Patent Application
20200123670
Embodiments described herein generally relate to the production of chemical solutions, and more specifically to the production of a chemical cleaning solution.
The use of electricity in the production of chemical solutions is known. Many of these systems rely on semi-permeable membranes to mechanically isolate the anodes and cathodes of an electrolyzing cell while permitting ion transfer between the anodes and cathodes to complete an electrical circuit.
Existing techniques reliant on this chemistry generally create solutions in volumetric systems. This requires the transfer of the solution from the system into the desired end products. This inevitably requires additional manufacturing and production resources.
A need exists, therefore, for systems, methods, and devices that overcome this disadvantage.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description section. This summary is not intended to identify or exclude key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In one aspect, embodiments relate to a solution production system. The system includes a vessel configured to contain a liquid, wherein the vessel includes a vessel inlet and a vessel outlet; and a base portion configured to receive the vessel, the base portion including: a base inlet configured to receive the liquid flowing from the vessel in one direction upon the base portion receiving the vessel; a first anode; a cathode spaced from the first anode to facilitate an electrochemical reaction with the received liquid to produce at least one of a bubble flow and a product solution; and a base outlet configured to transport at least one of the bubble flow and the product solution from the base inlet to the vessel in one direction and without pumping.
In some embodiments, the base portion receives the vessel by mating the vessel outlet with the base inlet and mating the vessel inlet with the base outlet.
In some embodiments, the vessel outlet includes a first valve to facilitate the flowing of liquid out of the vessel in one direction and the vessel inlet includes a second valve to control the transport of at least one of the bubble flow and product solution into the vessel.
In some embodiments, the base portion further includes a housing that maintains the spacing between the first anode and the cathode and is configured to direct at least one of the bubble flow and the product solution through the base outlet into the vessel. In some embodiments, a surface of the housing is angled to direct at least one of the bubble flow and the product solution through the base outlet into the vessel.
In some embodiments, the product solution includes at least one of hypochlorous acid and sodium hydroxide. In some embodiments, the system includes a friction reduction agent applied to the roof of the housing to facilitate the movement of at least one of the bubble flow and the product solution.
In some embodiments, the bubble flow produced by the electrochemical reaction circulates the liquid from the vessel into the base portion and back to the vessel in one direction without pumping.
In some embodiments, the vessel includes a dispenser configured to emit the product solution from the vessel.
In some embodiments, the liquid includes water, salt, and vinegar.
In some embodiments, the system further includes a second anode and the cathode is positioned between the first anode and the second anode.
According to another aspect, embodiments relate to a method of manufacturing a solution production device. The method includes positioning an anode in a receptacle; positioning a cathode in the receptacle spaced apart from the anode; and configuring the receptacle with an inlet portion and an outlet portion, wherein the inlet portion is configured to allow a liquid from a vessel to enter the receptacle upon the receptacle receiving the vessel, and the outlet portion is configured to allow a product of an electrochemical reaction between the cathode, anode, and the liquid to enter the vessel without pumping.
In some embodiments, the method further includes enclosing the anode and the cathode in a housing that maintains the spacing between the anode and the cathode and is configured to direct the product of the electrochemical reaction through the outlet portion and into the vessel. In some embodiments, the housing includes an angled surface to direct the product of the electrochemical reaction through the outlet portion and into the vessel.
According to yet another aspect, embodiments relate to a solution production device. The device includes an inlet portion configured to receive a liquid from a vessel upon the device receiving the vessel; a first anode and a cathode spaced apart to generate, upon receiving an electrical current, an electrochemical reaction with the received liquid to produce at least one of a bubble flow and a product solution; and an outlet portion configured to transport at least one of the bubble flow and the product solution into the vessel without pumping.
In some embodiments, the device further includes a power source configured to apply the current to the anode and the cathode to generate the electrochemical reaction.
In some embodiments, the device further includes a housing that maintains the spacing between the first anode and the cathode, wherein the housing is configured to direct at least one of the bubble flow and the product solution through the outlet portion and into the vessel. In some embodiments, the housing includes an angled surface to direct at least one of the bubble flow and the product solution through the outlet portion and into the vessel.
In some embodiments, the device further includes a second anode, wherein the cathode is positioned between the first anode and the second anode.
In some embodiments, the device is operably connected to a power source capable of producing up to 9 volts to generate the electrochemical reaction.
Non-limiting and non-exhaustive embodiments of the invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified.
Various embodiments are described more fully below with reference to the accompanying drawings, which form a part hereof, and which show specific exemplary embodiments. However, the concepts of the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as part of a thorough and complete disclosure, to fully convey the scope of the concepts, techniques and implementations of the present disclosure to those skilled in the art. Embodiments may be practiced as methods, systems or devices. Accordingly, embodiments may take the form of a hardware implementation, an entirely software implementation or an implementation combining software and hardware aspects. The following detailed description is, therefore, not to be taken in a limiting sense.
Reference in the specification to “one embodiment” or to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one example implementation or technique in accordance with the present disclosure. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment. The appearances of the phrase “in some embodiments” in various places in the specification are not necessarily referring to the same embodiments.
In addition, the language used in the specification has been principally selected for readability and instructional purposes and may not have been selected to delineate or circumscribe the disclosed subject matter. Accordingly, the present disclosure is intended to be illustrative, and not limiting, of the scope of the concepts discussed herein.
Features of various embodiments described herein disclose novel solution production systems, methods, and devices. The systems in accordance with various embodiments include a base portion with a power source, a control circuit and/or electronics, at least one anode, at least one cathode, and a means to maintain the spacing between the anode(s) and the cathode(s). The system further includes a liquid-containing vessel that can be removably attached to the base portion.
Once the vessel is attached to the base portion, liquid within the vessel may flow from the vessel into the base portion through a base portion inlet. A current may be applied to the liquid between the anode(s) and the cathode(s) to produce a bubble flow and a product solution. The bubble flow and/or the product solution may then flow back into the vessel, thereby filling the vessel with the product solution.
The product solution may be a cleaning solution that can be used in sanitizing applications, surfaces, volumes, systems, and venues including, but not limited to, restaurants, tables, pools, aquariums, military applications, third-world applications, areas of infectious disease outbreaks, door handles, knobs, airplanes, cruise ships, trains and rail cars, busses, taxis, cars, healthcare institutions, schools, airports, bus terminals, train stations, pipelines, restrooms, home exterior cleaning, industrial exterior cleaning, home filtration systems, refrigeration systems, misters, dishwashers, ice machines, HVAC systems, humidifiers, dehumidifiers, environmental control systems, locker rooms, public showers, prisons, detention centers interrogation rooms, play pens, ball pens, day care centers, playgrounds, play items, gymnasiums, gymnastic equipment and/or machinery, exercise equipment and/or machinery, churches, nursing homes, assisted living facilities, funeral homes, morgues, police stations nail salons, spas, cosmetics counters, sales counters, delicatessens, agricultural applications, green houses, hydroponics systems, water treatment facilities, gray water transport systems, systems using recycled water, fracking operations, waste treatment facilities, food processing plans, food processing machinery, robotic systems, medical treatment devices, or the like.
The vessel 102 may contain a liquid such as a cleaning solution generated by the electrochemical process discussed below. The vessel 102 may include an upper portion 106 with a dispenser 108 to dispense liquid from the vessel 102. The vessel 102 may also include a lower portion 110 that contains any required mechanical, electrical, and/or chemical components to accomplish the various features described herein. The vessel 102 may be formed of glass, plastic, metal, non-metal material, or any other type of material capable of storing the chemical cleaning solution discussed herein.
The liquid initially in the vessel 102 can be water from any source mixed with at least one additive and/or distilled water that is mixed with at least one additive and/or any combination thereof. That additive may include at least one salt and/or at least one acid, for example. The acid may include any weak acid of an organic salt including, but not limited to, at least one of acetic acid, citric acid, lactic acid, malic acid, and may be between 0.001% and 26% by weight in total of initial solution concentration. The salt may include chloride containing salt derived from the class of alkali metals or equivalents including; but not limited to, sodium chloride, lithium chloride, potassium chloride, cesium chloride; pseudo alkali metals or equivalents such as ammonium chloride. The salt may be between 10 PPM and 20,000 PPM in total of initial concentration.
The valves 302 and 304 may restrict or otherwise prevent liquid 308 from leaving the vessel 102 through the lower portion 110 until the vessel 102 is connected with the base portion 104. As seen in
Although the valves 302 and 304 are illustrated as spring loaded valves, other types of valves may be used. For example, the valves 302 and 304 may be configured as ball-check valves, mechanically-activated valves, electrically-activated valves, or the like. Any type of valve, whether available now or invented hereafter, may be used as long as they can accomplish the features of various embodiments described herein.
As discussed below, during the time that the vessel 102 is connected to or is otherwise received by the base portion 104, valve 302 may open to allow liquid 308 to flow from the vessel 102 and into the base portion 104. Then, after electrolysis (discussed below), the produced solution may enter the vessel 102 through the inlet port 312.
Also shown in
The base portion 104 may further include a flow path 410 which the liquid from the vessel 102 traverses. That is, the liquid may enter the base portion inlet 404, traverse the flow path 410, and exit the base portion outlet 406.
The base portion 104 also includes a housing 412, at least one anode 414, at least one cathode 416 spaced apart from the anode(s) 414, and any required electrical connections between the anode(s) 414 and cathode(s) 416. As the liquid traverses the flow path 410, the liquid undergoes an electrochemical reaction via the anode(s) 414 and cathode(s) 416 to produce the product solution. The resultant product solution may then travel through the base outlet portion 406 and into the connected vessel 102 via the inlet port 312.
The anode(s) 414 and cathode(s) 416 can be constructed from a conductive material that can include at least one coating to act as a catalyst. The conductive material and the coating may be the same for the anode(s) 414 and the cathode(s) 416. The anode(s) 414 and/or the cathode(s) 416 can each comprise in whole or in part a conductive screen and/or a perforated conductive material.
The anode(s) 414 and/or the cathode(s) 416 can be printed on a substrate, such as by thermoforming and/or in-molding techniques. In the context of the present application, “in-molding” refers to a process by which a conductive element is molded within an element that can be plastic or another thermoformable material, and can employ injection molding, thermoforming, casting, and/or blow molding. However, any other technique for forming the anode(s) 414 and the cathode(s) 416, whether known now or invented hereafter, may be used as long as the anode(s) 414 and the cathode(s) 416 can accomplish the features of various embodiments described herein.
The anode(s) 414 and the cathode(s) 416 may be in a planar configuration or in a stacked configuration (e.g., a single cathode 416 can be positioned between two anodes 414). In some embodiments, the anode(s) 414 may be in a stacked configuration such as that illustrated in
The anode(s) 414 and the cathode(s) 416 may also be separated by at least one insulating material. The exact configuration and type of anode(s) 414 and cathode(s) 416 may vary and include those described in Applicant's U.S. Pat. Appl. Publ. No. 2016/0330968, entitled “SANITIZING PRODUCT CREATION SYSTEM,” the entire contents of which are hereby incorporated by reference in their entirety.
Referring back to
The power source can produce a voltage that can favor the production of hypochlorous acid. Hypochlorous acid can be produced at a concentration in the range of 100-500 PPM, or at a concentration that is variable. The power source can produce a voltage that can favor the production of sodium hydroxide. Or, the voltage can produce both sodium hydroxide and hypochlorous acid.
The power source can provide direct current or alternating current. The power source can be an uncontrolled power source and/or supply random AC and/or DC voltage waveforms. The power source can also supply random AC and/or DC voltage waveform components. The direct current can be produced by at least one of a battery, fuel cell, solar cell, thermoelectric source, nuclear source, magnetic generator, or a generator that interacts with any source of mechanical energy. The direct current can be derived from the rectification of alternating current. The direct current can be half-wave or full-wave rectified alternating current. The direct current can be transformed using a control circuit and/or electronics to produce a predominantly constant current.
The power source(s) can include a transformer and/or power and/or voltage transformation system. The power source can produce a voltage between +10.5 and −10.5 volts, and the direct current can result in the creation of a variable current. The current density in the anode(s) 414 and the cathode(s) 416 can be in the range of 100-500 mA/cm2, for example.
The base portion 104 and/or the vessel 102 may include a means to measure pH by producing at least one pH signal. The pH signal can be used to provide feedback and/or to determine when to terminate a reaction by switching current off and/or altering the flow of current between the electrodes.
The systems, methods, and apparatuses described herein can further include the ability to control and/or alter the pH of at least one liquid or a solution containing reactants. As discussed in more detail below, the starting liquid can be water from any source mixed with at least one additive and/or distilled water mixed with the additive(s). The additive(s) can include salt and/or acid.
The acid may be a weak acid of an organic salt including, but not limited to, at least one of acetic acid, citric acid, lactic acid, and malic acid. The acid(s) can be between 0.001% and 26% by weight in total solution concentration.
The salt can be at least one chloride containing salt derived from the class of alkali metals or equivalents including but not limited to sodium chloride, lithium chloride, potassium chloride, cesium chloride, and rubidium, chloride, pseudo alkali metals or equivalents including but not limited to ammonium chloride. The at least one salt can be between 10 PPM and 20,000 PPM in total solution concentration.
The additive can be a self-contained and/or premixed mixture stored in packets that is added to a quantity of water in the vessel 102. The additive can further include a water softener.
Once the vessel 102 is connected with the base portion 104 such that the liquid flows into the base portion 104, a power source may supply power to the anode(s) 414 and cathode(s) 416 to initiate electrolysis. In some embodiments, the system 100 produces hypochlorous acid and/or sodium hydroxide using electricity passing between the anode(s) 414 and the cathode(s) 416.
Before the chemical reaction and as discussed above, the starting solution in the vessel 102 may contain water (H2O), sodium chloride (salt), and vinegar. Once power is supplied to the anode(s) 412 and the cathode(s) 414, an electrical current breaks apart the molecules of the starting solution to form sodium hydroxide and hypochlorous acid in accordance with the following equation:
Cl2+H2O=HClO+HCl
In some embodiments, system 100 may include a power source that is capable of producing up to 9V. The power source may be configured within the base portion 104 or otherwise in operable communication with the base portion 104. The amount of power supplied may of course vary and depend on the desired operational specifications.
For example, a 9 volt power source may provide 290 mAh to the anode(s) 414 and cathode(s) 416. With this amount of charge, the system 100 may produce the solution in approximately six minutes and thirty seconds. A lower amount of power may nonetheless produce the solution but require more time (e.g., up to ten minutes).
The chemical reaction occurring within the housing 412 therefore produces at least one of bubble flow and the product solution. The housing 412 is operably shaped and positioned to force the bubble flow and/or the product solution out of the housing 412, through the base portion outlet 406, and into the vessel 102.
The interior of the housing 412 may also be coated with or otherwise include a friction-reducing agent to facilitate the flow of bubbles and the produced solution out of the housing 412. It is noted that this flow is also in one direction.
Additionally, the electrodes dissipate heat energy into the water. The rising bubble flow and the warmer water create a thermal syphon, as indicated by the arrows in
The shape of the housing 412 may vary to force the bubbles and product solution into the vessel 102. For example,
Accordingly, by angling the housing 1300 appropriately, the bubbles and product solution may move out of the housing 1300 and into the vessel 102 without pumping. This saves power, as a mechanical or electrical pump is not required.
Once the vessel 102 filled with the product solution, a user may detach the vessel 102 from the base portion. The user may then use a dispenser (such as the dispenser 108) configured with the vessel 102 to dispense the product solution out of the vessel 102 and onto a surface for cleaning.
Step 1404 involves positioning a cathode in the receptacle. The cathode may be similar to the cathode(s) 416 of
Step 1406 involves enclosing the anode and the cathode in a housing. The housing may be similar to the housing 412 of
Step 1408 involves configuring the receptacle with an inlet portion and an outlet portion. These portions may be similarly configured to the inlet and outlet portions, 404 and 406, respectively, of
In some embodiments, the spacers may be made of a synthetic polymer, such as polytetrafluoroethylene. In some embodiments, the spacers may separate the anodes 20301, 20302 from the cathode 2040 and prevent the device from shorting out during the electrolysis process when liquid is added to the vessel. In some embodiments, the spacers 20501, 20502 may comprise a mesh material. The mesh material may allow liquid to flow through the spacers 20501, 20502 from the anodes 20301, 20302 to the cathode 2040. In some embodiments, the mesh material may be located between the solid bars 2052, 2054 of the spacer 2050 in a spacer window 2056.
In some embodiments, the spacers 2050 may have a width of between 30 and 50 mm across. In some embodiments, the spacers 2050 may have a width of 40 mm across. In some embodiments, the spacers 2050 may have a width of 46 mm across. In some embodiments, the spacers 2050 may have a width of approximately 39 mm and a height of approximately 046 mm.
In some embodiments, the spacers 2050 may comprise two windows 20561, 20562 in the spacers 2050, forming in the spacer material, a peripheral bar 2052 and a middle bar 2054 between the two windows. In some embodiments, the peripheral bar 2052 and the middle bar 2054 may have the same width. In some embodiments, the width of each bar 2052, 2054 may be approximately 2.5 mm. In some embodiments, the spacer window 2056 between the peripheral bar and the middle bar may be approximately 15.75 mm wide. In some embodiments, the spacers 2050 may be slightly larger than the cathode 2040 and anodes 2030.
In some embodiments, the spacers 2050 are configured to provide a complete separation between the cathode 2040 and the anodes 2030. In some embodiments, the spacers 2050 promote the movement of ions from cathode 2040 to anodes 2030 on charge and the reverse on discharge.
In some embodiments, the configuration of the spacers 2050 may allow the flow of electrolyte solution though the base of the solution production system. In some embodiments, the configuration of the spacers 2050 may promote disengagement of gases produced during electrolysis through the flow of the electrolyte through the windows of the spacers.
In some embodiments the separator is designed to be as thin as possible to not add dead volume to the cell. Additionally, in some embodiments, the separators 2050 are configured to allow for uniform wetting and further configured to prevent dry areas. In batteries, dry areas may create hot spots leading to cell failure. By keeping the width, length, and height of the bars in the separator 2050 uniform, the cell may be configured to prevent dry areas and shortages. By keeping a uniform window, the ions can exchange between the cathode and anodes. In some embodiments, if the cell were overheating in a local area, the separator 2050 may melt at the point of shorting and provide a local shutdown. Additionally, in some embodiments, the separator 2050 may be approximately equal in size to the electrodes 2030, 2040 to prevent the electrodes 2030, 2040 from contacting each other.
In some embodiments, electrodes 2030, 2040 and spacers 2050 may be in the base of the solution production system. In some embodiments, a brace may be used to stabilize the electrodes 2030, 2040 and spacers 2050 in the base of the solution production system.
The methods, systems, and devices discussed above are examples. Various configurations may omit, substitute, or add various procedures or components as appropriate. For instance, in alternative configurations, the methods may be performed in an order different from that described, and that various steps may be added, omitted, or combined. Also, features described with respect to certain configurations may be combined in various other configurations. Different aspects and elements of the configurations may be combined in a similar manner. Also, technology evolves and, thus, many of the elements are examples and do not limit the scope of the disclosure or claims.
Embodiments of the present disclosure, for example, are described above with reference to block diagrams and/or operational illustrations of methods, systems, and computer program products according to embodiments of the present disclosure. The functions/acts noted in the blocks may occur out of the order as shown in any flowchart. For example, two blocks shown in succession may in fact be executed substantially concurrent or the blocks may sometimes be executed in the reverse order, depending upon the functionality/acts involved. Additionally, or alternatively, not all of the blocks shown in any flowchart need to be performed and/or executed. For example, if a given flowchart has five blocks containing functions/acts, it may be the case that only three of the five blocks are performed and/or executed. In this example, any of the three of the five blocks may be performed and/or executed.
A statement that a value exceeds (or is more than) a first threshold value is equivalent to a statement that the value meets or exceeds a second threshold value that is slightly greater than the first threshold value, e.g., the second threshold value being one value higher than the first threshold value in the resolution of a relevant system. A statement that a value is less than (or is within) a first threshold value is equivalent to a statement that the value is less than or equal to a second threshold value that is slightly lower than the first threshold value, e.g., the second threshold value being one value lower than the first threshold value in the resolution of the relevant system.
Specific details are given in the description to provide a thorough understanding of example configurations (including implementations). However, configurations 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 configurations. This description provides example configurations only, and does not limit the scope, applicability, or configurations of the claims. Rather, the preceding description of the configurations will provide those skilled in the art with an enabling description for implementing described techniques. Various changes may be made in the function and arrangement of elements without departing from the spirit or scope of the disclosure.
Having described several example configurations, various modifications, alternative constructions, and equivalents may be used without departing from the spirit of the disclosure. For example, the above elements may be components of a larger system, wherein other rules may take precedence over or otherwise modify the application of various implementations or techniques of the present disclosure. Also, a number of steps may be undertaken before, during, or after the above elements are considered.
Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate embodiments falling within the general inventive concept discussed in this application that do not depart from the scope of the following claims.
The present application claims the benefit of co-pending U.S. patent application Ser. No. 15/850,922, filed on Dec. 21, 2017, which in turn claims priority to co-pending U.S. patent application Ser. No. 15/013,429, filed on Feb. 2, 2016, which in turn claims priority to U.S. provisional application No. 62/110,889, filed on Feb. 2, 2015, the entire disclosure of each of which are hereby incorporated by reference as if set forth in their entirety herein.
| Number | Date | Country | |
|---|---|---|---|
| 62110889 | Feb 2015 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15850922 | Dec 2017 | US |
| Child | 16670852 | US | |
| Parent | 15013429 | Feb 2016 | US |
| Child | 15850922 | US |
