Patent Publication Number: US-2010126545-A1

Title: Rapidly deployable military vehicle repair facility

Description:
FIELD OF THE INVENTION 
     The present invention is a system for quickly establishing at field locations the facilities and equipments needed to repair, repaint, camouflage, or treat corrosion on military vehicles. 
     SUMMARY OF THE INVENTION AND DESCRIPTION OF RELATED ART 
     The system of the present invention enables military vehicles to be repaired and/or treated with chemicals such as paint, camouflage treatments, or corrosion treatments. Where chemicals are involved, safety in handling the chemicals, and in the protection of personnel is accomplished in the invention by provision of safety and environmental sub-systems 
     The present invention is a modification over a prior system which was designed for operation in remote field areas. The major systems in the prior system included an inflatable tent and a number of sub-systems required because of the need to transport and set up the system to remote areas and enable it to operate entirely with its own resources. These sub-systems for example included a portable water purification system, a portable solvent distiller, blast equipment and portable pneumatic gun cleaning integrated with a distiller 
     The present invention provides a field deployable solution for military vehicle corrosion removal, bodywork, CARC painting, CPC applications, rust proofing and underbody coatings, and marking and stenciling. Use of the present invention complements existing military maintenance facilities and depots on a rapid, temporary and portable basis by providing increased capacity and throughput when it is needed, where it is needed and for only so long as it is needed. 
     The invention reduces military vehicle and equipment transportation costs and vehicle downtime by bringing the invention into the field to supplement the capabilities at the existing remote vehicle equipment sites. 
     The major systems in the invention are a shelter, a ventilation system with integrated real time environmental monitoring. The intended use of the present invention is as a temporary supplemental facility not required to operate independently. Local power sources may be used, or if required, portable power sources housed in a truck can be provided. 
     Environmentally friendly materials are employed including water dispersible/reducible CARC, de-ionized water/waste water, exempt solvents and recyclable/reusable plastic media blast. 
     Environmental controls are provided including manometers on the backside of the system, thermo anemometers on the front side of the system, vapor monitors providing zone approach for validating system effectiveness, dosimeter badges for personnel safety, iron test kits for water purification validation, humidity, barometric pressure, wind and temperature charting and non-contact infrared surface temperature readers. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the rear of the shelter; 
         FIG. 2  is a perspective view of the front of the shelter; 
         FIG. 3  is a perspective view of the mounting of a shelter support pole; 
         FIG. 4  is a perspective view of the interior of the shelter; 
         FIG. 5  is a perspective view of the shelter support frame; 
         FIG. 6  is a perspective view of interior of the shelter front wall; 
         FIG. 7  is a perspective view of the front entrance to the shelter; 
         FIG. 8  is a perspective view of a portion of the front wall of the shelter; 
         FIG. 9  is a perspective view of the top of the shelter showing IR lamp support; 
         FIG. 10  is a front view of the shelter; and 
         FIG. 11  is a plan view of a special tool. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The invention is used to provide the following processes and services:
         Explosion Resistant Coatings (ERC) Armor Application—IED Blast mitigation; NATO Round resistant   Stealth Coatings—Infrared Reflective, Chemical Agent \Resistant, Biological Agent Resistant, CARC   Corrosion removal, repair, and prevention   Camouflage coatings application   Undercarriage coating application   Blast damage repair, and general bodywork   Vehicle marking—military unit numbers and serial numbers   Preventative Vehicle Maintenance—oil &amp; lube, filters, etc.       

     The Tensioned Fabric Shelter 
     The shelter is constructed so that in can be put up with three people and a 12 foot ladder. A special tool is utilized to mount sections of the shelter support poles into place for connection. The ends of the poles are color coded so that can be easily matched for assembly. 
     The front door has an integrated detachable particulate screen portion. When the dual filter/ventilation system is running 24,000 CFM of air is drawn in through the facility and exhausted through the rear exhaust systems (12,000 CFM per system). The integrated particulate screen prevents dirt, dust, and other contaminants from being drawn into the facility and damaging the vehicle finish while eliminating the need to replace disposable air intake filters—the integrated particulate screens also eliminate another potential waste product from the system—dirty, disposable fiberglass filters. 
     The above referenced screen has a roll up cover that can be strapped to at the top to allow in-take air or they can let down and secured with VELCRO®. They may be lowered and secured at night to prevent moisture and dew from settling on the freshly coated vehicles and consequently ruining the finish. 
     The particulate screen is detachable. At the end of the work-day, the screen is removed and the solid fabric door is lowered. This prevents rain or dew from entering through the screen. The closed door with solid fabric is weather tight. 
     Around the perimeter of the shelter there are 24″ integrated flaps that act as a rain and moisture barrier. These also act as wind flaps that allow wind gusts to pass through easily to prevent the shelter from acting as a sail. The shelter sits on a heavy duty tarp which is then rolled up under the flaps. The rolled up tarp acts as a berm for ground water and the flaps allow rain to roll off the shelter and away from the interior of the shelter. There is dry paint on the tarp since vehicles are painted on it and when the material becomes wet again (from rain) it can leech and/or be carried off as storm water. The design of this system ensures that water does not enter the system and eliminates ground contamination concerns. 
     The Ventilation System 
     A two unit symmetrical ventilation system is employed. The dimensions of each unit are 6′ tall×11′ wide×3′ deep. Each unit made of galvanized steel to eliminate corrosion concerns in the field. It runs off a three HP single phase motor—to work with a standard generator. Each has a 12,000 CFM tube axial fan. The wall is designed in small sections so that it will fit in a cargo van with the shelter. The ventilation system is assembled with self tapping screws and washers, nuts so that only a power drill with Philips head is required. The ventilation system employs eighteen 20″×20″ integrated filter frames. These frames are deep enough (3″) to accept two layers of filters. The first set are fiberglass and intended to capture over spray and atomized waste. The second are carbon and act as an odor neutralizer. The system is sized to turn air over in facility every 90 seconds providing a safe environment for technicians to work in. 
     Because each unit is placed at opposite sides of the end of the shelter adjacent the exit door, a symmetrical air flow is generated in the shelter. This allows a “drive through” design since the large entrance door is positioned between the two ventilation and filtration units. 
     Heating and Curing System 
     The invention employs a “balanced system”. Conventional heating systems supply warmed air into the shelter through a hose or duct and, at 24,000 CFM per minute exhaust the heat faster that it can be produced. The heat supply would not keep pace with the exhaust system. Furthermore, by pulling in the outside air, which when it is cold, further negates the benefits of conventional heating methods. 
     The present heating system is based on Infrared (IR). Most coating facilities cannot use high intensity IR to warm or cure since the heat source is intense and presents a severe combustion hazard. The present invention is environmentally safe and is predicated upon the use of water based materials which are also non-flammable. The shelter material is also non-flammable minimizing the risk of combustion. 
     IR heating is also beneficial for the reason that it heats objects not the air. So when a vehicle is in the shelter and the IR lamps are on, the vehicle surface temperature itself is rising. This means that even though the cold air is entering the shelter and passing over the vehicle and out the exhaust, the vehicle is still under the IR lamps and radiating heat. The IR intensity can also be increased, thus increasing the core temp of the vehicle. At the same time the IR is also heating the concrete or asphalt. All of these continue to radiate heat when the lamp/heater is ON. It is extremely efficient and requires no external power source. It uses propane tanks and a milliamp thermostat (DC). 
     The lamps serve a dual purpose. The IR lamps are used to cure the paint thus decreasing the wait time until the vehicle can be returned to the military. Traditionally, paints cure from the outside in. The outer layer of the paint is exposed to the ambient air. The warmer the ambient air, the faster the drying time. Infrared heats from the metal substrate and dries the paint from the inside out. When combined with ambient air drying, the entire drying process is accelerated. 
     Solar Lighting 
     Lighting is accomplished by the use of sixteen solar light fixtures. These fixtures contain cold weather ballasts capable of operating in temperatures below normal commercial or household temps. Traditional ballasts cannot start at temperatures below 45° F. These fixtures are attached to the interior of the shelter by hanging them on the shelter supports. The use of solar lighting within the shelter enhances the ability to deploy the system in remote locations by not needing electrical service. 
     Power Plant 
     The power plant consists of two primary pieces of equipment: a diesel powered compressor capable of generating 185 CFM air displacement and a large gasoline powered 33 HP generator with 17,500 watts capacity. 
     Fuel 
     Fuel is stored and dispensed on site and it is held in 300 gallon portable storage containers. The containers have secondary spill containment incorporated into them and a third level of spill containment is provided by utilizing spill containment berms. By containing all aspects of the power plant and fuel with a high capacity containment system, fuel can be directly filled and dispensed from the fuel storage containers into each component of the power plant. A dispensing handle is attached to the container. The tanks are filled by a fuel tanker delivery service. 
     Steam Cleaning System 
     It is known that waste water and detergents are key contributors to ground contamination. Hydrocarbons are in the oils and greases found on and in the vehicles being serviced. These get washed off and end up in the ground, sewage system, or in storm drains. 
     The present invention employs a closed loop system that eliminates waste from the cleaning process. Instead of using 4 GPM pressure water that produces gallons of water per minute, which then becomes dirty, the present invention uses a high temperature (reaching 300° F.) steam system. This reduces water consumption by over 60% and eliminates the need for detergents. Heat is a powerful replacement for cleansers and detergents. Furthermore, an evaporator is used to convert the waste water into steam. The water is pumped out of the containment system that the vehicle is parked in and pumped to the evaporator. The water is heated and evaporates off as steam. What&#39;s left is a small clump of solid matter and solids that were in the waste water. This is incidental and is usually no more than about 5 ounces of material per 5 gallons of waste water. We have removed contaminated waste water from the hazardous waste stream. 
     On Site Water Purification 
     Water purification is accomplished by two methods: 
     A portable water deionization system is used. Typically water pressure is required to produce deionized water because reverse osmosis is used which requires water to be forced through a series of filters and membranes. 
     We have discovered that metal objects coated with water based military coatings were rusting prematurely. We believe this is caused by the iron content found in some water in different localities. The iron in the water causes rust to form on the metal surfaces prematurely. So, while the prior art applied these specialty coatings in an attempt to preserve their integrity and prevent the onset of corrosion, they were actually facilitating the process, unknowingly. Accordingly, a means of producing deionized water in the field without a traditional plumbing, or water supply system, is employed. 
     We connect the reverse osmosis system to a portable pressure pot by means of a series of hoses. We then fill the pressure pot with tap water. This water can be brought to the site in a gallon container from a hotel, a spigot, or any other traditional water source. The remaining space in the pressure pot is filled with air from the compressor. The air forces the water through the hoses and membrane filters. One hose is purified water and goes into a container marked “deionized.” The other hose is color coded and goes into a container marked “waste water.” The waste water has a high mineral content and has some abrasive qualities to it. It is perfectly suited for cleaning and flushing application equipment and spray guns throughout the day. One gallon of tap water can be converted into about ½ gallon of deionized water which is sufficient for thinning approximately one day&#39;s worth of work/coating application. 
     In areas of operation where water is scarce, a modified system typically used to produce water from air in small quantities for drinking purposes is employed. A small capacity (5 gallon) dehumidifier is used to collect moisture removed from the air. This water is then run through the reverse osmosis system and purified for use. 
     All water is tested using water test kits. The entire reverse osmosis system fits into a hard side brief case for ease in transportation and set up to produce clean useable water by simply opening it up and connecting to either a water source, a pressure pot, or a dehumidifier&#39;s reservoir. 
     Solvent Recycler and Automatic Gun Cleaner 
     The processes and uses of the invention generate a waste stream. Handling and disposing hazardous waste in the field is accomplished by creating a closed loop system where virtually no hazardous waste is generated. One major component of this system/process is the reduction of solvent use and any solvent waste. 
     First, a small automatic gun cleaner is used were air pressure pumps solvents through the spray gun and other paint contaminated tools. The dirty solvent drains through the bottom of the cleaner and into a five gallon pail. The solid matter settles to the bottom of this five gallon pail leaving clean solvent at the top of the pail. The intake tube for the cleaning system is at the top of the container so that only the clean solvent is recycled back through the cleaner, leaving the solid matter that settled on the bottom undisturbed. 
     Eventually, the solid matter rises to a point where it is at the level of the intake tube and only dirty solvent is cycled through the cleaner. This results in ineffective cleaning. Typically this solvent must be disposed of through a licensed hauler. In a field environment, a solvent recycler is used to eliminate this waste stream. The 5 gallon container of dirty solvent cleaner is poured into a large stainless steel container and closed. The dirty solvent is then distilled by heating it to its boiling point. It converts it into a vapor which is collected and then converted back into a virgin form solvent in an empty container underneath the stainless steel bowl. What is left in the bowl after the distillation process is referred to as a “waste cookie”, and is dry paint waste—the solids that were causing the solvent to become dirty and ineffective. The resulting clean solvent is then returned to the gun cleaner and the loop is complete. 
     An important feature of the present invention is the shelter. As shown in  FIG. 1 , a rear view of the shelter, a rear door  1  is formed in a plurality of panels. Two exhaust fans,  2  and  3  are open to the rear of the shelter. A panel  4  is provided to house a manually actuable rear door control mechanism, which may be powered or operated by a hand crank. A cover is provided to cover the mechanism when not in use. A plurality of connecting straps  5 - 10  are provided to hold the rear wall of the shelter onto the outer shelter surface. Wind flaps  49  and  50  are provided near the floor of the shelter. These flaps extend along the length of the shelter and permit release of interior pressure built up by wind. 
       FIG. 2  is a front view of the shelter. A large front door  11  is also formed in a plurality of panels to permit equipment to enter the shelter. A smaller front door  12  is provided so that personnel can enter the shelter and easily escape in the event of an emergency. A panel  13  is provided at the front of the shelter housing the front door control mechanism. A plurality of connecting straps  15 - 20  are used to connect the front wall of the shelter to the outer shelter surface. Flap portions such as  14  are provided around the shelter to aid in drainage of rain away from the bottom of the shelter and thereby away from the interior of the shelter. 
       FIG. 3  is a perspective view of the mounting of one of the shelter support poles  25 . A plate  22  as an adjustable strap buckle  23  mounted thereon. The buckle  23  serves to house, loosen and tighten strap  28 . The strap  28  fits around a rod  27  which is sewn into a pouch formed on the interior of the shelter. A plurality of strap buckles are provided each one adjacent to the mounting structure of shelter support pole  25 . 
     Also affixed to the plate  22  is a collar  26 . The hollow end of pole  25  fits over the collar and is held in place by a nut and bolt  24  mounted in mating through holes in the collar and in the shelter pole. The plate  22  may be secured to the ground via stakes. A cloth floor  21  is provided to provide ground covering for the work area beneath the shelter. 
       FIG. 4  is an interior view of the rear of the shelter. Rear door  1  is formed of a plurality of draped panels so that it can be easily raised and lowered manually because of its light weight. As can now be seen, shelter support poles  29 ,  30 ,  31  and  34  are shown spaced every six feet. These support poles are multi-sectional so that the end of one section fits into the end of the other. Each end is color coded to save time whereby the appropriately colored sections are meant to be jointed together. Lateral framing support is provided by rods such as  32  and  33 . These lateral rods are spaced every six feet. The ends of each support pole,  29 - 31  and  34  are supported by the plate structure shown in  FIG. 3 . 
       FIG. 5  shows the supporting frame for the shelter. Specifically, the top shelter lateral supports such as  38  and  39  are connected together at the juncture  37  of two sections of the shelter support poles. The ends of the lateral support are flattened and apertured so that a nut and bolt fastening between them and the shelter support pole is made. A hook is connected to nut and bolt fastening  37  to suspend a chain  35  and a hanger  36 . As will be further apparent, a number of hangers  36  are suspended along the top of the interior of the shelter to serve as supports for other structures. 
     One end of lateral support  38  is also connected to the juncture of two sections of shelter support pole  31 . In this manner, the lateral supports are connected across the interior of the shelter. 
       FIG. 6  shows a portion  42  of the front wall of the shelter. Additional cross braces  40  and  41  are provided on both sides of the shelter support adjacent to the front shelter wall. The bottom of the front wall  42  is loosely secured to a bar  44  mounted on the ground via cords. An additional cross brace  43  is provided near the bottom of the front wall  42 . 
       FIG. 7  shows a portion of the front entrance of the shelter. The front wall has a screen portion  45  to aid in control of air flow into the shelter and a solid portion  46 . This screen portion may be covered in whole or in part via a flap. Cross brace  44  is attached to vertical bar  47 . The bar supports a cord  51  which is attached to the ends of front wall portion  42 . 
       FIG. 8  is an interior view of a portion of the front wall of the shelter. It shows the crank housing  13  attached to a door control cord  48 . The crank housing is affixed to support bar  43 . 
       FIG. 9  shows three sections,  53 ,  54 , and  56  of IR lamps connected to their power source  55 . These sections are connected together and suspended from a plurality of hangers shown and described in connection with  FIG. 5 . 
       FIG. 10  shows the detail of the screen  45  connected to a base flap  52  and being “closed” by flapped closure  46 . 
       FIG. 11  shows the special tool which as a long handle,  57  connected to a U-shaped support  58  for manipulating the shelter poles. 
     Commercially available parts of the system are set forth below: 
     Shelter and Solar Lighting, Vendor: MDM Shelters, 105 Woodmont Road, Milford CT 06460 Enhancements made: Shelters are modified with a safety door, sewn mesh screens for garage doors and air entry, and better fastening mechanisms. Solar Lighting has special brackets made to hold them in the shelter. Exhaust ports or exit ports are also cut and sewn into the shelter. 
     50′ LP Hoses/LV404B9 Regulator and Pigtail Connectors. Vendor: MGS Corporation 309 Route 72, Barnegat N.J. 08005, used to make enhancements to Infrared Heater—regulated manifold 
     The flooring is made of TEMPER Tent Vinyl Coated Polyester fabric. This fabric is flame retardant, waterproof and tear resistant. TEMPER Tent fabric is very cold resistant. This fabric has been widely used by military. It is available from Harpster of Philipsburg, Inc., 202 Airport Road, Philipsburg Pa. 16866. 
     Dual Low Intensity Infrared Heater, Vendor: Parent &amp; Kirkbride Inc., 3434 York Road, Furlong Pa. 18925, Enhancements made: The heating/flame element is enclosed with a regulated manifold for added safety features. 
     Wall mounted unmanned fire extinguishers, Vendor: Griot&#39;s Garage, Inc., 3500-A 20 th  Street E, Tacoma, Wash. 98424, are used for: fire suppression in the shelter. 
     3 Horse Power/Single Phase Motor Fans×2 and 2 6 foot high, custom designed filter walls with rear exhaust offset, Vendor: Standard Tools &amp; Equipment, 4810 Clover Road, Greensboro, N.C. 27405, are used to filter out paint emissions through HEPA filtration system emitting no VOC&#39;s into the atmosphere. An environmental monitor is attached to the filter wall to measure when the filters need to be changed. 
     Retractable Air Hose, Vendor: Nation Toolwarehouse.com (E-Commerce Vendor), is attached to the filter wall and is the air hose for painting and corrosion removal tools. 
     Mesh Fabric, Vendor: Bruin Plastics Company, 61 Joselin Road, Glendale R.I. 02826 is used to modify the shelter garage doors for ventilation purposes. 
     Further modifications to the methods and apparatus of the invention may be made without departing from the spirit and scope of the invention.