US20260029143A1

US20260029143A1 - Mobile, Expandable Cleanroom Systems, Methods, and Devices

Info

Publication number: US20260029143A1
Application number: US19/282,231
Authority: US
Inventors: Corey Meeks; Tyler Heckenlively; Kara Grubis; Ben Turner; Andrew Bokhart
Original assignee: Agile Space Industries
Current assignee: Agile Space Industries
Priority date: 2024-07-27
Filing date: 2025-07-28
Publication date: 2026-01-29

Abstract

Mobile, expandable cleanroom systems, methods, and devices are provided in accordance with various embodiments. Various embodiments include an expandable cleanroom that may include one or more tent enclosures and one or more door assemblies. Some embodiments include one or more HVAC systems. Some embodiments include a raisable truss structure that may lift and support the one or more tent enclosures. The expandable cleanroom may be coupled with an antechamber and/or a mechanical room. The combination of expandable cleanroom, antechamber, and/or mechanical room may be based on the form of a shipping container that may be transported by flatbed truck, railcar, boat, or other vehicles. This May allow for rapid deployment along with avoiding the need for wide-load permits; the various embodiments may also provide for inconspicuous deployment.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a non-provisional patent application claiming priority benefit of U.S. provisional patent application Ser. No. 63/676,342, filed on Jul. 27, 2024 and entitled “MOBILE, EXPANDABLE CLEANROOM SYSTEMS, METHODS, AND DEVICES,” the entire disclosure of which is herein incorporated by reference for all purposes.

BACKGROUND

Launches from austere and/or remote environments on short notice may involve infrastructure that does not yet exist in the necessary form factor. In the future, a mission launch may be called up and within hours a mobile launch facility may happen at the desired location. Mission payloads may involve being configured, fueled, and integrated on site. There may thus be a need for new tools and techniques to support such launches and payload processing.

SUMMARY

Mobile, expandable cleanroom systems, methods, and devices are provided in accordance with various embodiments. For example, some embodiments include a method that may include: deploying one or more door assemblies of an expandable cleanroom; deploying one or more tent enclosures of the expandable cleanroom; positioning a payload within the expandable cleanroom; processing the payload within the expandable cleanroom; removing the payload from the expandable cleanroom; and stowing the expandable cleanroom through at least stowing the one or more tent enclosures or closing the one or more door assemblies.
Some embodiments of the method include transporting the expandable cleanroom to a location for deployment. Some embodiments include transporting the expandable cleanroom away from the location for deployment.
In some embodiments of the method, deploying the one or more tent structures of the expandable cleanroom includes at least: raising a truss structure coupled with the one or more tent enclosures; or putting the expandable cleanroom under positive air pressure with respect to ambient.
Some embodiments of the method include processing the payload within the expandable cleanroom, which may include fueling the payload within the expandable cleanroom. Some embodiments include putting the expandable cleanroom under negative air pressure with respect to an antechamber coupled with the expandable cleanroom while fueling the payload within the expandable cleanroom.
Some embodiments of the method include utilizing an overhead hoist coupled with the truss structure to support the payload within the expandable cleanroom. Some embodiments include utilizing the truss structure to support air filtration for the expandable cleanroom.
Some embodiments of the method include passing the payload through an antechamber coupled with the expandable cleanroom to reach the expandable cleanroom. Some embodiments of the method include utilizing one or more catchments coupled with the expandable cleanroom to capture liquids within the expandable cleanroom. Some embodiments of the method include inflating one or more supports coupled with the tent structure. Some embodiments of the method include folding the one or more tent enclosures with respect to one or more hinge regions formed from one or more layers of the one or more tent enclosures.
Some embodiments include a system that includes an expandable cleanroom that may include one or more door assemblies and one or more tent enclosures coupled with the one or more door assemblies. The system may also include a first HVAC subsystem coupled with the expandable cleanroom.
In some embodiments of the system, the first HVAC subsystem inflates the one or more tent enclosures into a deployed state. In some embodiments of the system, the expandable cleanroom further includes a raisable truss structure coupled with the one or more tent enclosures that lifts and supports the one or more tent structures in a deployed state. Some embodiments include an overhead trolley coupled with the raisable truss structure. In some embodiments, the raisable truss structure is stowed between a floor of the expandable cleanroom and at least a portion of the one or more door assemblies in a stowed state. Some embodiments of the system include one or more catchments positioned below a workspace of the expandable cleanroom. In some embodiments, the first HVAC subsystem includes one or more HEPA filters positioned within the raisable truss structure.
Some embodiments of the system include an antechamber coupled with a first end of the expandable cleanroom. Some embodiments include a fueling panel positioned within the antechamber. Some embodiments include a second HVAC subsystem coupled with the antechamber. In some embodiments, at least the first HVAC subsystem or the second HVAC subsystem are configured to maintain the antechamber at a higher pressure than the expandable cleanroom.
Some embodiments of the system include one or more inflatable supports coupled with the one or more tent enclosures. In some embodiments of the system, the one or more tent enclosures include multiple layers that include at least an outer flexible shell layer or an inner insulation layer.
Some embodiments include systems, devices, and/or methods as described in the specification and/or shown in the figures.
The foregoing has outlined rather broadly the features and technical advantages of embodiments according to the disclosure in order that the detailed description that follows may be better understood. Additional features and advantages will be described hereinafter. The conception and specific embodiments disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. Such equivalent constructions do not depart from the spirit and scope of the appended claims. Features which are believed to be characteristic of the concepts disclosed herein, both as to their organization and method of operation, together with associated advantages will be better understood from the following description when considered in connection with the accompanying figures. Each of the figures is provided for the purpose of illustration and description only, and not as a definition of the limits of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

A further understanding of the nature and advantages of different embodiments may be realized by reference to the following drawings. In the appended figures, similar components or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a dash and a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

FIG. 1A and FIG. 1B show systems and/or devices in accordance with various embodiments.

FIG. 2A, FIG. 2B, and FIG. 2C show systems and/or devices in accordance with various embodiments.

FIG. 3A, FIG. 3B, FIG. 3C, FIG. 3D, FIG. 3E, FIG. 3F, and FIG. 3G show systems and/or devices in accordance with various embodiments.

FIG. 4A, FIG. 4B, FIG. 4C, FIG. 4D, and FIG. 4E show systems and/or devices in accordance with various embodiments.

FIG. 5A and FIG. 5B show aspects of systems and/or devices in accordance with various embodiments.

FIG. 6 shows aspects of a system in accordance with various embodiments.

FIG. 7A, FIG. 7B, and FIG. 7C show devices in accordance with various embodiments.

FIG. 8A, FIG. 8B, and FIG. 8C show aspects of systems and/or devices in accordance with various embodiments.

FIG. 9 shows a system and/or devices in accordance with various embodiments.

FIG. 10A and FIG. 10B show aspects of systems and/or devices in accordance with various embodiments.

FIG. 11 shows a flow diagram of a method accordance with various embodiments.

FIG. 12 shows a flow diagram of a method in accordance with various embodiments.

FIG. 13 shows a flow diagram of a method in accordance with various embodiments.

FIG. 14 shows a flow diagram of a method in accordance with various embodiments.

DETAILED DESCRIPTION

This description provides embodiments, and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing embodiments of the disclosure. Various changes may be made in the function and arrangement of elements.
Thus, various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, it should be appreciated that the methods may be performed in an order different than that described, and that various stages may be added, omitted, or combined. Also, aspects and elements described with respect to certain embodiments may be combined in various other embodiments. It should also be appreciated that the following systems, devices, and methods may individually or collectively be components of a larger system, wherein other procedures may take precedence over or otherwise modify their application.
Mobile, expandable cleanroom systems, methods, and devices are provided in accordance with various embodiments. Various embodiments include an expandable cleanroom that may be coupled with an antechamber and a mechanical room. The combination of expandable cleanroom, antechamber, and mechanical room may be based on the form of a shipping container that may be transported by flatbed truck, railcar, boat, or other vehicles. This may allow for rapid deployment along with avoiding the need for wide-load permits; the various embodiments may also provide for inconspicuous deployment.
Some embodiments are referred to as mobile payload processing centers. The expandable cleanroom may provide facilities for rapid payload assembly, processing, and/or fueling. The payloads may include space and/or terrestrial payloads, including but not limited to, satellites and/or launch vehicles. Some embodiments include catchment systems for spills or other liquids that may be utilized with respect to the payload being processed. The antechamber typically provides an entrance for the expandable cleanroom along with accommodating features such as cleanroom clothing and equipment; some embodiments of the antechamber provide for propellant handling. The mechanical room typically includes HVAC and filtration components; fire suppression and electrical boxes may also be provided.
Some embodiments include modifying an existing shipping container to form the expandable cleanroom, antechamber, and mechanical room; some embodiments may be built from the ground up.
Turning now to FIG. 1A, system 101 may be shown with respect to various embodiments. System 101 may include an expandable cleanroom 110 that may include one or more door assemblies 114 and one or more tent enclosures 112 coupled with the one or more door assemblies 114. The one or more door assemblies 114 may be referred to as deployable doors or wings that may be hinged for deployment; some embodiments configure the one or more door assemblies 114 to slide for deployment. The one or more tent enclosures 112 may include single layer or multiple layer structures; the one or more tent enclosures 112 may be referred to as soft wall structures and/or inflatable wall structures. The system 101 may also include a first HVAC subsystem 131 coupled with the expandable cleanroom 110. The first HVAC subsystem 131 may provide air to the expandable cleanroom 110. In some embodiments, the first HVAC subsystem 131 facilitates inflating the expandable cleanroom 110 with respect to the one or more tent enclosures 112.
In some embodiments of the system 101, the first HVAC subsystem 131 inflates the one or more tent enclosures 112 into a deployed state. In some embodiments of the system 101, the expandable cleanroom 110 further includes a raisable truss structure 120 coupled with the one or more tent enclosures 112 that lifts and supports the one or more tent structures 112 in a deployed state. The raisable truss structure 120 may be lifted hydraulically, mechanically elevated, and/or vertically actuated. Some embodiments include an overhead trolley coupled with the raisable truss structure 120. In some embodiments, the raisable truss structure 120 is stowed between a floor of the expandable cleanroom 110 and at least a portion of the one or more door assemblies 114 in a stowed state. Some embodiments of the system 101 include one or more catchments positioned below a workspace of the expandable cleanroom 110. In some embodiments, the first HVAC subsystem 131 includes one or more HEPA filters positioned within the raisable truss structure.
Some embodiments of the system 101 include an antechamber (such as antechamber 140 of FIG. 1B, for example) coupled with a first end of the expandable cleanroom 110. Some embodiments include one or more fueling panels positioned within the antechamber 140. Some embodiments include a second HVAC subsystem coupled with the antechamber 140. In some embodiments, at least the first HVAC subsystem 131 or the second HVAC subsystem are configured to maintain the antechamber 140 at a higher pressure than the expandable cleanroom 110.
Some embodiments of the system 101 include one or more inflatable supports coupled with the one or more tent enclosures 112. The one or more inflatable supports may help tension the one or more tent enclosures 112. In some embodiments of the system 101, the one or more tent enclosures 112 include multiple layers that include at least an outer flexible shell layer or an inner insulation layer.
FIG. 1B provides a mobile, expandable cleanroom system 101-a in accordance with various embodiments. System 101-a may be an example of system 100 of FIG. 1A. System 101 may include an expandable cleanroom 110-a that may be coupled with an antechamber 140 and/or a mechanical room 130. FIG. 1B may also show a mobile, expandable cleanroom transport system 100 that may include system 101-a along with a transport vehicle 150, such as a flatbed truck, railroad car, boat, or other vehicle. The system 101-a may be configured to ride on the transport vehicle 150. In some embodiments, the system 101-a is integrated with the transport vehicle 150.
System 101-a may include a wide variety of features. In general, system 101-a
generally looks like a standard shipping container, which may allow for inconspicuous transportation. System 101-a includes antechamber 140, which generally provides an intermediate portion of the system 101-a prior to accessing cleanroom 110-a. This generally may provide proper gowning facilities for entrance into the cleanroom 110-a; in some embodiments, the antechamber 140 facilitates propellant loading for a payload within the cleanroom 110-a. The cleanroom 110-a generally provides an expandable cleanroom work area, which generally provides sufficient working room for payload processing. Various embodiments of system 101-a provide for rapid field deployment in three hours or less once on location.
System 101-a may include an electrical infrastructure that may be powered by standard 120V/240V supply (external). Merely by way of example, some embodiments include 200 A main to power equipment onboard with standard single-phase voltage for COTS power delivery. Some embodiments include an adequate number of power receptacles for cleanroom operations; auxiliary power may be included for additional hand tools or equipment. Embodiments generally include lighting for all indoor working areas; all manned/operation areas generally may be lit regardless of the environment. Some embodiments are configured for 208V and/or 480V.
System 101-a generally includes a mechanical room 130; the mechanical room 130 generally houses operational equipment and may be configured as a separate chamber in system 101-a. Access is generally provided for each of the three main chambers: the antechamber 140, the cleanroom 110-a, and the mechanical room 130; this generally provides for work and/or maintenance.
Other features may be included in various embodiments including, but not limited to HEPA Fan Filtration Units (Designed to meet ISO 7), Electrostatic Discharge Controls (ESD), Fire Suppression System, Antechamber Gowning Racks & Storage, Antechamber Shoe Cleaning Washdown Capability, Catchment System and External Catchment Storage
Containers, Potable Water Supply, Propellant Management Components, Payload Hoist, and/or Lift Gate.
FIG. 2A, FIG. 2B, and FIG. 2C show examples of a mobile, expandable cleanroom system 101-b and a mobile, expandable cleanroom transport system 100-b in accordance with various embodiments, which may be examples of system 101 of FIG. 1A, system 101-a of FIG. 1B, and/or system 100 of FIG. 1B. FIG. 2A shows a collapsed or stowed configuration of the system 101-b; this may also be referred to as a transport configuration. FIG. 2B shows an expanded or deployed configuration of the system 101-b. System 101-b may include an expandable cleanroom 110-b. System 101-b may include a mechanical room 130-b and/or an antechamber 140-b. The expandable cleanroom 110-b may include a tent enclosure 112-b and two deployable door assemblies 114-b; in this embodiment, the tent enclosure 112-b may include one or more cleanroom curtain walls 143 that may be positioned between the expandable cleanroom 110-b and the antechamber 140-b; in some embodiments, a curtain wall 143 may be positioned with respect to the opening to ambient for the antechamber 140-b; the curtain walls 143 may also be configured a sealed doors. Some embodiments include a sealed side wall 133 that seals the expandable cleanroom 110-b with respect to the mechanical room 130-b. The tent enclosure 112-b may be deployed using air pressure from various HVAC components, which may be referred to as a first HVAC subsystem and may be housed in the mechanical room 130-b. The resulting expanded cleanroom 110-b may be held at higher pressure than the antechamber 140-b, though in some cases, such as during propellant handling, this pressure differential may be reversed. In some embodiments, a second HVAC subsystem may be included related to the antechamber 140-b. System 100-b may include a trailer bed 150-b. The assembly of the mechanical room 130-b, the antechamber 140-b, and the expandable cleanroom 110-b may be referred to as a mobile, expandable system 101-b. FIG. 2C shows a side perspective of system 101-b in a deployed state, including antechamber 140-b, expanded cleanroom 110-b, and mechanical room 130-b. This figure also highlights that a sealed wall 133 may exist between the mechanical room 130-b and the cleanroom 110-b. Cleanroom curtain walls or sealed doors 143 may be positioned between the antechamber 140-b and the cleanroom 110-b and/or between the antechamber 140-b and an outer opening. Tent enclosure 112-b and HVAC ductwork 113 are also referenced. Ductwork 113 may provide air to the cleanroom 110-b, which may also facilitate inflating the tent enclosure 112-b. Some embodiments may include a catchment system 127, which may include one or more trays and one or more drains, positioned below a flooring of the antechamber 140-b and/or the cleanroom 110-b to capture various liquids. Both the antechamber 140-b and the mechanical room 130-b may include container doors 195 for entry into the respective portions of the system 101-b
In some embodiments, system 101-b may include a modified 40 ft high cube shipping container that may include the expandable cleanroom 110-b, the mechanical room 130-b, and the antechamber 140-b. This system configuration may be configured for transportation on a 40 ft flatbed trailer or comparable alternative, such as a rail car. In general, the expandable clean room 110-b includes two deployable wings or doors 114-b to increase cleanroom space. The wings 114-b may be deployed and retracted via multiple winches connected to hoist rings on the wings 114-b, for example. The winches may be mounted to an internal I-beam support structure within the container. The hoist rings may rotate independently of the wings 114-b. The winches and hoist rings may be located outside of the cleanroom inflatable cover 112-b. The cleanroom cover 112-b may be deployed after wings 114-b have been dropped into position.
System 101-b and/or system 100-b may help improve upfront coordination
processes by streamlining on-demand access to payload processing facilities, thus facilitating rapid responsive launch. Some embodiments decrease the mission timeline between identification and execution. Some embodiments increase the mission capability through rapid responsive deployment in remote areas. Various embodiments provide for rapid responsive deployments through providing a facility where payloads may be configured, updated, and checked out in the field.
The mobile, expendable cleanroom systems (such as system 101-b), methods, and devices disclosed here may provide over 3× of lay down space over commercial options while allowing easy transport to remote sites because it may be the same size as a single-wide standard shipping container. The various embodiments provide a clean, ESD safe environment that may be designed with hazardous material and personnel safety in mind.
System 101-b may be designed to provide quick support where needed. For example, a-foot-long high cube shipping container generally fits on a flatbed truck and may be expandable to provide over 500 sq ft of ESD safe working space in a Class 10,000 (ISO 7) cleanroom; other embodiments include other container sizes and other work space square footage. As part of designing a safe working space, integrated fire suppression and chemical washdown may be native built into the system. With a fluid catchment built under the container in some embodiments, any chemical contamination that may occur may be washed down and safely isolated until the time it may be dealt with properly.
System 101-b may support responsive launch where mere hours may be available to set up a launch site. It may be preferable to travel to the launch site without having to secure wide load permits. Various embodiments provide more room for work, and a mobile platform to transport it where it may be needed, thus providing unparalleled versatility.
System 101-b may also be used for commercial satellite work in locations without a resident payload processing facility. While there may be commercially available mobile cleanrooms, those solutions may not allow enough room to work around a standard ESPA CubeSat payload. Various embodiments may easily accommodate a standard ESPA payload. The generous clean, safe, and secure volume may allow for multiple operators to simultaneously work on large payloads. Sizes larger than ESPA Grande payloads may fit within the ample space. This capability may allow for the processing of custom payloads that are larger than ESPA class, opening a large portion of the commercial space launch needs as a market opportunity for various embodiments.
The mobile, expandable cleanroom systems (such as system 101-b), methods, and devices provide a flexible solution to the various challenges that may be encountered working with commercial space applications. The underlying platform may also be outfitted as a mobile test stand, hypergolic decontamination unit, or any other temporary shelter or laboratory for non-defense purposes.
System 101-b may provide a cost-effective and flexible method of getting facilities to any location. As many players seek to drive down launch costs using economies of scale, the various embodiments may provide sufficient square footage and height to handle larger commercial payloads.
In addition to serving the commercial space sector, system 101-b may also provide a compelling platform for any science related work necessitating a mobile controlled environment. In the case of medical use, for example, the solution may be used for rapid deployment to isolated areas. With the system being designed to operate off of a high-clearance semi-trailer, it may be transported over terrain that is difficult for existing solutions to access.
While mobile and/or modular cleanrooms may exist, they generally lack the workspace and mechanical systems involved with providing a safe and functional environment for rapid responsive launch and other applications. Unable to expand, the mobile alternatives typically offer less overall working space and less overall height. The various embodiments produced may expand to provide more working area and height; for example, some embodiments include approximately 500 sq ft of working area and 15 ft of height, which may make them capable of accommodating payloads that were previously restricted to permanent on-premises cleanrooms.
System 101-b may provide the capability to fill roles involving cleanroom conditions, they may also be used as a mobile facility for short-notice deployment for on-site payload work in rapidly developing situations and for clean missile depot activities. If configured for a non-cleanroom area, the various embodiments have the potential to be used as a mobile command center, propellant loading facility, decontamination unit, or any other facility in support of tactically responsive launch.
System 101-b meet ISO 7/Class 10,000 cleanroom requirements. This is generally the same cleanliness standard used for missile guidance and optics production facilities. This may allow depot activities to be performed at the storage locations. Various embodiments contain sufficient cleanroom space to fit some of the largest military components.
As a mobile command center, propellant loading facility, decontamination unit, etc., the various embodiments of system 101-b include a platform that may allow the logistical needs of a situation to be met with a standardized solution. Designed to be operated on a typical semi-trailer, the various embodiments are easily transported with standard over-the-road hauling solutions.
System 101-b may provide for multiple mobile capability solutions. Examples include, but are not limited to, custom hot fire test stands, decontamination chambers, safety showers, along with propellant handling, holding, and mixing facilities.
Some embodiments provide for the ability to process full size payloads in austere locations that may involve rugged transport. In some cases, payloads may be already fueled and may involve special handling considerations for hazardous materials.
System 101-b may perform a variety of functions, including hot fire test stands, decontamination units, safety showers, and propellant mixing.
System 101-b may also be useful for applications beyond spacecraft payload processing. For example, various embodiments may be utilized for mobile missile maintenance and field repair.
System 101-b provide a variety of features. For example, some embodiments include a large working space that may support payloads up to 82″W ×96″H×120″ L; some embodiments support other payload dimensions. Some embodiments include an expandable cleanroom 110 of Class 10,000 (ISO 7) with a gowning antechamber 140. Some embodiments include emergency equipment including exits, shower, eye wash, fire suppression, and/or hazardous material catchment. Some embodiments include hazardous material monitors. Some embodiments include supports to hang payloads up to approximately 10,000 lbm; some embodiments may handle heavier payloads. Some embodiments include ruggedized construction that may allow access to austere environments. Embodiments generally provide secure and concealed transport as the various systems generally look like a standard shipping container.
Some embodiments of system 101-b are referred to as a mobile payload processing center (MPPC). These embodiments generally meet ISO 7/Class 10,000 cleanliness standards. The MPPC may be constructed from a modified high-cube shipping container (40 ft×8 ft×9.5 ft, for example) for durability and ease of secure, covert transport. Upon arrival at site, the container may be capable of transforming into a 500 sq ft cleanroom 110 by utilizing a combination of hinged walls and an expandable or raisable overhead structure; some embodiments provide other cleanroom sizes. Merely by way of example, the MPPC may be made up of two 20 ft containers mated together for easier transport to austere locations or a single 40 ft container for simplified deployment and teardown.
The MPPC may be divided into three compartments including an antechamber 140-b, an expandable cleanroom 110-b, and a mechanical room 130-b as generally shown in the various figures herein. Some embodiments include fire suppression and hazardous chemical containment and wash-down capabilities within the cleanroom area. The embodiments generally provide for transforming a shipping container to provide a rapidly deployable clean working space.
FIG. 3A, FIG. 3B, FIG. 3C, FIG. 3D, FIG. 3E, FIG. 3F, and FIG. 3G show examples of a mobile, expandable cleanroom system 101-c in accordance with various embodiments. System 101-c may be an example of system 101 of FIG. 1A and/or FIG. 101 -a of FIG. 1B. FIG. 3A shows a collapsed or stowed configuration of system 101-c; this may also be referred to as a transport configuration. FIG. 3B shows a partially expanded or deployed configuration of the system 101-c. FIG. 3C shows a fully expanded or deployed configuration of the system 101-c. System 101-c may include an expandable cleanroom 110-c. System 101-c may include a mechanical room 130-c and/or an antechamber 140-c.
System 101-c may include two deployable door assemblies 114-c. The expandable cleanroom 110-c may include a tent enclosure 112-c as may be shown in FIG. 3C. System 101-c may include a raisable truss structure 120-c, which may also be referred to as a cleanroom ceiling assembly. FIG. 3B shows the ceiling assembly 120-c in a stowed configuration while FIG. 3C shows the ceiling assembly 120-c in a deployed configuration. The ceiling assembly 120-c may be hydraulically raised into place and may act as a filtration plenum, delivering air to the expanded cleanroom 110-c; in some embodiments, the raisable truss structure 120-c may be mechanically elevated or vertically actuated. The raising of the ceiling assembly 120-c may facilitate deployment of the tent enclosure 112-c. FIG. 3D shows an exemplary air flow within system 101-c with the tent enclosure 112-c removed, where air may be delivered from the mechanical room 130-c to the ceiling assembly 120-c from where it is delivered to the main workspace of the expanded cleanroom 110-c and then recirculated back to mechanical room 130-c. Both the antechamber 140-c and the mechanical room 130-c may include container doors 195-c for entry into the respective portions of the system 101-c.
FIG. 3C and FIG. 3D also show bulk propellant storage capabilities, such as a propellant skids 142 that may house fuel and/or oxidizer for providing propellant loading capabilities; the propellant skids 142 may be referred to as commodity storage in general. Some embodiments may store various other gas cylinders in the skids 142, such as helium and/or nitrogen canisters, though separate skids and/or pallets may be utilized for these commodities. This example shows two propellant skids 142 on opposite sides of the antechamber 140-c. The propellant skids 142 may be coupled with the antechamber 140-c through one or more fueling panels 141, which may also be referred to as commodity panels; the backside of one fueling panel 141 may be seen. The commodity panel 141 may provide fuel or oxidizer, for example; typically, one propellant skid 142 may provide fuel, while the other propellant skid 142 on the opposite side of the antechamber 140-c may provide oxidizer. The exposed view of FIG. 3D also shows a sealed door 143-c that may separate the antechamber 140-c from the cleanroom 110-c. The views from FIG. 3C and FIG. 3D also show various components that may be housed within the mechanical room 130-c, which are further described in FIG. 5A and FIG. 5B. Flexible ductwork 113-c may couple the mechanical room's HVAC components with the cleanroom 110-c, such as through the raisable truss structure 120-c and/or door assemblies 114-c. Some embodiments also include adjustable support legs 121 coupled with the door assemblies 114-c. Merely by way of example, support legs 121 may have a holding capacity of 7000 lbs per support leg, with a total holding capacity of 14,000 lbs in some embodiments. Some embodiments may include a maximum lift height of 10″ with 5″ of adjustment for uneven surfaces. A single pin joint may allow for support legs 121 to be easily removed for transport. Other embodiments can utilize other capacities, heights, and/or adjustments.
FIG. 3E and FIG. 3F show the mobile, expandable cleanroom system 101-c with the tent structure 112-c removed. These figures also generally highlight hydraulic structures that may be utilized to lift an overhead structure 120-c into place from a transport state to a deployed state in accordance with various embodiments. For example, multiple telescope hydraulic cylinders 123 may be utilized to lift and deploy the overhead truss structure 120-c. FIG. 3E also shows one or more commodity supply panels 144, which may provide fuel, oxidizer, and/or various gases to a payload for fueling purposes.
FIG. 3G provides a cross-sectional view of system 101-c and may highlight various features. For example, the antechamber 140-c and mechanical room 130-c are shown with the cleanroom 110-c in a deployed state. Features of the raisable truss structure 120-c are shown, such as multiple filtration units 125 that may include filters 132; one unit is called out, though eight in total are shown. In addition, inflatable supports 161 are shown that may support the deployed tent enclosure 112-c. The inflatable supports 161 may tension the tent enclosure 112-c. Other features are shown such as commodity panel(s) 141, commodity supply panel(s) 144, hydraulic cylinders 123, sealed door 143-c between cleanroom 110-c and antechamber 140-c, ductwork 113-c, and deployable door assembly 114-c. FIG. 3G may also show a catchment system 127-c, which may include one or more trays and one or more drains positioned below the flooring of the antechamber 140-c and/or the cleanroom 110-c to catch spilled liquids.
Various HVAC subsystems may also be shown in FIG. 3G. Various cleanroom HVAC components may be shown, typically located within the mechanical room 130-c. For example, HVAC subsystem 131-c may include blowers, filters, evaporators, heaters, and/or coolers. These may generally be referred to as the first HVAC subsystem. Antechamber HVAC subsystem 170 may include a variety of components, such as a blower, a heater, a cooler, an evaporator, and/or a filter; the antechamber HVAC subsystem may be referred to as the second HVAC subsystem. Mechanical room 130-c may also house an hydraulic power unit 138 to support hydraulic cylinders 123.
The raisable truss structure 120-c may provide a rigid truss structure that may be integrated into the container's footprint. The truss 120-c generally lifts vertically from the cleanroom floor via hydraulic actuation or other means, becoming the structural spine for the overhead systems once deployed. The use of the raisable truss structure 120-c may provide several functional and structural advantages. For example, the truss 120-c may serve as the primary structural support for the inflatable soft wall cleanroom enclosure 112-c. During deployment, the truss 120-c may assist in pulling the tent 112-c upward and outward. During stowage, as the truss 120-c lowers, it may guide the enclosure 112-c into an orderly, inward collapse for compact storage within the system 101-c.
In some embodiments, the truss 120-c acts as the HVAC supply plenum, housing HEPA-filtered uniform laminar flow diffusers, such as filtration units 125, for example, to deliver vertical airflow across the cleanroom envelope. This vertical laminar flow, combined with low-wall air returns, may help in maintaining ISO 7/8 class cleanliness. The structure 120-c may also provide a dedicated path for installing overhead lighting, allowing for high-quality, maintainable, and compliant illumination throughout the cleanroom environment. The rigid truss 120-c may also support integration of an overhead trolley hoist system. This may enable safe and efficient payload movement within the cleanroom 110-c, which may eliminate the need for external lifting systems and minimizing contamination risk from outside interventions.
The truss 120-c may provide a natural overhead pathway for power. signal. and control routing. which may help keep critical lines clear of the cleanroom workspace and reducing clutter and trip hazards. The truss structure 120-c may be capable of withstanding expected environmental loads such as wind and snow, enhancing system 101-c's ability to operate in austere and unpredictable deployment locations.
Some embodiments of system 101-c can provide a deployable clean ESD safe environment where payloads may be configured, updated, and inspected in austere locations. Some embodiments focus on responsive launch capability and responsive payload supply. Some embodiments involve fully responsive ground operations to enable agile and responsive launch of reliable payloads. Responsive launches may be required from any existing spaceport on short notice and may also be needed from mobile, and potentially austere, launch sites. Rapidly fieldable, mobile, and safe payload processing facilities may be needed to provide expanded payload processing capacity at existing space ports on extremely short notice and mobile capacity at mobile, austere, launch sites.
Some embodiments of system 101-c involve large mission payloads that may be configured, fueled, and integrated at any launch site. Some embodiments provide payload processing function for various applications. Some embodiments provide payload processing services for various spacecraft. Some embodiments provide a flexible on-site and on-demand payload processing center. Some embodiments transform an easily transportable 40 ft shipping container into a 500 sq ft working space. Some embodiments provide a fully functioning ISO7 cleanroom.
Some embodiments of system 101-c include the integration of propellant loading capabilities. Some embodiments maximize personnel safety in the event of a propellant spill. Some embodiments provide a fully outfitted system with ISO7 cleanroom and propellant handling capability that may de-couple tactically responsive launch from hard assets in fixed positions, providing rapid threat response from any location.
Some embodiments of system 101-c provide base operational functionality, which may refer to the features and capabilities of various embodiments to perform various functions effectively-namely as a clean environment in which to perform payload configuration, maintenance, and checkouts. Other features or enhancements may be built.
Manufacturing the raisable truss structure 120-c in accordance with various embodiments may include a variety of stages. For example, a first stage may include forming the truss structure 120-c. Next, fan filtration units 125 and ducting 113-c may be provided. Next, walls and ceiling elements may be installed. Finally, the cleanroom ceiling assembly or raisable truss structure 120-c may be integrated with other aspects of the mobile, expandable cleanroom system 101-c. Manufacturing the mobile, expandable cleanroom system 101-c in accordance with various embodiments may include a variety of stages. At a first stage, floor beams may be formed, followed by upper beams and door plates in a second state. In a third state, a tray catchment 127-c and floor support may be installed. At a fourth stage, an antechamber and cleanroom grating may be installed. At a fifth stage, the truss structure 120-c and hydraulics 123 may be installed. At a sixth stage, deployable door frame and winch system may be installed. At a seventh stage, exterior doors may be installed. At a ninth stage, walls and ceilings may be installed. At a final stage, the system 101-c may be fully integrated. For both the raisable truss structure 120-c and system 101-c, other methods of manufacturing may be utilized as these steps are merely provided as examples.
FIG. 4A, FIG. 4B, FIG. 4C, FIG. 4D, and FIG. 4E show examples that may
highlight various features of a mobile, expandable cleanroom system 101-c in accordance with various embodiments. For example, FIG. 4A provides a side perspective of mobile, expandable cleanroom system 101-c in accordance with various embodiments. FIG. 4A shows a collapsed or stowed configuration of the system 101-c; this may also be referred to as a transport configuration. This figure generally highlights aspects of the deployable door assembly integration. For example, system 101-c may include two deployable door assemblies 114-c. Transport configuration connections may include hinges 118 and plate lock joints 119; in this example, there may be four hinges 118 and two plate lock joints 119 for each door assembly 114-c. Deployed configuration connections (per door 114-c) may include hinges 118 and plate lock joints 119. FIG. 4B highlights an example of one of the door hinges 118. The door hinges 118 may be welded onto the exterior of the structure for high strength. The hinges may be positioned for floor alignment with a clean room grating and may be greaseable for long service life and smooth operation. FIG. 4C highlights examples of the plate lock joints 119, which may be located at each top corner of deployable door 114-c. Multiple pins 111 may lock each door 114-c when door 114-c is fully closed; this may provide structural support during transport such that additional support such as beams running the length of cleanroom 110-c may not be needed. Joint U channel lined with high density rubber bushing may also be included, which may mitigate metal on metal strikes and may limit vibration.
FIG. 4D and FIG. 4E show aspects of the deployable door assemblies 114-c of a mobile, expandable cleanroom system 101-c with regard to a winch system that may be utilized to open and close the cleanroom doors 114-c from a deployable door assembly 114-c. Winches 115 may let out cables 116 to open the cleanroom doors 114-c. Pneumatic door actuators 117 may initiate opening the doors 114-c. Various pulleys and swiveling sheave heads may allow the winch cable 116 to articulate with the door assembly 114-c. FIG. 4D shows the system 101-c in a stowed state, while FIG. 4E shows the system 101-c in a deployed state, including the deployed cable 116 and deployed tent enclosure 112-c along with antechamber 140-c.
FIG. 5A and FIG. 5B provide two different perspectives views of the mechanical room 130-c of a system 101-c in accordance with various embodiments. In particular, this mechanical room 130-c may include a clean room HVAC unit 131-c, which may be referred to as the first HVAC subsystem. Some embodiments include a hydraulic power unit 138, which may be utilized to support the hydraulic cylinders 123. Other components may include an air compressor 139 and air outlet fans 137. Ductwork 113-c may also be shown coupling the mechanical room 130-c to the cleanroom. In some embodiments, a condenser 135 may be included that may be coupled with HVAC components located in the antechamber 140-e and may be referred to as the antechamber condenser 135.
Some embodiments of system 101-c include a dual power electrical feed system, which may allow it to operate from either 208V or 480V three-phase power sources. This capability may maximize compatibility across a broad range of deployment scenarios, whether at developed launch facilities with existing infrastructure, commercial or industrial sites with varying power standards, or remote locations reliant on generator power. FIG. 4E includes an electrical enclosure 196 for 208V, while FIG. 5B includes an electrical enclosure 197 for 480V.
Some architectures may be built on a 208V input, a common standard in light commercial and generator-fed operations. However, some systems may benefit from 480V, particularly for the hydraulic power unit and cleanroom HVAC. Supporting 480V devices may involve including both 480V and 208V panels, such as enclosures 196 and 197, as well as a transformer to step voltage up or down depending on the input. Some embodiments can include a traditional three-phase transformer, though size constraints may preclude it from being placed in the mechanical room and it may involve a separate skid. Some embodiments include three discrete single-phase transformers, one per leg of the three-phase system. This approach, which may be used in tight-space applications, may enable distributed mounting of the transformers, optimizing available space within the mechanical room while still meeting all functional and performance requirements. With internal power distribution infrastructure now capable of operating from either voltage input, some embodiments include a dual-voltage inlet box. This unit may include features such as Camlock-style quick-disconnect connectors for both 208V and 480V, providing a simple and robust connection interface for field operators.
FIG. 6 provides an example of a trolly hoist system 122 in accordance with various embodiments. The hoist system 122 may be integrated into the raisable truss structure 120-c. The hoist 122 may generally travel under the truss structure 120-c. Some embodiments utilize a festoon cable system. The hoist system 122 may be configured based on the weight capacity needs for various embodiments. Merely by way of example, some embodiments include a rated capacity of 2,000 lb.
FIG. 7A, FIG. 7B, and FIG. 7C provide examples of aspects tent enclosure 112-c in accordance with various embodiments. FIG. 7A provides a perspective view of the tent enclosure 112-c, while FIG. 7B shows a cross-sectional view, which may highlight various internal features. The tent enclosure 112-c generally provides a barrier between the clean room space and outside environment. The tent enclosure 112-c may be lifted as the raisable truss structure is lifted. In some embodiments, the fabric of the tent enclosure 112-c is integrated into deployable doors. In some embodiments, the tent enclosure 112-c may be constructed to form one complete piece, while in other embodiments, the tent enclosure 112-c may form several separate pieces that may be coupled together. The tent enclosure 112-c may include single layer or multiple layer structures; the tent enclosure 112-c may be referred to as a soft wall structure and/or an inflatable wall structure.
The tent enclosure 112-c may provide a compact stow configuration while enabling rapid deployment into a structurally and environmentally efficient cleanroom enclosure. The tent enclosure 112-c may include a series of interconnected soft-wall panels that may be made from encapsulated foam or other fabric materials. In some embodiments, the tent enclosure 112-c is, supported by an inflatable structural skeleton 161, which may also be referred to as inflatable supports. The tent enclosure 112-c may be integrated into the cleanroom ceiling truss and may raise and lower with the raisable truss structure, which may simplify setup and breakdown during field deployment.
To ensure repeatable deployment and efficient retraction, the enclosure 112-c may be engineered with intentional ridges and stress reliefs 162 that may encourage the structure 112-c to collapse inward as the truss lowers. This origami-inspired folding pattern may ensure space-efficient stowage within the system's footprint while reducing the risk of snagging, bunching, or damage to soft goods.
The tent enclosure 112-c may be further integrated with hinged deployable doors that expand outward during setup. Some of the reliefs 162 may be zippered, which may allow the tent enclosure 112-c to expand at high-stress transition points, minimizing strain on the fabric and seams during deployment and collapse.
To maintain geometric form and provide structural rigidity, the tent enclosure 112-c may be reinforced with a series of inflatable columns and ribs 161. In some embodiments, these inflatable support structures 161 may include nylon-reinforced TPU air members that may be pneumatically inflated using standard NPT connections for ease of integration with onboard air systems. Dump valves may allow for rapid deflation during stowage operations.
The tent enclosure 112-c and inflatable supports 161 generally provide sufficient strength to handle adverse weather conditions when deployed and collapse for compact and efficient stowage in the transportation configuration.
The tent enclosure 112-c may also include multiple hinge regions 165, which may also facilitate deployment and stowage of the tent enclosure 112-c. FIG. 7C provides further details regarding how the hinge region 165 and other features of the tent enclosure 112-c may be formed.
FIG. 7C highlights aspects of a tent enclosure 112-c-1 with respect to a hinge region 165-c, which may be an example of tent enclosure 112-c and hinge regions 165 of FIG. 7A and FIG. 7B. Hinge region 165-c may be constructed from multiple layers that may be bonded together in a region; various materials may be utilized, such as thermoplastic polyurethane (TPU).
One challenge of the inflatable enclosure 112-c-1 may include achieving
meaningful thermal insulation performance without compromising collapsibility. Some embodiments of the tent enclosure 112-c-1 incorporate 1¼-inch of open-cell polyurethane foam 166 encapsulated in a TPU outer shell 167 for durability, chemical resistance, and flexibility. When the tent enclosure 112-c-1 is in the stowed or transportation configuration, the insulation system may be compressed to 40% of its original thickness, for example. Over time, the foam 166 may be expected to experience minor permanent deformation of approximately 15%, dropping the system R-value from 4.8 to 4.0, for example. This estimated post-deformation R-value generally remains within acceptable limits, which may ensure that adequate thermal regulation may be preserved over the enclosure's operational lifecycle.
Some embodiments of the tent enclosure 112-c-1 include a layer of conductive fabric 168 intended to provide electrostatic discharge (ESD) protection. This layer may be welded onto the interior tent surface to mitigate electrostatic risks to sensitive hardware.
FIG. 8A provides a cross-sectional view of the raisable truss structure 120-c in accordance with various embodiments. Arrows generally indicate the direction of air flow with respect to the truss structure 120-c. The raisable truss structure 120-c may be configured as a supply air plenum for the cleanroom. Some embodiments include multiple filtration units 125 to provide filtration of the air entering the cleanroom; each filtration unit 125 may include a filter 132, such as a HEPA filter. Eight filtration units are shown with one called out. Some embodiments include fans in each filtration unit 125. In some embodiments, the truss structure 120-c is configured as a uniform laminar flow diffuser. Merely by way of example, some embodiments support a maximum airflow with 7× filtration units @600 cfm each=4,200 cfm, which may include 45 air changes per hour (ACH); other embodiments handle other maximum air flows with other filtration units. This example may include a 42″×12″ supply plenum at 1,200 fpm, though other embodiments can utilize other dimensions. Merely by way of example, a nominal airflow may include 5× filtration units @600 cfm each=3,000 cfm, which may include 35 air changes per hour; in this example, the 42″×12″ supply plenum may provide 857 fpm. FIG. 8A also shows flexible ductwork 113-c that may couple the truss structure 120-c with the HVAC subsystem typically housed within the mechanical room.
In general, embodiments can provide for ISO 7/Class 10k cleanrooms. This may include filtration to 70 particles/ft3>5 microns and/or 10,000 particles/ft3 >0.3 μm. Air changes may be dependent on particle generation. Some embodiments include 30 air changes per hour common.
The cleanroom airflow in accordance with various embodiments include 5,000 ft³cleanroom volume, which may involve a minimum 30 air exchanges per hour=2,500 cfm. Some embodiments are designed for 2,500 cfm circulation+makeup air, where makeup air assumes≤10% leakage by volume ˜500 cfm.
FIG. 8B provides an example of a schematic for a cleanroom HVAC system 131-d in accordance with various embodiments and may be referred to as a first HVAC system; in particular, one or more of the components housed within a mechanical room 130-d may be referred to as the first HVAC subsystem 131-d, with the other components providing for delivery of air to the cleanroom 110-d or return from the cleanroom 110-d to the first HVAC subsystem 131-d. This schematic includes a supply air system, which generally includes the raisable truss structure 120-d with multiple filtration units 125-d (this example shows eight filtration units with one called out); the filtration units 125-d may include filters, such as HEPA filters. A cleanroom supply box 180 may be included in the truss structure 120-d.
The first HVAC system 131-d may include a return air system 181 that may include multiple cleanroom return plenums 182, one typically associated with each side of the cleanroom 110-d and/or door assemblies of the cleanroom 110-d. Return grilles 183 may be coupled with each return plenum 182; four return grilles 183 are shown for each return plenum 182, with one called out for each. Air from the return plenums 182 may be generally direct through ductwork 113-d to the mechanical room 130-d; multiple collars 184 may facilitate coupling the ductwork 113-d with the mechanical room 130-d components. The mechanical room 130-d may include various components of the first HVAC subsystem 131-d, such as damper(s) 185, pre-filter(s) 186, evaporator coil(s) 188, air handler(s) 189, and/or heater(s) 190. Some embodiments include makeup air components, such as pre-filter(s) 186 and blower(s) 187. Air from the mechanical room 130-d may then be delivered to the supply air system as part of truss 120-d.
FIG. 8C provides an example of a schematic for an antechamber HVAC system 170-e in accordance with various embodiments and may be referred to as a second HVAC system. The second HVAC system 170-e may be referred to as an antechamber HVAC subsystem. Various components may be included such as a filtration units 171 (such as a uniform laminar flow diffuser), which may include filter(s), such as a HEPA filter. The filtration unit 171 may be coupled to a supply air grille 176 to deliver air to the cleanroom. Return air grilles 177 may supply air to the various components of the antechamber HVAC system 170-e located in the antechamber 140-e through ductwork 113-e; this may include a return air plenum 178, a pre-filter 179, and various HVAC components 172, such as a blower, a heater, a cooler, and/or evaporator. In mechanical room 130-e, a pre-filter 179 may deliver air to make up air blower 175 which may deliver air through ductwork 113-d to return air plenum 178. A condenser may be included in the mechanical room 130-e that may be coupled to the antechamber HVAC components located in the antechamber 140-e.
The architecture of FIG. 8B and FIG. 8C may enable precise environmental control in each space and may introduce operational flexibility essential for supporting both contamination-sensitive payload processing and/or hazardous propellant loading operations.
The various HVAC systems such as the first HVAC system 131-d and/or the second HVAC system 170-e may be run in a variety of manners. For example, in a standard cleanroom mode, the focus may be on contamination prevention. In the standard mode, the cleanroom may be maintained at a higher pressure than the antechamber, which generally creates a positive pressure differential that may prevent airborne contaminants from migrating into the cleanroom. This is generally the default mode for general payload integration, inspection, and contamination-sensitive processing activities.
Some embodiments are configurable with a propellant loading mode, which may focus on hazard containment. For example, when hazardous fueling operations are conducted, the system may transition to the propellant loading mode, in which the antechamber is generally maintained at a higher pressure than the cleanroom. This inversion of the pressure gradient may ensure that any accidental chemical release in the cleanroom cannot migrate into the antechamber where operators are generally stationed. In this mode, personnel may safely operate the fueling equipment remotely from the antechamber while maintaining full visual and procedural control over the operation inside the cleanroom.
Some embodiments include integrated pressure control logic. A single switch, generally located in the antechamber, may simultaneously command both HVAC systems 131-d and 170-e to shift between operating modes. This coordinated control generally eliminates the need for manual adjustment or sequencing across multiple components and ensures that transitions between contamination prevention and hazard containment configurations are resistant to human error.
This dual-HVAC approach may not only increase system reliability and safety during propellant operations but also may underscore mission flexibility. Whether deployed for standard spacecraft integration tasks or hazardous fueling operations, the HVAC architecture may dynamically adapt to protect both personnel and payload integrity.
FIG. 9 provides an example of a mobile, expandable cleanroom system 101-f configured for propellant operations in accordance with various embodiments. System 101-f may be an example of system 101 of FIG. 1A, system 101-a of FIG. 1B, and/or system 101-c of FIGS. 3A-3G. In general, the antechamber 140-f may be configured for propellant personnel, where the pressure of the antechamber 140-f is generally at a higher pressure than the pressure of the cleanroom 110-f during propellant fueling operations. In some embodiments, the antechamber 140-f may include one or more commodity panels 141-f, such as a fueling panel and/or an oxidizer panel. In some embodiments, commodity panels 141-f may include panels configured to deliver various gases, such as helium and/or nitrogen. Multiple hazmat monitors 124 may be positioned within the cleanroom 110-f; one or more hazmat monitors 124 may be positioned within the antechamber 140-f. In some embodiments, commodity service panels 144-f may be included within the cleanroom 110-f, which may correspond to the fuel panel, oxidizer panel, and/or gas panels 141-f positioned within antechamber 140-f. Various lines (obscured from view, generally running underneath the flooring of the cleanroom 110-f) may couple with these panels to deliver fuel, oxidizer, and/or gases between the commodity panels 141-f and the commodity service panels 144-f. The commodity service panels 144-f located in the cleanroom 110-f may provide control while in cleanroom 110-f.
In some embodiments, the commodity panels 141-f may distribute gases, such as helium, to the commodity skid 142-f and/or payload 155. In some embodiments, the commodity panels 141-f may supply nitrogen for purging back lines when complete. Some of the commodity panels 141-f may also be utilized to provide control of propellant flow within the antechamber 140-f.
Propellant handling in accordance with various embodiments may involve utilizing an external propellant supply cart or structure with independent secondary containment. These may generally be referred to as bulk storage 142-f, such as bulk fuel storage and/or bulk oxidizer storage; bulk storage 142-f may be referred to as propellant supply cart or propellant skid. In some embodiments, the bulk storage 142-f may be configured for gas bottles, such as helium and/or nitrogen bottles. Some embodiments also utilize a separate pressure source, such as a pressure chart, though some embodiments may include pressurization and vacuum capability with the respective propellant and/or oxidizer supply. This may help ensure maximum flexibility of the base operational unit with specific use cases such as propellant loading being designed as add-on features. This may also provide for simplified decontamination procedures by relegating decontamination to the propellant loading hardware only. Propellant skids 142-f for fuel and oxidizer are typically located on opposites of antechamber 140-f so as to avoid possible connections swaps. Propellant skids 142-f located on opposing sides of the system 101-f may provide adequate standoff distance. The propellant skids 142-f may be connected to the commodity panels 141-f with one or more flex hoses 145 that may be field installed. Propellants, such as fuel and oxidizer, may be operated separately on different days to avoid the chance of mixing vented vapors.
Operationally, propellant loading may be done from the antechamber 140-f using interconnects between the propellant supply cart 142-f and a temporary or permanent fuel panel 141 in the antechamber 140. Performing propellant loading from the antechamber 140-f generally enables operators to work at a safe distance from the payload during hazardous operations. Additionally, the antechamber 140-f may be operated on an independent HVAC system at a higher pressure than the cleanroom 110-f during propellant handling operations to ensure hazardous materials are contained in the cleanroom 110-f and do not endanger personnel. This may potentially render SCAPE suits unnecessary during propellant loading operations. The antechamber 140 of various embodiments provides both splash and vapor protection. Disconnecting from the spacecraft or other payloads being processed may be done utilizing a short duration supplied air mask or a filtered Powered Air Purifying Respirator (PAPR) as there may generally be no risk of bulk propellant release at that point. Removing the use of SCAPE suits may greatly increase the flexibility of the fueling team.
In some embodiments, the one or more commodity panels 141-f can be treated as a module for each potential propellant or gas, which may allow for additional modules to be developed as needed. Merely by way of example, a Hydrazine and MON-3 panel module may be utilized. Each of these may be based on a standardized interface such as a 3 ft×3 ft panel or similar that would be temporarily installed into the antechamber. Other panel modules may be used for other applications. Some embodiments include mounting to a rolling cart, while others may be mounted within the antechamber 140-f, sometimes in a temporary configuration. Connections between commodity panels 141-f and commodity skids 142-f may utilize flex hoses 145 to provide flexibility with layout and terrain. The hoses 145 may be disposed of after operations as consumables.
Propellant measurement may be done via load cells in the cleanroom 110-f under the payload 155, a scale in the propellant supply cart 142 with a readout on the interconnected commodity panel 141-f in the antechamber 140-f, or via flow meters integrated into the fueling panel 141-f itself. Hazmat monitors 124 may be integrated into cleanroom 110-f with another monitor 124 in the antechamber 140-f. A user interface and control system may be implemented to automatically vent or scrub cleanroom air in the event of a chemical release, for example. In some embodiments, the commodity service panels 144-f may provide some of these functions. One or more flex hoses 146 may couple the payload 155 with the commodity service panels 144-f and/or commodity panels 141-f. The connections between commodity service panels 144-f and the payload 155 may be short flex hoses 146 to provide flexibility with size and location of payload's fill and drain valves. Cross country hardlines (obscured from view under floor of cleanroom) may couple the commodity panels 141-f with the community service panels 144-f. Some embodiments may not include commodity service panels 144-f and may couple the commodity panels 141-f with the payload 155 directly utilizing various hoses 146. The commodity service panels 144-f may be closely located for both propellants, such as fuel and oxidizer, so different sized end fittings may be utilized to mitigate any swapped connections.
In some embodiments, propellant handling includes ground support equipment for propellant operations. Several other materials and systems may be included to ensure a safe working environment. For example, these materials and systems may include, but are not limited to, Propellant Loading Cart/System, Tank Scales, Payload Scale, and/or Flow Meters, Propellant Panel/Valves/Gauges, etc, Class 1 Division 2 Electrical (Distribution, Receptacles, Lighting, HVAC), Supplied Air Breathing System, Stainless-Steel Materials (where applicable), Hazmat Monitors, Air Venting/Scrubbing Solution, Safety Shower, Eye Wash Station, User Interface and Control System (Monitoring/Safety/etc.), Security System/Cameras, and/or Propellant CONOPS User's Manual.
The layout of the system 101-f may be site dependent. For example, the system 101-f may be set up with the mechanical room 130-f upwind. Some embodiments include breathing air supplies that may be positioned upwind of the commodity storage 142-f. The commodity skids 142-f for propellants may include vent stacks that are downwind of the antechamber 140-f of the system 101-f.
Some embodiments are configured to provide a deionized water (DI) supply, which may be utilized for decontamination of various lines and/or components once fueling is complete. Some embodiments include a common supplied breathing air source (bottles or pump) manifolded that may provide air taps in the cleanroom 110-f, the antechamber 140-f, and/or outside the propellant skids 142-f for the system operators.
FIG. 10A shows an example of a catchment system 127-g in accordance with various embodiments. The catchment system 127-g may include one or more trays 128. Tray 128 may include a single pan sloped to the center below a floor grating of the cleanroom and/or antechamber. Catchment system 127-g may include a gravity drain 126 to handle a flow rate of liquids being captured. Multiple riser beams 129 may be coupled with the tray 128, which may separate a flooring of the cleanroom and/or antechamber, such as structural floor beams, from the bottom of the tray 128. The rise beams 129 may also facilitate directing fluid to the drain 126.
In some embodiments, the catchment system 127-g may include one or more troughs, which may be connected to the side of the tray 128. The troughs may be located under a deployable door hinge gap. The tray 128 and/or troughs may catch liquids in general, such as liquid spills or washdown liquids, on the deployable door wings. Some embodiments include a manifold and isolation valve that may provide a drain to an external storage solution.
FIG. 10B shows an example where the catchment system 127-g may be positioned below a flooring 181 (such as a grating) of a cleanroom 110-g and/or an antechamber 140-g of a system 101-g, which may be an example of system 101 of FIG. 1A, system 101-a of FIG. 1B, system 101-b of FIGS. 2 , system 101-c of FIGS. 3 , and/or system 101-f of FIG. 7 . The tray(s) 128 may lay in gaps between structural floor beams of the cleanroom 110 and/or antechamber 140. Riser beams 129 may support the elevated grating 181 above a floor base. This may allow for unrestrained access for spills to flow to the catchment system 127-g. The grating 181 may cover the antechamber 140-g and/or cleanroom 110-g floors and generally elevates personnel above spilled liquids.
FIG. 11 shows a flow diagram of a method 1100 in accordance with various embodiments. This method may be implemented utilizing the variety of systems and/or devices shown and/or described with respect to FIGS. 1-10 . Method 1100 generally involves the deployment of a mobile, expandable cleanroom system in accordance with various embodiments.
At block 1110, one or more door assemblies of an expandable cleanroom may be deployed. In some embodiments, the door assemblies may hinge or slide for deployment. At block 1120, one or more tent enclosures of the expandable cleanroom may be deployed. At block 1130, a payload may be positioned within the expandable cleanroom. The one or more tent enclosures may include single or multiple layered structures, which may be insulated; the one or more tent enclosures may include soft wall structures and/or inflatable wall structures. At block 1140, the payload may be processed within the expandable cleanroom. At block 1150, the payload may be removed from the expandable cleanroom. At block 1160, the expandable cleanroom may be stowed through at least stowing the one or more tent enclosures or closing the one or more door assemblies.
Some embodiments of the method 1100 include transporting the expandable cleanroom to a location for deployment. Some embodiments include transporting the expandable cleanroom away from the location for deployment.
In some embodiments of the method 1100, deploying the one or more tent structures of the expandable cleanroom includes at least: raising a truss structure coupled with the one or more tent enclosure; or putting the expandable cleanroom under positive air pressure with respect to ambient. Some embodiments include inflating the expandable cleanroom with respect to the one or more tent enclosures.
Some embodiments of the method 1100 include processing the payload within the expandable cleanroom that may include fueling the payload within the expandable cleanroom. Some embodiments include putting the expandable cleanroom under negative air pressure with respect to an antechamber coupled with the expandable cleanroom while fueling the payload within the expandable cleanroom.
Some embodiments of the method 1100 include utilizing an overhead hoist coupled with the truss structure to support the payload within the expandable cleanroom. Some embodiments include utilizing the truss structure to support air filtration for the expandable cleanroom.
Some embodiments of the method 1100 include passing the payload through an antechamber coupled with the expandable cleanroom to reach the expandable cleanroom. Some embodiments of the method include utilizing one or more catchments coupled with the expandable cleanroom to capture liquids within the expandable cleanroom. Some embodiments of the method include inflating one or more supports coupled with the tent structure. Some embodiments of the method include folding the one or more tent enclosures with respect to one or more hinge regions formed from one or more layers of the one or more tent enclosures.
FIG. 12 shows a flow diagram of a method 1200 in accordance with various embodiments. This method may be implemented utilizing the variety of systems and/or devices shown and/or described with respect to FIGS. 1-10 . Method 1200 generally involves the deployment of a mobile, expandable cleanroom system in accordance with various embodiments. Method 1200 may be an example of aspects of method 1100.
Typically, the mobile, expandable cleanroom system in accordance with various embodiments is transported via truck, rail, boat, or other vehicles to a deployment location. At block 1210, one or more door assemblies of an expandable cleanroom may be deployed. At block 1220, a cleanroom tent structure of the expandable cleanroom may be deployed, such as through pressurizing the cleanroom or utilizing mechanical means to lift the cleanroom tent structure, to form an expanded cleanroom. The resulting cleanroom may be put under positive pressure with respect to an antechamber, though this may be reversed in certain situations such as during propellant handling. At block 1230, a payload may be moved into the expanded cleanroom, typically passing through the antechamber. At block 1240, the payload may be processed in a wide variety of ways including assembling, cleaning, and/or fueling within the mobile, expanded cleanroom. At block 1250, the processed payload may be removed from the expanded cleanroom. At block 1260, the expanded cleanroom may be collapsed through the door assemblies being closed. The collapsed cleanroom may be removed from the deployment location.
FIG. 13 shows a flow diagram of a method 1300 in accordance with various embodiments. This method may be implemented utilizing the variety of systems and/or devices shown and/or described with respect to FIGS. 1-10 . Method 1300 generally involves the deployment of a mobile, expandable cleanroom system in accordance with various embodiments. Method 1300 may be an example of aspects and/or variations of method 1100 and/or method 1200.
Typically, the mobile, expandable cleanroom system has been delivered to a location for the deployment. The system may be attached to a power supply and in some cases an air compressor and/or hydraulic system may be powered on. At block 1310, one or more cleanroom doors may be lowered. In some embodiments, flexible return air ducts may be installed. At block 1320, the cleanroom ceiling structure may be raised; in some embodiments, ceiling support trusses may be raised into position. Cleanroom supply air ducts may also be installed. At block 1330, one or more pneumatic actuators may actuate to deploy a cleanroom tent structure. At block 1340, fan filtration and/or HVAC system may be turned on.
FIG. 14 shows a flow diagram of a method 1400 in accordance with various embodiments. This method may be implemented utilizing the variety of systems and/or devices shown and/or described with respect to FIGS. 1-10 . Method 1400 generally involves the deployment of a mobile, expandable cleanroom system in accordance with various embodiments. Method 1400 may be an example of aspects and/or variations of method 1100, method 1200, and/or method 1300.
At block 1410, a mobile, expandable cleanroom may be transported to a location. This may utilize a wide variety of transport vehicles including, but not limited to, truck, rail, and/or boat. At block 1420, the mobile, expandable cleanroom may be expanded at the location. At block 1430, a payload may be processed within the expanded cleanroom. At block 1440, the expanded cleanroom may be collapsed. At block 1450, the mobile, expandable cleanroom may be removed from the location.
It should be noted that the methods, systems, and devices discussed above are intended merely to be examples. It must be stressed that various embodiments may omit, substitute, or add various procedures or components as appropriate. For instance, it should be appreciated that, in alternative embodiments, the methods may be performed in an order different from that described, and that various stages may be added, omitted, or combined. Also, features described with respect to certain embodiments may be combined in various other embodiments. Different aspects and elements of the embodiments may be combined in a similar manner. Also, it should be emphasized that technology evolves and, thus, many of the elements are exemplary in nature and should not be interpreted to limit the scope of the embodiments.
Specific details are given in the description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, well-known circuits, processes, algorithms, structures, and techniques have been shown without unnecessary detail in order to avoid obscuring the embodiments.
Also, it is noted that the embodiments may be described as a process which may be depicted as a flow diagram or block diagram or as stages. Although each may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be rearranged. A process May have additional stages not included in the figures.
Having described several embodiments, it will be recognized by those of skill in the art that various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the different embodiments. For example, the above elements may merely be a component of a larger system, wherein other rules may take precedence over or otherwise modify the application of the different embodiments. Also, a number of stages may be undertaken before, during, or after the above elements are considered. Accordingly, the above description should not be taken as limiting the scope of the different embodiments.

Claims

What is claimed is:

1. A method comprising:

deploying one or more door assemblies of an expandable cleanroom;

deploying one or more tent enclosures of the expandable cleanroom;

positioning a payload within the expandable cleanroom;

processing the payload within the expandable cleanroom;

removing the payload from the expandable cleanroom; and

stowing the expandable cleanroom through at least stowing the one or more tent enclosures or closing the one or more door assemblies.

2. The method of claim 1, further comprising:

transporting the expandable cleanroom to a location for deployment.

3. The method of claim 1, wherein deploying the one or more tent structures of the expandable cleanroom includes at least:

raising a truss structure coupled with the one or more tent enclosures; or

putting the expandable cleanroom under positive air pressure with respect to ambient.

4. The method of claim 1, wherein processing the payload within the expandable cleanroom includes fueling the payload within the expandable cleanroom.

5. The method of claim 4, further comprising:

putting the expandable cleanroom under negative air pressure with respect to an antechamber coupled with the expandable cleanroom while fueling the payload within the expandable cleanroom.

6. The method of claim 2, further comprising

transporting the expandable cleanroom away from the location for deployment.

7. The method of claim 3, further comprising:

utilizing an overhead hoist coupled with the truss structure to support the payload within the expandable cleanroom.

8. The method of claim 3, further comprising:

utilizing the truss structure to support air filtration for the expandable cleanroom.

9. The method of claim 1, further comprising passing the payload through an antechamber coupled with the expandable cleanroom to reach the expandable cleanroom.

10. The method of claim 1, further comprising utilizing one or more catchments coupled with the expandable cleanroom to capture liquids within the expandable cleanroom.

11. The method of claim 1, further comprising inflating one or more supports coupled with the tent structure.

12. The method of claim 1, further comprising folding the one or more tent enclosures with respect to one or more hinge regions formed from one or more layers of the one or more tent enclosures.

13. A system comprising:

an expandable cleanroom that includes:

one or more door assemblies;

one or more tent enclosures coupled with the one or more door assemblies; and

a first HVAC subsystem coupled with the expandable cleanroom.

14. The system of claim 13, wherein the first HVAC subsystem inflates the one or more tent enclosures into a deployed state.

15. The system of claim 13, wherein the expandable cleanroom further includes a raisable truss structure coupled with the one or more tent enclosures that lifts and supports the one or more tent structures in a deployed state.

16. The system of claim 15, further comprising an overhead trolley coupled with the raisable truss structure.

17. The system of claim 15, wherein the raisable truss structure is stowed between a floor of the expandable cleanroom and at least a portion of the one or more door assemblies in a stowed state.

18. The system of claim 13, further comprising one or more catchments positioned below a workspace of the expandable cleanroom.

19. The system of claim 13, further comprising an antechamber coupled with a first end of the expandable cleanroom.

20. The system of claim 19, further comprising a fueling panel positioned within the antechamber.

21. The system of claim 20, further comprising a second HVAC subsystem coupled with the antechamber.

22. The system of claim 21, wherein at least the first HVAC subsystem or the second HVAC subsystem are configured to maintain the antechamber at a higher pressure than the expandable cleanroom.

23. The system of claim 13, further comprising one or more inflatable supports coupled with the one or more tent enclosures.

24. The system of claim 14, wherein the first HVAC subsystem includes one or more HEPA filters positioned within the raisable truss structure.

25. The system of claim 13, wherein the one or more tent enclosures include a plurality of layers that include at least an outer flexible shell layer or an inner insulation layer.