PECK, Adrian James (90 Stowmarket Road, Needham Market, Suffolk IP6 8DX, GB)
| CLAIMS: 1. A method of restoring a water-damaged vehicle, the method comprising: identifying and removing interior and exterior water-damaged components and electrical components which have been submerged; treating said removed components in an ultrasonic bath of water-based cleaning solution; drying said water-damaged vehicle from which said components have been removed and at least a subset of said treated components in a de-humidifying tent; re-assembling said dried, treated components into said vehicle; and performing a bacteria test on one or more portions of said re-assembled vehicle to validate said drying and restoration. 2. A method as claimed in claim 1 further comprising rinsing one or both said treated components and said vehicle with an anti-bacterial agent. 3. A method as claimed in claim 1 or 2 further comprising a step, between said drying and said re-assembling, of treating one or both said treated components and said vehicle with ozone. 4. A method as claimed in claim 3 wherein said treating of said vehicle with ozone includes a step of passing ozone through air ducts of said vehicle to kill bacteria within. 5. A method as claimed in any one of claims 1 to 4, further comprising drying at least a sub-set of said treated components in a temperature-controlled oven prior to said drying in said de -humidifying tent. 6. A method as claimed in any one of claims 1 to 5 further comprising not allowing said water-damaged vehicle to dry out prior to commencing said restoration. 7. A method as claimed in any one of claims 1 to 6 comprising commencing said restoration with a depth of water of at least 5cm within a passenger cabin of said vehicle. 8. A method as claimed in any preceding claim further comprising a bacterial mitigation step comprising maintaining said vehicle for a period in a relative humidity of no more than 50% RH and a temperature controlled in the range 160C - 22° C. 9. A method as claimed in any preceding claim wherein said bacteria test comprises an ATP (adenosine triphosphate) test. 10. A method as claimed in any preceding claim further comprising subjecting said vehicle to an accelerated aging test after said restoration. 11. A method of reducing a level of contaminants in a water-damaged vehicle, comprising: identifying and removing interior and exterior contaminated components of said water-damaged vehicle; treating said contaminated components in an ultrasonic bath of water-based cleaning solutions to reduce the level of contaminants; drying said at least a sub- set of said treated components in a temperature- controlled oven; drying a remaining sub-set of said treated components and said water-damaged vehicle from which said contaminated components have been removed in a de- humidifying tent; re-arranging said dried, treated components into said vehicle, and performing an ATP (adenosine triphosphate) test in one or more portions of said re-assembled vehicle to confirm a reduction in said level of contaminants. 12. A kit of apparatus for performing the water-damaged vehicle restoration/treatment method of any preceding claim, the kit comprising: at least one ultrasonic bath of water-based cleaning solution for treating said components of said vehicle; at least one temperature-controlled oven solution for drying said components of said vehicle; a de-humidifying tent for said vehicle, said de-humidifying tent having a controllable relative humidity and temperature; and a bacteria tester to performing a bacteria test said vehicle after said restoration/treatment to validate said restoration/treatment of said vehicle. 13. A kit of apparatus as claimed in claim 12 wherein said bacteria tester is an ATP tester. 14. A kit of apparatus as claimed in claim 12 or 13 further comprising an ozone generator for treating said vehicle and/or ducting of said vehicle with ozone to kill bacteria. 15. A method of reducing the level of contaminants in a water-damaged vehicle substantially as herein described with reference to the drawings. 16. A method of restoring a water-damaged vehicle substantially as described herein with reference to the drawings. 17. A kit of apparatus for restoring a water-damaged vehicle substantially as described herein with reference to the drawings. |
This invention generally relates to technical aspects of restoring a water-damaged vehicle, and to vehicles so-restored.
BACKGROUND TO THE INVENTION
Little science has been applied to the problem of restoring a water-damaged vehicle to its original, pre-incident condition. Previous attempts at achieving this have generally consisted of using powerful fan heaters, but the results are generally poor.
There is a need for improved techniques, particularly with the increased likelihood of flooding due to climate change. By a process of experimentation, the inventors have identified a procedure which in embodiments is able to restore a severely water- damaged vehicle back to almost showroom condition.
SUMMARY OF THE INVENTION
According to the present invention there is therefore provided a method of restoring a water-damaged vehicle, the method comprising identifying and removing interior and exterior water-damaged components and electrical components which have been submerged, treating said removed components in an ultrasonic bath of water-based cleaning solution, drying said water-damaged vehicle from which said components have been removed and at least a subset of said treated components in a de-humidifying tent, re-assembling said dried, treated components into said vehicle and performing a bacteria test on one or more portions of said re-assembled vehicle to validate said drying and restoration. In embodiments of the procedure the treated components and/or vehicle may also be rinsed with an anti-bacterial agent and, optionally, the components and/or vehicle may also be treated with ozone to kill residual bacteria. In embodiments the bacteria test is performed in a plurality of locations on the restored vehicle, preferably including at least one location within the passenger cabin of the vehicle, and preferably at least one location which was originally below the water line in the passenger cabin.
Counter- intuitively preferred implementations of the procedure begin with the vehicle wet, preferably with much or all of the original depth of flood water in the passenger cabin, as this has a substantial effect on controlling corrosion. Thus in preferred embodiments of the method the water damaged vehicle is not allowed to dry out prior to commencing restoration and, preferably, there is at least 5cm of water within the passenger cabin.
In preferred implementations of the method the vehicle is preferably subjected to an accelerated aging test after restoration, for example by means of a road-or stress-test.
In a related aspect the invention provides a method of reducing a level of contaminants in a water-damaged vehicle, comprising: identifying and removing interior and exterior contaminated components of said water-damaged vehicle; treating said contaminated components in an ultrasonic bath of water-based cleaning solutions to reduce the level of contaminants; drying said at least a sub-set of said treated components in a temperature-controlled oven; drying a remaining sub-set of said treated components and said water-damaged vehicle from which said contaminated components have been removed in a de -humidifying tent; re-arranging said dried, treated components into said vehicle, and performing a bacteria test in one or more portions of said re-assembled vehicle to confirm a reduction in said level of contaminants.
The invention also provides a kit of apparatus for performing the water-damaged vehicle restoration/treatment method of any preceding claim, the kit comprising: at least one ultrasonic bath of water-based cleaning solution for treating said components of said vehicle; at least one temperature-controlled oven solution for drying said components of said vehicle; a de-humidifying tent for said vehicle, said de-humidifying tent having a controllable relative humidity and temperature; and a bacteria tester to performing a bacteria test said vehicle after said restoration/treatment to validate said restoration/treatment of said vehicle.
Preferably the bacteria tester is an ATP tester. Preferably the kit also includes an ozone generator for treating the vehicle and/or ducting of the vehicle with ozone to kill bacteria.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other aspects of the invention will now be further described by way of example only, with reference to the accompanying figure in which:
Figure 1 shows an overview of the process, including technical restoration aspects; and
Figure 2 shows a bacterial control procedure component of a technical restoration procedure according to an embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to Figure 1, the steps are as follows:
Vehicle Condition Report
Purpose: quickly verify condition of vehicle.
Full Mechanical and Electrical Inspection
Purpose: to ascertain level of damage and contamination to vehicle to formulate an action plan of the restoration:
Exterior - all body panels and parts including light units, glass, bumpers, trim, door locks and paintwork. Interior - Condition and operation of all electrical components, seats, trim, headlining, door trims, luggage area, carpets, seat belts, switches and load covers.
Mechanical Under-Body - full visual inspection including fuel system & braking system, gear box and axles, wheel bearings, steering and suspension systems, exhaust system, chassis condition, wheels and tyres.
Mechanical Engine and Drive Train - full inspection to ascertain level of water ingress and damage to engine, gearbox, axles, drive shafts, differential and electrical systems.
This includes:
On-Board Diagnostics using a vehicle diagnostics machine to read and check for errors.
Brake fluid water content check.
Power steering fluid water content check.
Engine and drive train oil/water content check.
Vehicle Restoration
Purpose: to restore the vehicle back to at least pre-incident condition.
Interior
Remove all interior components contaminated by water damage:
Carpets
Seats
Trim panels
Door panels
All electrical items below or close to 'water' line
Decontaminate all removed items using a Technical Restoration Process (described further below).
Refit all components as per manufacturers specification.
Remove/replace any SRS/ESP/ABS effected ECU or sensor units (safety related systems). Once reassembled the vehicle is subjected to Ozone Generation.
Exterior
Remove any exterior components contaminated by water damage as identified in the pre-inspection process.
Replace parts as necessary.
Decontaminate items as necessary using a Technical Restoration Process (described further below).
Refit all components as per manufacturers specification.
Mechanical Under-Body
Remove any components contaminated by water damage as identified in the pre- inspection process.
Replace parts as necessary
Decontaminate items as necessary using a Technical Restoration Process (described further below).
Refit all components as per manufacturers specification.
Replace brake fluid as necessary from water content check.
Remove wheels, conduct full brake condition check and rectification as required. Check wheel bearings for operation and water ingress and rectify as required.
Decontaminate under-body and exterior with high pressure or stream cleaning equipment with final rinse of anti-bacteria agent.
Mechanical Engine & Drive Train
Engine:
Strip engine components to remove water ingress as required.
Replace parts as necessary - oil filters, air filters.
Decontaminate items as necessary using a Technical Restoration Process (described further below).
Refit all components as per manufacturers specification.
Drain and refill engine oil as necessary.
Test engine operation and management systems using On-Board Diagnostics. Rectify faults as necessary.
AU other mechanical:
Remove contaminated components as required.
Replace parts as necessary.
Decontaminate items using a Technical Restoration Process (described further below).
Refit all components as per manufacturers specification.
Drain and refill all contaminated fluids.
Decontaminate engine bay with high pressure or stream cleaning equipment with final rinse of anti-bacteria agent.
Testing and quality Control
Purpose: ensure the integrity of the vehicle is not compromised through the restoration processes and the delivered result (vehicle) meets manufacturer's specification and quality.
Work Programme Quality Control and Audit: During the work programme each operation is conducted using competent technicians following industry and/or manufacturer approved work methods. Such process are monitored and managed by quality control procedures; a project is also subjected to sample auditing by external independent engineering consultants to approve the restoration methods and quality.
Floor Testing
A static test is conducted once the vehicle has been reassembled fully checking all mechanical and electrical functionality to include:
On-Board Diagnostics check
Electrical circuit and charging system
Moisture content of brake fluid
Bacteria Testing
The vehicle is subjected to bacteria test using ATP testing in five areas:
Steering wheel Drivers lower seat fob
Drivers carpet
Headlining above drivers seat
Luggage area carpet
Road Testing
The final stage of the restoration process is a 500 mile road test at different road speeds and traffic conditions.
Independent Inspection and Quality Mark
Once the project is complete a final quality process is conducted by an independent consultant:
Full mechanical and electrical inspection
Road test
On-Board Diagnostics check
Bacteria test
Brake fluid moisture content
If the vehicle passes the independent inspection the consultant issues a 'Quality Mark'. We next describe details of the technical restoration process mentioned above. Technical Restoration Process The technical restoration steps comprise:
Identifying and removing interior and exterior water-damaged components and electrical components which have been submerged.
Treating said removed components in an ultrasonic bath of water-based cleaning solution, including rinsing one or both the treated components and vehicle with an antibacterial agent, and treating the components and vehicle with ozone. Drying the treated components in a temperature-controlled oven and then drying the skeleton water-damaged vehicle from which said components have been removed, and separately the treated components, in a de-humidifying tent, but importantly not allowing said water-damaged vehicle to dry out prior to commencing said restoration. It is preferable to start the process wet, for example with a depth of water of at least 5cm within a passenger cabin of said vehicle.
Re-assembling the dried, treated components into said vehicle.
Performing a bacteria test on one or more portions of said re-assembled vehicle to validate said drying and restoration, for example by taking swabs and using a uv-light based detector (for example of the type used in the food industry) to perform a bacterial count. Locations to swab may include one or more of: steering wheel, driver' s seat, driver's carpet, head lining(s), boot carpet. Food safety standards may be used as suitable standards below which a level of bacteria should be reduced.
Preferably, then, the vehicle is subjected to an accelerated aging test, for example a road/stress test.
We now describe further details of steps of the above procedure, as implemented in preferred embodiments of the invention.
Ultrasonic Cleaning
The aim of the ultrasonic cleaning is the rapid and preferably substantially complete removal of contaminants from objects by immersing them in a tank of liquid flooded with high frequency sounds waves. The process is brought about by high frequency electrical energy that is converted by a transducer into ultrasonic energy, the non- audible sound waves creating a scrubbing brush action within the fluid. The cleaning power of a unit stems from the ultrasonic transducer's performance: The efficiency of the transducer will affect both the cleaning time and efficacy achieved during the cleaning cycle. The ultrasonic energy enters the liquid within the tank and causes the rapid formation and collapse of minute bubbles (cavitation) which gently lifts contamination off the surface and innermost recesses of intricately shaped parts. Preferably a large scale ultrasonic cleaning bath is used, such as model M-115 from Morantz Inc., USA, which has a 435 Litre capacity.
Controlled Industrial Drying Ovens
To ensure cleaned components are dried properly items are placed in controlled temperature large industrial ovens, big enough to hold many items at a constant state. For absorbent materials moisture meters are used to ensure items are completely dry before re-fitment.
Bacteria Control
Referring to Figure 2, we next describe a bacterial control procedure incorporated into the technical restoration procedure according to a preferred embodiment of the invention.
Flooding can cause the disruption of water purification and sewage disposal systems, causing them to overflow and therefore contaminating the flood water. Although most floods do not cause serious outbreaks of infectious disease, they can contain infectious organisms, including intestinal bacteria such as E coli, Salmonella, and Shigella; Hepatitis A Virus; and agents of typhoid, paratyphoid and tetanus.
Control Measures and certification
To effect a full decontamination a strict process is followed:
Inspection
Mitigation
Disassembly
Decontamination
Drying
Reassembly
Deodorising Final Inspection and Bacteria testing
Inspection
Upon delivery of a vehicle we use a Triage Process to evaluate the extent of damage and the viability of a cost effective successful restoration. Part of this triage process includes inspection of the vehicle and microbiology testing to establish number of microbes and different classes including microbes, bacteria, fungi, (moulds and yeasts), protozoa, viruses, algae and prions. Trained staff using microbiology meters determine indications of bacteria quantities present within the water damaged vehicle.
Mitigation
All vehicles are power washed externally to remove loose contamination. The interior is given a pre-mitigation clean by wet vacuuming, to remove excess water, and control of bacteria using purposely a sanitising solution (for example, Munters FAV 202). This is sprayed onto the interior surfaces of the vehicle to mitigate and control bacteria during the restoration process.
Vehicles are then placed into environmentally controlled conditions comprising dehumidified and heated areas to provide a relative humidity of no more than 50% RH and, in preferred embodiments, temperatures controlled between 17 0 C - 21° C (less preferably 15 0 C - 23° C). These conditions are very important in stabilising the condition of the vehicle and also assist in the prevention of bacteria growth.
Installed into these environmentally controlled environments are air filtration systems that use ozone to kill contaminates in a single cycle, purifying air which could be carrying bacteria and viruses. This provides an environment free from bacteria and unpleasant odours to ensure a safe working environment and is also very important in the mitigation and control to eliminate flood related bacteria Disassembly
All vehicles are fully disassembled as necessary to allow thorough decontamination. This includes removal of all carpets, upholstery and trim to allow further assessment and decontamination.
Decontamination/Drying
The decontamination processes varies for different components and depending on the extent of contamination found during disassembly. The processes used comprise:
Ultrasonic Cleaning
Steam under pressure
Filtration
Dry Heat
Ultrasonic cleaning
Ultrasonic cleaning is a relatively effortless, quick and efficient method of cleaning. Moreover it has proven extremely effective in destroying bacteria including even, for example, MRSA.
Steam under Pressure
The steam cleaning process uses steam at 135° C to decontaminating upholstery, carpets and trims, helping to sanitise these and kill bacteria. The process is extremely searching and very useful for hard to reach by hand areas.
Filtration
The air manager filtration process is in continual operation during the decontamination and sanitisation process ensuring airborne bacteria are very quickly killed. This assists with both sanitisation of the vehicle and also in providing safe working conditions for the restoration operatives. Dry Heat
Once complete and thorough decontamination has taken place the vehicle and all components are dried using heat and dehumidifiers. To provide optimum drying the vehicle is placed in its own cocoon for intense drying, whilst components are dried in separate controlled fan assisted drying ovens set to 5O 0 C.
Deodorising and sanitation
Upon completion of decontamination the vehicle receives a final deodorising and sanitisation process using ozone generation. The vehicle is placed in a sealed cocoon and ozone is pumped through the vehicle to ensure sanitisation and removal of flood related bacteria down to a level fit for re-use. The ducting system within the car is also blasted with ozone treatment to ensure any living bacteria found hidden within are killed.
Final Inspection and Bacteria Testing
The final inspection ensures all areas are fully decontaminated, bacteria testing swabs are taken from (but not limited to) the following high impact areas:
Drivers carpet
Drivers seat
Steering wheel
Headlining
Luggage area (i.e. boot carpet)
Using this process we are able to substantially guarantee the vehicle is free from bacteria and issue a certificate of cleanliness. To conduct this test we use an ATP Tester. ATP Tester
ATP (adenosine triphosphate) is present in all organic material, and is the universal unit of energy used in all living cells. ATP is produced and/or broken down in metabolic processes in all living systems. Processes such as photosynthesis in plants, muscle contraction in humans, respiration in fungi and fermentation in yeast are all driven by ATP. Therefore, most foods and microbial cells will contain some level of naturally occurring ATP.
The ATP tester uses bioluminescence to detect residual ATP as an indicator of surface cleanliness. The presence of ATP on a surface indicates improper cleaning and the presence of contamination, including food residue, allergens and/or bacteria. This implies a potential for the surface to harbour and support bacterial growth.
No doubt many other effective alternatives will occur to the skilled person. It will be understood that the invention is not limited to the described embodiments and encompasses modifications apparent to those skilled in the art lying within the scope of the claims appended hereto.