Means and method for aseptic particle-free production of articles

• US 4,880,581 A
• Filed: 12/24/1986
• Issued: 11/14/1989
• Est. Priority Date: 12/24/1986
• Status: Expired due to Fees

• Current Assignee: Alcon Laboratories Incorporated (Alcon Incorporated)
• Original Assignee: Alcon Laboratories Incorporated (Alcon Incorporated)
• Inventors: Senkowski, Bernard Z., Vin, Gaurang R., Dastoli, Frank R., Wagener, Dieter W., Bogdanffy, George H.
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): McCarthy, Neil M.
• Application Number:
  US06/946,342
• Time in Patent Office: 1,056 Days
• Field of Search: 264/37, 264/525, 264/39, 264/238, 425/210, 425/225, 425/522, 425/538, 425/542, 425/317, 425/342.1, 425/387.1, 425/446, 425/812, 425/815, 425/216.116, 425/73, 425/74, 55/279, 55/385 R, 55/385 A, 98/33.1, 98/31.5, 98/115.3
• US Class Current: 264/39
• CPC Class Codes: A61L 9/16 using physical phenomena
• CPC Class Codes: B29C 2049/4635 being sterile
• CPC Class Codes: B29C 2049/4697 Clean room
• CPC Class Codes: B29C 49/46 characterised by using particular environment or blow fluids other than air
• CPC Class Codes: B29C 67/00 Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
• CPC Class Codes: F24F 3/167 Clean rooms, i.e. enclosed spaces in which a uniform flow of filtered air is distributed air distribution by perforated walls F24F7/10
• CPC Class Codes: Y02A 50/20 Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y10S 425/812 Venting
• CPC Class Codes: Y10S 425/815 Chemically inert or reactive atmosphere

Abstract

An apparatus and method for aseptic, particle-free production of articles. A shroud is placed around at least a portion of the device which produces the articles to substantially isolate that portion from the external environment. The device for producing the articles and the shroud are sterilized and the air inside the shroud is filtered and sterilized. A laminar or other type of flow of filtered, sterilized air is imparted through the shroud over the articles being produced. A secondary shroud encloses the corridor or work area adjacent the shroud and device which produces the articles. The corridor and secondary shroud are sterilized, and sterilized and filtered air is continually introduced therein. The articles therefore are particle-free and sterilized for further use. The apparatus and method can be used for any component production process employing high temperatures and/or pressures, including, but not limited to, blow molding, injection molding, and production of semiconductor electronic components. In the case of blow molding, sterilization of the interior of the article being blow molded is accomplished by blowing the article with filtered and sterilized air.

Claims

1. A method of aseptic, particle-free production of interiors and exteriors of articles, to avoid the need for chemical or irradiation treatment of the articles, and to provide aseptic articles which are prepared for further processing, comprising the steps of:

creating an aseptic environment within a clean room;

shrouding at least a portion of an article producing means of a production machine to substantially segregate the portion of the article producing means from the clean room but retaining some communication with the clean room;

substantially isolating the portion of the article producing means which is shrouded from any external environment and from the clean room;

sterilizing the interior of the clean room, the portion of the article producing means within the shroud, the interior of the shroud, and any surfaces of the shroud inside and communicating with the clean room;

filtering and sterilizing any air enclosed by the clean room and the shroud; and

imparting a flow of filtered, sterilized air through the clean room and into the shroud, over and around the articles being produced on the portion of the article producing means within the shroud, and out of the shroud, so that the articles produced will be aseptic interiorally and exteriorally and ready for further processing.

2. The method of claim 1 wherein the production machine for producing the articles comprises a blow molding machine which is located outside and adjacent to said clean air room.

3. The method of claim 2 comprising the further step of blow molding the articles by injecting filtered, sterilized air into the article being blow molded.

4. The method of claim 1 wherein the flow of filtered, sterilized air is a laminar flow.

5. The method of claim 1 wherein the production machine for producing the articles comprises an injection molding machine which is located outside and adjacent to said clean air room.

6. The method of claim 1 wherein the production machine for producing the articles comprises an electrical semiconductor component producing machine which is located outside and adjacent to said clean air room.

7. A method for aseptic, particle-free blow molding of interiorally and exteriorally sterile articles comprising the steps of:

shrouding a portion of an article producing means of a production machine for blow molding sterile articles to substantially isolate the article producing portion of the blow molding machine from the remainder of the machine and from any external environment;

sterilizing the portion of the article producing means of the blow molding machine and the machine shroud;

filtering and sterilizing the air entered into the machine shroud;

shrouding the work area adjacent to the shrouded portion of the article producing machine;

sterilizing the work area and the shroud enclosing the work area;

filtering and sterilizing the air entering the work area shroud;

imparting a laminar flow of filtered, sterilized air over and around the articles being blow molded; and

exhausting the laminar flow of filtered, sterilized air from the machine shroud;

blowing filtered, sterilized air into the articles being blow molded.

8. An apparatus for aseptic, particle-free production of interiors and exteriors of articles comprising:

a clean room having an aseptic environment;

a production machine including a means for producing the articles, at least a portion of said article producing means being sterilized, said article producing portion of the machine being adjacent said clean room;

a shroud substantially isolating the article producing portion of the machine from the remainder of the machine and from any external wnvironment, the shroud being sterilized;

an inlet opening in the shroud communicating between the clean room and the shroud;

means for filtering and sterilizing air entering the clean room and the shroud;

means for imparting a laminar flow of filtered, sterilized air over and around the articles being produced;

at least one outlet opening in the shroud for exhausting the laminar flow of filtered, sterilized air from the shroud.

9. The apparatus of claim 8 wherein the machine for producing articles comprises a blow molding machine located outside and adjacent to said clean room.

10. The apparatus fo claim 9 wherein the blow molding machine includes means for presenting filtered, sterilized air to blow mold the articles located outside and adjacent to said clean room.

11. The apparatus of claim 8 wherein all surfaces of the portion of the article producing means and the shroud are smooth and sterilized located outside and adjacent to said clean room.

12. The apparatus of claim 9 wherein the blow molding machine injects, extrudes, blows, and discharges the articles being produced.

13. The apparatus of claim 8 wherein the means for filtering and sterilizing the air and for imparting a laminar flow of filtered, sterilized air includes microfilters.

14. The apparatus of claim 8 wherein said means for laminar flow of filtered, sterilized air includes fans, adjustable air flow rate gates, and conduits.

15. The apparatus of claim 8 further comprising means to recirculate filtered, sterilized air.

16. The apparatus of claim 8 further comprising discharge and transport means for the articles being produced, said laminar flow of filtered, sterilized air also being directed on the discharge and transporting means.

17. The apparatus of claim 8 wherein said machine for producing the articles is an injection molding machine located outside and adjacent to said clean room.

18. The apparatus of claim 8 wherein said machine for producing the articles is a semiconductor electronic component producing machine located outside and adjacent to said clean room.

19. The apparatus of claim 8 wherein the outlet opening comprises a perforated wall having a plurality of openings dispersed over the wall to enhance laminar flow of air.

20. The apparatus of claim 8 further comprising a negative pressure means in communication with the outlet opening to enhance laminar flow over and around the articles being produced by the machine.

21. The apparatus of claim 8 further comprising a turbulence barrier means located between the inlet opening in the shroud and the portion of the article producing means to reduce turbulence caused by the portion of the article producing means in the shroud and to direct turbulence away from the inlet opening.

22. The apparatus of claim 8 further comprising turbulence barrier means located in the path of the laminar flow of the filtered, sterilized air between the inlet opening and the outlet opening of the shroud.

23. The apparatus of claim 8 further comprising turbulence barrier means associated with the portion of the article producing means of the production means to reduce turbulence caused by movement of the portion of the article producing means.