schematic diagram showing the layout of the building 20 of the modularized facility according to the embodiment. As shown in FIG. 2, the building 20 is a three-story building, in which the bio-drug cultivation area 22 is located on the third floor, the bio-drug purification area 24 is located on the second floor, and the drug substance area 26 is on the first floor. Are arranged. Raw materials and materials are stored in a separate warehouse.

Since the process from the biopharmaceutical culture process to the purification process is continuous, the biopharmaceutical culture area 22, the biopharmaceutical purification area 24, and the drug product area 26 are arranged in an overlapping manner in this manner to efficiently perform biotechnology. Pharmaceuticals can be manufactured. In addition, when the bio-drug cultivation area 22 and the bio-drug purification area 24 are arranged on the same floor, the floor area becomes large and the balance with the area of the preparation area 26 deteriorates. By disposing the drug substance culture area 22 and the bio-drug substance purification area 24 on different floors, a good balance with the area of the preparation area 26 can be achieved.

A machine room area 27, a warehouse area 28, and a module expansion area 29 are arranged on each floor. Furthermore, a module maintenance area 30 and an inspection area 31 are arranged on the first floor. Of these, the module 2 is not carried into any area other than the module expansion area 29. In this way, by limiting the application of modularization to the process chambers such as the culture area 22 for the bio-drug substance, the purification area 24 for the bio-drug substance, the preparation area 26, and the module expansion area 29, the number of modules 2 is increased. It is possible to prevent an increase in construction period and cost due to too much.

Here, the module extension area 29 is provided on the carry-in side so that the module 2 can be loaded in a short period in preparation for future expansion of the module 2. As a result, the module 2 can be efficiently added when the process is changed due to the progress of development. The ceiling height of each floor of the building 20 is set to a height of 4.5 m or more and 7 m or less so that the module 2 can be easily carried in or moved.

The constituent members of the module 2 do not correspond to the steel members that form the main structural portion of the building 20, and the module 2 is designed as a part of the interior material of the building 20. As a result, it is possible to improve the design flexibility and versatility of the module 2.

Next, a method of constructing a modularized facility will be described by taking as an example a case where both the module 2 and the building 20 are newly manufactured and constructed. First, when the construction of the building 20 is prepared or undertaken, the module 2 is manufactured in a factory (not shown) (manufacturing process). In this manufacturing process, first, the structure of the main chamber module 6 and the air supply chamber 8 is formed by combining the frame and the floor material, and then the main chamber 4 of each main chamber module 6 is designed based on the design plan. The equipment is installed in. Then, the air supply chamber 8 is assembled on the main chamber module 6.

Here, FIG. 3 is a layout diagram showing a combination pattern of the modules 2 in the building 20. 3A shows a layout of a process room for large machines, FIG. 3B shows a layout of a process room for medium machines, and FIG. 3C shows a layout of a process room for other small machines. In this way, by consolidating the combination patterns of the modules 2 into a limited pattern, it is possible to reduce the risk of construction cost increase and construction error.

In the factory, equipment is installed in the main chamber module 6 so that a layout of such a pattern can be constructed in the future. Since each module 2 is transported in units, the device is installed for each module 2 so as not to straddle between the modules 2. Further, the main chamber module 6 and the air supply chamber 8 are tightly connected by bolts.

Here, with respect to the main chamber module 6, a brace 32 may be temporarily installed in the side opening portion 21 as shown in FIG. 4 so that a predetermined rigidity can be maintained during transportation or lifting by a crane. Further, as shown in FIG. 5, as for the module 2 ′ in which the main chamber module 6 has a plurality of layers, the factory has prepared the module 2 including only one layer of the main chamber module 6 and the air supply chamber 8 (see FIG. 1(b)), the main chamber module 6 is further added and assembled in the building 20.

When the module 2 on which the device is installed is completed in the factory, the module 2 on which the device is installed is placed one by one on the truck bed and transferred to the construction site of the building 20 (transfer process). Here, since the size of the module 2 is limited, all the modules 2 can be transported without having to apply in advance to the competent authority.

When the truck arrives at the building 20, the module 2 is carried into the building 20 (carrying-in step). Specifically, the module 2 placed on the bed of the truck is lifted by a crane and transferred to each floor in the building 20. Next, as shown in FIG. 6A, the module 2 is placed on the roller 33 and horizontally pulled, and is installed at a target position on each floor as shown in FIG. 6B. Here, as shown in FIG. 6C, when there is a temporary brace 32, it is removed, and when there is an adjacent module 2, it is horizontally connected by bolting.

When the layout in the building 20 is formed by using the module 2 in which the devices are installed in advance, as shown in FIG. 7, the air conditioning equipment is arranged in the building 20 along the module 2 and the clean room is formed in the building 20. It is formed. Here, FIG. 8 is a conceptual diagram of the air conditioning equipment arranged in the building 20. As shown in FIG. 8, the air conditioning equipment includes an outside air system 34, an exhaust system 35, and a circulation system 36.

The outside air system 34 is shown by a solid line and includes an outside air processing air conditioner 37, an air supply duct 38, an outside air intake filter unit 40, and a fan filter unit 42. The outside air that has been sucked from the outside air processing air conditioner 37, filtered, and subjected to the primary temperature control is sent to the outside air intake filter unit 40 arranged in the air supply chamber 8 through the air supply duct 38. The outside air supplied from the outside air intake filter unit 40 into the supply chamber 8 is further cleaned by the fan filter unit 42 and then supplied to the main chamber 4.

The exhaust system 35 is shown by a broken line and includes an indoor suction port 46, an exhaust duct 48, and an exhaust fan 50. Here, the indoor suction port 46 is arranged so as to be located on the floor side of the main chamber 4. When the air in the main chamber 4 is sucked in by the indoor suction port 46, it is exhausted to the outside by the exhaust fan 50 via the exhaust duct 48. As described above, by supplying the air cleaned by the fan filter unit 42 into the main chamber 4 and further exhausting the air inside the main chamber 4, the air conditioning in the main chamber 4 can be appropriately performed. .. Further, by arranging the indoor suction port 46 on the floor side of the main chamber 4, it is possible to configure an air flow from the fan filter unit on the ceiling surface of the main chamber to the indoor suction port, and Floating can be suppressed.

The circulation system 36 is shown by a one-dot chain line and includes an indoor suction port 52, a circulation duct 54, and an air conditioner 56. Here, the air in the main chamber 4 sucked from the indoor suction port 52 located on the floor side is sent to the air conditioner 56 via the circulation duct 54. The air whose temperature and/or humidity is adjusted by the air conditioner 56 is supplied to the main chamber 4 again. Thereby, the temperature and humidity in the main chamber 4 are always maintained appropriately.

The indoor suction ports 46 and 52 are provided in the main chamber module 6, and the outside air intake filter unit 40, the fan filter unit 42, and the air conditioner 56 are provided in the air supply chamber module 10.

According to the module of this embodiment, the length of the module 2 in the long-side direction and the short-side direction is regulated to a size that does not require a special vehicle passage permission in advance, thereby reducing the labor of transportation. Therefore, the road can be easily transported. Moreover, by using such a module 2, it becomes possible to construct a modularized facility in a short construction period.

In addition, in the above-described embodiment, the case where both the module 2 and the building 20 are newly manufactured and constructed is described as an example, but at least one of the module 2 and the building 20 is an existing one. Good. For example, the newly manufactured module 2 may be carried into the existing building 20. Here, when the existing building 20 has an RC structure, an SRC structure, or the like, it is conceivable that the span between the columns 62 becomes small as shown in FIG. 9. In such a case, in addition to the standard size module 2, a custom size module 2 adapted to the size between the columns 62 may be separately manufactured in a factory. By disposing the custom-sized module 2 between the pillars 62, it is possible to prevent wasted space.

Further, the existing module 2 may be carried into the newly built building 20. In this case, the existing module 2 is reused as it is placed in another existing facility and is appropriately loaded into the building 20 according to the progress of the construction of the building 20. It is needless to say that the existing module 2 was also manufactured in the factory and the equipment was installed before being placed in another facility.

Further, the existing module 2 may be carried into the existing building 20. Even in this case, the existing module 2 is to reuse the module that was placed in another existing facility.

Moreover, although the case where the modularization facility is a biopharmaceutical manufacturing facility is described as an example in the above-described embodiment, the application of the modularization facility is not limited to this. For example, it may be applied to a semiconductor manufacturing factory, a food manufacturing factory, a facility requiring a clean room such as an operating room of a hospital.

Moreover, in the above-mentioned embodiment, the building 20 of the modularized facility is not necessarily limited to the three-story building. For example, the first floor may be the piloty floor and the formulation area 26 may be arranged on the second floor. In this case, the bio-drug refinement area 24 is arranged on the third floor, and the bio-drug culture area 22 is arranged on the fourth floor.

2 module 4 main chamber 6 main chamber module 8 air supply chamber 10 air supply chamber module 20 building 21 side opening 22 culture area 24 purification area 26 formulation area 27 machine room area 28 warehouse area 29 module expansion area 30 module maintenance area 31 Inspection area 32 Brace 33 Roller 34 Outside air system 35 Exhaust system 36 Circulation system 37 Outside air processing air conditioner 38 Air supply duct 40 Outside air intake filter unit 42 Fan filter unit 46 Indoor suction port 48 Exhaust duct 50 Exhaust fan 52 Indoor suction port 54 Circulation Duct 56 air conditioner 62 pillars

Claims (13)

A multi-layered module having a rigid frame structure,
A main chamber module in which a space to be a main chamber is formed in a lower layer, and an air supply chamber module in which a space to be an air supply chamber for supplying air to the main chamber is formed in an uppermost layer,
The length of the module in the long side direction is 5 m or more and 12 m or less, and the length in the short side direction is 2 m or more and 2.5 m or less,
Said main chamber height modules than 2m 3m or less, the height of the air supply chamber module Ri der least 1.5m below 0.8 m,
The main chamber module is
The floor,
An indoor suction port that is disposed above the floor surface and is separated from the floor surface on the floor surface side of the main chamber module, and that sucks air in the main chamber.
Equipped with
The air supply chamber module,
An outside air intake filter unit for supplying outside air to the main chamber,
A fan filter unit for cleaning the outside air supplied to the main chamber,
An air conditioner for adjusting at least one of temperature and humidity of the main chamber,
Module comprising: a. The module according to claim 1, comprising one or two layers of the main chamber module and one layer of the air supply chamber module. A modularized facility in which the module according to claim 1 or 2 is arranged,
A layout of the building area is formed using the module in which the equipment is installed in advance,
The modularized facility, wherein the device does not straddle the adjacent modules. The modularized facility according to claim 3 , wherein the module is arranged in an existing building. The modularized facility according to claim 4 , wherein the module having a size corresponding to a space between columns in the existing building is arranged. The module modularized facility according to any one of claims 3-5, characterized in that to form a clean room which is provided on the modular facilities. Culture area of biotechnology drug, bio-drug purification area, modular facility according to claim 6, characterized in that arranged in different layers of the formulation area, respectively. Wherein each layer in the building, the modular facility according to any one of claims 3-7, characterized in that the additional area for expending the module is formed. A method of constructing a modularized facility, wherein the module according to claim 1 or 2 is arranged in a building,
A manufacturing process of assembling the module structure in a factory and installing the equipment,
A transfer step of transferring the module in which the device manufactured in the manufacturing step is installed in the building,
A method of constructing a modularized facility, comprising a carrying-in step of carrying in the module in a predetermined layout in the building. A method of constructing a modularized facility, wherein the module according to claim 1 or 2 is arranged in a building,
A device is installed, and a transfer process of transferring the module, which has been placed in another existing facility, to the building,
A method of constructing a modularized facility, comprising a carrying-in step of carrying in the module in a predetermined layout in the building. The method for constructing a modularized facility according to claim 9 or 10 , wherein the equipment is installed in each of the main chamber modules so as not to straddle between the adjacent modules when performing the layout. The said module is conveyed to the construction site of the said building in the said conveyance process, The construction method of the modularization facility as described in any one of Claims 9-11 characterized by the above-mentioned. The method for constructing a modularized facility according to any one of claims 9 to 12 , wherein the module is loaded into an existing building in the loading step.

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