Abstract:
A method for assembling a prefabricated modular carwash assembly, including a carwash module and an equipment module, and transporting the assembly to a predetermined building site includes the fabrication of the carwash and equipment modules at an origin and transporting those modules to a desired location. The carwash module includes a skeletal system secured on a flooring, wherein the skeletal system supports the carwash equipment. The equipment module is constructed like the carwash module, and is positioned proximate the carwash module at the building site. The equipment module includes washing and drying components such as a water pumping station and an air compressor for generating a stream of air to dry the vehicle.

Description:
[0001]     This utility application is a division of U.S. patent application Ser. No. 10/423,532, filed on Aug. 11, 2003 and currently pending, which claims priority to U.S. Provisional Patent Application No. 60/377,509, filed on May 1, 2002, both of which are herein incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates generally to carwashes and, more particularly, to modular prefabricated carwashes that may be easily transported to a desired site complete with equipment installed and tested.  
         [0004]     2. Description of the Related Art  
         [0005]     Many people have become accustomed to the convenience of using a carwash. Carwashes are frequently installed at gas stations whereby drivers can purchase gas and at the same time purchase a carwash. For the drivers, the combination of getting gas and a carwash at the same location is a great convenience. For the owners of the gas stations or convenience stores, the carwash presents an additional opportunity to increase sales and revenue. From a competitive aspect, many gas stations and convenience stores want a carwash in order to lure additional customers to their stores.  
         [0006]     The construction of carwashes normally requires expertise in several different areas. After a suitable location has been secured, the floor plan of the building must be laid and the car washing equipment position determined. The building generally consists of a tunnel in which the car washing equipment is located and where the car is washed and a mechanical room where the controls for the equipment are kept. The distribution and delivery of power and supplies to such equipment must then be designed. Since each car wash building may be slightly different, each layout for the equipment is also slightly different, and the design of a system for the distribution and delivery of supplies for the equipment previously required individual attention for each carwash. The design and installation of such a system requires considerable expertise in the areas of plumbing, electricity and hydraulics. Skilled plumbers and electricians employed in the construction must also be specifically experienced in carwash equipment.  
         [0007]     Before the present invention, the building of a carwash in a remote location required a considerable expenditure of time and effort. It was required that the builder travel to the location in order to contract skilled electricians, plumbers, and equipment installation personnel in order to ensure their availability as necessary for the installation.  
         [0008]     Once these experienced technicians had been scheduled, it was required that they design, and subsequently install chemical, electrical and hydraulic distribution systems to deliver supplies to the equipment to be used in the carwash. This required a large expenditure of time and concerted effort by these skilled technicians, resulting in a high cost to the builder.  
         [0009]     After installation of the equipment and supply distribution and delivery systems, these systems were subject to inspection and approval by local officials. In view of the fact that the systems were designed and built specifically for the single carwash in which they were located, these inspections were often rigorous. Occasionally parts of the systems might need to be replaced in order to meet municipal codes. Additionally, the entire design and installation would have to be supervised by representatives of the builder in order to ensure the system met the builder&#39;s standards.  
         [0010]     Other problems with prior art carwash supply distribution systems include a difficulty in servicing defective or worn out parts such as valves or solenoids because they may be permanently installed as parts of the plumbing. Additionally these valves or solenoids may be located in the carwash tunnel, increasing the deleterious exposure to chemicals and water used in the car washing process.  
         [0011]     The plumbing, hydraulic and electrical lines for conventional carwashes normally require that they be secured to the walls of the carwash tunnel for support. This greatly hinders the task of cleaning the walls of the tunnel. Dirt and grime are thus more likely to accumulate and associated problems arise within the carwash tunnel.  
         [0012]     If the supplies of chemicals are also located in the carwash tunnel, the tunnel itself might need to be heated, as some of the chemicals would suffer adverse effects from low temperatures. If this were the case an additional problem arises since the viscosity of the concentrated chemicals to be used in the carwash increases substantially at low temperatures. This causes problems in the dilution and mixing of the chemicals.  
         [0013]     Oftentimes, a carwash can be installed on-site in approximately three months. During this time, the owner of the carwash will contact with a general contractor who oversees construction of the carwash. The general contractor coordinates and schedules the various laborers involved in constructing the carwash. During a first phase, the necessary groundwork is performed, including laying the concrete and running a drainage pipe to a sewer system. Constructing the carwash involves erecting the walls of the tunnel and also constructing the equipment room with suitable access to the outside. The washing unit itself is then installed within the tunnel. This washing unit may comprise an overhead gantry system in which case the washing unit is placed upon a set of support beams. The washing unit may comprise other types of units, such as a floor-mounted gantry system.  
         [0014]     During the construction of a prior art carwash, plumbers are needed for the running of the drainage pipe, connecting the carwash to a water supply, and for the various interconnection within the carwash itself. Electricians are also needed for the power and control wiring. Carpenters or other such laborers are needed to erect the walls and ceilings of the buildings and additional laborers needed for doing the necessary ground preparation work, laying the concrete, and perhaps for erecting an exterior elevation, such as bricks or stucco.  
         [0015]     Thus, as can be appreciated by those skilled in the art, the construction of a carwash requires the careful coordination of a large number of skilled craftspersons. Because the construction of a carwash requires the assistance of so many people, the failure of any particular person or group of people to satisfactorily perform their tasks can have deleterious effects on the carwash. Oftentimes, problems arise during the construction of the carwash and the general contractor is forced to determine which sub-contractor is at fault, with the sub-contractors typically accusing each other of the problems in the construction of the carwash. Also, the laborers may not have experience in constructing a carwash and, as a result, the quality of their work may be sub-standard. For example, an electrician may have experience with power distribution but may not have sufficient experience with control wiring within a carwash to do a quality job on a that portion of the job. In light of all these variables in the workforce, the quality and installation of carwashes across the country is not uniform.  
         [0016]     In addition to dealing with likely problems or obstacles in the construction of the carwash, the future owner of the carwash must also endure long delays before the carwash is operational. The typical time for constructing a carwash is on the order of three months. During this time, the future owner must cope with the nuisance of having a worksite on its premises, which could interfere with the ability to carry on normal operations at the business. This long delay also presents a financial burden to the future owner because of the financial resources tied up in the construction and the wait of three or so months before the carwash can generate any revenue. Thus, the future owner of the carwash has a great incentive to expedite construction of the carwash, not only to minimize the nuisance but also to expedite when the carwash can begin to generate revenue.  
         [0017]     This pressure to expedite construction, however, may unnecessarily hasten work on the carwash and cause the laborers to sacrifice quality in order to meet shortened deadlines. The future carwash owner must perform a careful balancing between pushing the general contractor and sub-contractors to finish the job with the desire to have a quality constructed carwash. Any sacrifice in the quality may only cause the carwash owner to incur greater repairs down the road and an additional nuisance and expense associated with those repairs.  
         [0018]     Some attempts have been made to simplify the construction of a carwash. For example, some carwash owners, especially gas stations, have a standard design for the carwash. The carwashes therefore may have the same dimensions, the same walls and ceilings, and same equipment installed within the carwash. By adopting a single design, the installation and construction of a carwash can become more routine and thus less prone to unforeseen problems. Another approach is to prepare assemblies of components which are then installed within the carwash structure. For instance, U.S. Pat. No. 4,955,405 describes a “Prefabricated Car Wash Distribution And Delivery System And Method” wherein a raceway is prefabricated with lines and hoses and this assembly is transported to the car wash for installation. By fabricating the raceway as a preassembled structure, the work that is needed on site for making the necessary interconnections and wiring between the equipment is reduced. While this patent addresses some of the problems mentioned above, the construction of a carwash still requires the assistance of various skilled laborers, including electricians and plumbers.  
         [0019]     A need exists for systems and methods for constructing carwashes that address the above-mentioned problems. For example, a need exists for systems and methods for constructing a carwash that is consistently constructed according to high quality standards and can be installed in a minimal amount of time. As mentioned above, these two desires run counter to each other since hastening the construction of a carwash often results in sacrificing quality.  
       SUMMARY OF THE INVENTION  
       [0020]     An object of the present invention is to provide a modular carwash for simple construction on site.  
         [0021]     A further object of the present invention is to provide a prefabricated modular carwash assembly to reduce the number of technicians required for installation at a carwash location.  
         [0022]     Yet a further object of the present invention is to provide a fully assembled modular carwash that can be constructed in a short period of time.  
         [0023]     The modular carwash assembly of the present invention is modular in design such that it may be transported to any desired location.  
         [0024]     The modular carwash assembly of the present invention includes a carwash module and an equipment module that are easily installed at a work site. Alternatively these components may be erected at a predetermined location and transported to the building site. In either case, the carwash module and equipment module are easily constructed and easily connected to each other.  
         [0025]     The carwash module includes a skeletal system secured on a sloped flooring, wherein the skeletal system is able to support the carwash equipment. The skeletal system includes a series of columns, with pairs of columns being connected by crossarms. The skeletal system thereby is able to support a carriage that is supported on two carriage rails mounted between two crossarms. The carriage supports a pair of spray arms that direct water and cleaning fluid towards a vehicle positioned within the carwash module.  
         [0026]     The equipment module is constructed in substantially the same manner as the carwash module, with the equipment module being positioned proximate the carwash module at the building site. The equipment module includes washing and drying components such as a pumping station for delivering water and fluid to the spray arms and an air compressor for generating a stream of air to dry the vehicle after washing. Additionally, the equipment module may include water purifiers, water softeners and related equipment.  
         [0027]     The equipment module is therefore designed to be easily connected to the carwash module. More specifically, the carwash equipment mounted in the carwash module is easily connected with the carwash equipment housed in the equipment module, such that the connections can be completed in a quick fashion without requiring the work of plumbers, electricians, and other specialists. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0028]     A modular carwash embodying the features of the present invention is depicted in the accompanying drawing which form a portion of this disclosure and wherein:  
         [0029]      FIG. 1A  is a front end view of the modular carwash assembly of the present invention;  
         [0030]      FIG. 1B  is a rear end view of the modular carwash assembly of the present invention;  
         [0031]      FIG. 1C  is a first side view of the modular carwash assembly of the present invention;  
         [0032]      FIG. 1D  is a second side view of the modular carwash assembly of the present invention;  
         [0033]      FIG. 2  is a top plan view of the modular carwash assembly of the present invention;  
         [0034]      FIG. 3  is a sectional top view of the modular carwash assembly of the present invention as illustrated in  FIG. 2 ;  
         [0035]      FIG. 4  is a schematic view of the modular carwash assembly of the present invention as illustrated in  FIG. 3 ;  
         [0036]      FIG. 5  is a partially exploded view of the carwash equipment used in the modular carwash assembly of the present invention;  
         [0037]      FIG. 6  is a top plan view of the carwash equipment attached to the building skeleton;  
         [0038]      FIG. 7  is an end view of the modular carwash assembly of the present invention;  
         [0039]      FIG. 8A  is a sectional view of the first side of the modular carwash assembly;  
         [0040]      FIG. 8B  is a sectional view of the second side of the modular carwash assembly; and  
         [0041]      FIG. 9  is a sectional view of the flooring of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0042]     Reference will now be made in detail to preferred embodiments of the invention, non-limiting examples of which are illustrated in accompanying  FIGS. 1 through 9 . These figures illustrate just one example as to how a carwash assembly  10  according to a preferred embodiment of the present invention may be manufactured. Elevations may be customized for a location (brick, stucco, ACM and split face block) rooflines also. It should be understood that the drawings do not limit the invention to the precise embodiment disclosed; rather, carwashes according to the invention may have other dimensions or made of other materials.  
         [0000]     Overview  
         [0043]     Systems and methods according to preferred embodiments of the present invention address the problems mentioned in the Background section of this application by providing a modular carwash assembly  10  that may be constructed in an expedited manner and prefabricated to be shipped to a desired location. In particular, the modular carwash assembly  10  of the present invention includes a carwash module  12  and an equipment module  13 , wherein the carwash equipment  30  is installed in both modules  12 ,  13 . The carwash module  12  includes a series of walls  14 , a ceiling  16 , and a sloping floor  18 . By prefabricating the entire carwash assembly  10  or substantially all of the carwash assembly  10 , both the carwash module  12  and the equipment module  13  can be transported to the site for the establishment of the carwash assembly  10 , installed, and ready to use in a minimal amount of time. For example, in contrast to the typical construction cycle of three months or more, the modular carwash assembly  10  can be installed on the building site and ready to use in as little as one or two days. Further advantages and benefits of the carwash assembly  10  according to the present invention will be apparent from the description below.  
         [0000]     Structure  
         [0044]     Significantly, the carwash module  12  and equipment module  13  of the modular carwash assembly  10  are such that they can be shipped either with all of the necessary carwash equipment  30  installed or the various components of the modules  12 ,  13  can be transported to the building site and the carwash equipment  30  then installed. An important feature of the carwash module  12  is that the walls  14  of the carwash assembly  10  are constructed with sufficient strength to support the weight of the carwash equipment  30 . By mounting a portion of the carwash equipment  30  directly to the walls  14  of the carwash module  12 , the carwash assembly  10  according to the invention avoids the need for additional support beams or other similar structure for supporting the weight of overhead washing units.  
         [0045]     In the preferred embodiment, both modules  12 ,  13  include a skeletal system  20 , which will include a series of columns, advantageously steel columns,  22  and crossarms, advantageously steel crossarms,  24 . With the carwash module  12 , the inner surface of the columns  22  advantageously are engaged by an impervious protective layer  26 , while the outer surface of the steel columns  22  are engaged by an exterior layer  28 . This skeletal system  20  can therefore reduce the width of the carwash assembly  10  as compared to conventional carwashes, and more importantly can reduce the height of the carwash assembly  10 . With conventional carwash designs, the walls are made of metal paneling and must be constructed high enough so that the overhead washing unit and support structure can be received within the carwash. In doing so, the conventional carwash cannot have its structure prefabricated since the height of the carwash is too high to pass underneath bridges during transit on the highway. In contrast, the carwash assembly  10  according to the preferred embodiment of the present invention enables the carwash module  12  to be prefabricated and shipped preassembled to the desired site for placement, and to be within such height restrictions.  
         [0046]     Another advantage of the carwash assembly  10  according to preferred embodiments of the present invention results from the use of the impervious protective layer  26 , which surrounds a tunnel  25 . During the fabrication of the carwash module  12 , the protective layer  26  is connected with the skeletal system  20  to form the tunnel  25  of the carwash assembly  10 . The protective layer  26  will thereby protect the carwash module  12  from the corrosive environment created during use of the carwash assembly  10 . This corrosive environment is created through the use of the various chemicals used and applied to the vehicle being cleaned as well as to the ambient environmental conditions. The protective layer  26  is preferably impervious to these chemicals and to the exposure to environmental conditions to protect the skeletal system  20 . Some examples of suitable impervious protective layers  22  include fiberglass, polyurethane or like coating, which may be applied within the tunnel  25 . It should be noted that the protective layer  26  may be sprayed onto an interior of the tunnel  25 .  
         [0047]     The ceiling  16  of the carwash assembly  10  according to a preferred embodiment of the invention can accommodate any suitable elevation to allow the desired vehicular traffic through the carwash module  12 . Moreover, the exterior layer  28  can be formed of a variety of desired materials, such as thin set brick, panels, stucco, and so forth, as well as any desired shape, such as a gabled roof, flat roof, windows, and the like. Thus, carwashes  10  according to the preferred embodiment of the invention are not limited in any set of dimensions, but may be compacted in size as needed for a particular location.  
         [0000]     Carwash Equipment  
         [0048]     Looking to  FIGS. 5 and 6 , the carwash equipment  30  is housed in both the carwash module  12  and the equipment module  13 . The preferred embodiment of the carwash equipment  30  will include a carriage  32  that is mounted on a pair of carriage rails  34  using a set of carriage wheels  33 . The carriage wheels  33  are thereby driven by a carriage motor (not illustrated) for the carriage  32  to traverse the carwash tunnel  25 . At least one spray arm  36  is rotatably connected to the carriage  32  such that each spray arm  36  may swivel about the vehicle positioned in the tunnel  25 . The spray arm  36  is connected to a fluid pumping station  38  located in the equipment module  13  via a spray conduit  40 . As a result, water is provided for soaking the vehicle. The fluid pumping stating  38  is housed in the equipment module  13 , such that the spray conduit  40  is used to connect between the carwash module  12  and the equipment module  13 .  
         [0049]     In addition to the fluid pumping station  38 , other components of the carwash equipment  30  are protectively stored in the equipment module  13 . For example, a motor control unit  44  is stored in the equipment module  13  and connected to the carriage  32  to control transverse movement of the carriage  32  within the carwash module  12 . Additionally, the carwash assembly  10  includes means for drying the vehicle after it has been washed. The drying means may include an air compressor  42  that is stored in the equipment module  13  and connected to air vents  44  in the carwash module  12  via an air conduit. As a result, a stream of air is generated to be directed toward to the center of the carwash module  12  toward the vehicle to force water from the vehicle.  
         [0050]     In addition to these components, the carwash assembly  10  may include various accessories to aid in cleaning vehicles. Some accessories are to be secured and used within the carwash module  12 . Such accessories may include a “photoeye” (not illustrated) for monitoring the vehicle in the tunnel  25  of the carwash module  12  or a directional sign (not illustrated) mounted proximate the carriage  32  to assist persons driving their vehicle into the tunnel  25 . In addition, there may be an operational interface (not illustrated) positioned at the entrance of the tunnel  25  to assist the user. Further accessories may be positioned in the equipment module  12 , such as a water purifier or softener (not illustrated).  
         [0051]     One embodiment of the modular carwash assembly  10  as disclosed herein is fabricated to the inventors&#39; specifications and uses carwash equipment  30  in the tunnel  25  according to the inventors&#39; specification. However, it should be understood that carwash assemblies  10  according to the present invention are not limited to any manufacturer nor are they limited to the precise type of carwash equipment. For example, with regard to the carwash equipment  30 , the carwash assembly  10  may comprise a full service tunnel, self-serve, in-dash bay automatic, or fleet/truck wash configuration. Moreover, the carwash equipment  30  may include a touchless washing system or a frictional engagement washing system (e.g., using a cloth brush or nylon bristles) for cleaning vehicles.  
         [0000]     Construction of the Carwash Assembly  
         [0052]     The carwash module  12  and the equipment module  13  of the present invention advantageously are constructed using the various components at a predetermined site and then delivered to the proper location. By producing the modules  12 ,  13  prior to delivery, the construction on the desired site can be prompt. Looking at  FIGS. 7 and 9 , the carwash module  12  is advantageously manufactured by first forming a layer  19   a,  advantageously of lightweight concrete, above a frame  19   b  (such as an intermediate rib decking) so as to create a sloping floor  18 . The various columns  22  of the skeletal system  20  are set in the layer  19   a,  if layer  19   a  is concrete, while the concrete hardens. Advantageously layer  19   a  is angled such that the water will drain to a central location, at which place a grate  21  is placed for the drain. A series of crossarms  24  are used to connect opposing columns  22 , on top of which is affixed a roof decking  46 .  
         [0053]     At least two of the crossarms  24  are mounted on the columns  22  at opposed ends of the carwash module  12 . Connected between these two crossarms  24  are two carriage rails  34 . The carriage rails  34  support the carriage  32  on carriage wheels  33  rotatably connected to the carriage  32  and driven by the carriage motor. As a result, the carriage motor drives the carriage  32  longitudinally on the carriage rails  34  for the carriage  32  to traverse the tunnel of the carwash module  12 .  
         [0000]     Operation of the Carwash Assembly  
         [0054]     As discussed above, the carwash assembly  10  is separated into the equipment module  13  containing a substantial portion of the carwash equipment  30  and the carwash module  12  which forms the tunnel  25  for receiving the vehicle to be cleaned. Both modules  12 ,  13  are preferably prefabricated for use together, and these two modules  12 ,  13  are placed next to each other and coupled together at the construction site. Coupling the two structures  12 ,  13  together is simple and can be performed in a short period of time relative to the construction of conventional carwash assemblies. While the invention has been shown and described as having two modules or structures, it should be understood that the carwash assembly  10  according to an embodiment of the invention may be formed as one structure or may be formed of more than two structures. For instance, for carwashes having longer tunnels, it is possible that the tunnel portion  27  of the carwash module  12  may be formed using two or more carwash modules  12  coupled together at the site. Two or more modules  12  may also be coupled together in a manner to form multiple bays.  
         [0055]     The drawings show a carwash assembly  10  having a superstructure  20  formed with columns, preferably steel columns,  22 . These columns  22  form part of a skeletal system  20  that is capable of supporting carwash equipment and other equipment within the tunnel structure  14 . In addition to the skeletal system  20 , the carwash is also equipped with mounting hardware for enabling the carwash equipment  30  to be mounted to the skeletal system  20 . This mounting hardware can take any form. One example provides a series of brackets that are mounted to the walls  14  and to the skeletal system  20  within the walls  14  to support the rails  34  and crossarms  24 .  
         [0056]     The walls  14  advantageously include protective layer  26 , which in this example is shown as fiberglass insulation. While fiberglass is one example of a protective layer, other embodiments of protective layers  26  may be used. Also, while the skeletal system  20  of the preferred embodiment provides the strength necessary to support the carwash equipment  30  through the use of columns  22 , other types of supports may be used, as well as other arrangements of supports, and other materials.  
         [0057]     Thus, although there have been described particular embodiments of the present invention of a new and useful Prefabricated Modular Carwash Assembly, it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.