Patent Grant
8411406
The present invention relates generally to the field of ionizers, and more particularly, to a fluid cooled ionizer and methods of making and using a fluid cooled ionizer.
Ionizers are prevalent in a wide variety of industries and applications. A known problem with standard ionizers, and with high voltage ionizers in particular, is the generation of uncontrolled electric arc, sometimes referred to as electrical arc or as arc, which may lead to failure of the dielectric in the ionizer and, thus, failure of the ionizer. Another problem with standard high voltage ionizers is the generation of heat due to uncontrolled electric arc, due to high frequency operation of the ionizer, or for some other reason; heat may cause deterioration of the ionizer dielectric, also leading to ionizer failure.
The excessive generation of ultra-violet (UV) light, may degrade the dielectric used in ionizers, also leading to premature failure. For example, UV light may cause the crystallization of glass and the breakdown of certain polymers used in the manufacture of dielectrics for ionizers.
An ionizer is a device that causes the formation or creation of ions of atoms or molecules. An ion may be an atom, group of atoms or molecule, as is well known. An ion is an atom or molecule with a dearth or excess of electrons compared to the atom or molecule at its ground state.
One type of prior ionizer uses a pair of parallel, spaced apart glass tube electrodes, each of which is filled with a conductive material, e.g., a gas. A fan blows air in the narrow gap, e.g., about ⅛ inch wide, between the electrodes. A voltage applied across the electrodes causes an electric arc to occur in the gap. Air blown in the gap is ionized as it passes through the electric arc. This type of ionizer has a number of disadvantages, e.g., the gap is narrow, the electric arc tends to be very thin, and much of the air blown by the fan flows past the glass electrodes on the sides thereof that do not face the gap and is not exposed to the electric arc; therefore, the amount of air that is ionized is relatively small, and such an ionizer is relatively inefficient—the relatively low ion output for a given volume of exposed fluid gas leads to this inefficiency. Another disadvantage is that the glass electrodes are relatively fragile and may too easily break.
Another type of prior ionizer uses a glass tube outside of which one electrode is located and inside of which is a metal electrode. A voltage applied across the electrodes creates a corona discharge in the interior space of the tube, and air blown through the tube is exposed to that corona discharge and becomes ionized. A usual electrode inside the tube is a solid metal rod, and the gap between that electrode and the glass tube dielectric is relatively small, e.g., on the order of about 1/32 inch to about 1/16 inch. This type of ionizer has a number of disadvantages, e.g., the gap is relatively narrow and the gap has to be relatively accurately maintained to avoid failure due to the corona discharge migrating to one end of the rod forming an electric arc and burning the rod. Also, since the air blown through the ionizer is directly exposed to the metal electrode, there is the possibility that the output from the ionizer disadvantageously will contain metal. Also, exposure of the metal electrode to air and to the ionized material may hasten corroding, pitting, or other degradation and/or other failure of the metal electrode.
Still a third type of prior ionizer uses a pair of parallel spaced apart generally planar electrodes that are separated by a dielectric sheet and an air gap. A first electrode has flow passages for a cooling fluid. Air is blown in the gap between the dielectric sheet and the first electrode. A voltage applied across the electrodes causes a discharge from the first electrode into the air in the gap. A number of sets of two electrodes and dielectric spacers may be stacked together. This type of ionizer has a number of disadvantages, such as those described above, including the difficulty in maintaining accurate spacing of the electrodes and the migrating of the corona discharge to an edge of the electrode and burning of the electrode by electric arc if accurate uniform spacing is not maintained. Also, the direct exposure of the air to the first electrode may lead to the output from the ionizer disadvantageously containing metal and the exposure of the ionized fluid to the metal may hasten corroding, pitting, or other degradation and/or failure of the electrode.
Also, in the latter two of the above ionizers, the gap where the electric arc occurs is relatively narrow and, therefore, a relatively expensive, high pressure, substantial energy consuming centrifugal blower may be needed to blow air through the gap.
It will be appreciated that there is a need for an improved ionizer.
It also will be appreciated that there is a need to provide an efficient ionizer that reduces or avoids metal in the output.
It also will be appreciated that there is a need to improve the durability and longevity of an ionizer.
It will also be appreciated that there is a need to improve efficiency of ionizers.
The present invention is directed to an ionizer in which the electrodes are supported in relatively accurately spaced apart relation by a dielectric honeycomb structure that has a number of flow fluid flow channels through which the fluid to be ionized may flow. In response to a voltage applied across the electrodes ionization occurs in the channels, but the electrodes are spaced away from the fluid in the channels and do not come in contact with the fluid.
The ionizer may be composed somewhat like a capacitor of stacked capacitor subunits, each of which capacitor subunits includes a dielectric honeycomb structure and one electrode at a surface thereof and fluid flow channels through the honeycomb structure. The capacitor subunits may be stacked together in parallel overlying relation to provide electrodes on the opposite sides of each honeycomb structure. A voltage may be applied across a pair of electrodes to ionize the fluid in the channels in the honeycomb between those electrodes without the fluid coming in contact with the electrodes. It will be appreciated that such ionizers in a sense are air capacitors to which the voltage applied is greater than the voltage required to ionize the fluid between the capacitor/ionizer electrodes, e.g., break down voltage of the fluid in the channels.
The size, shape and/or arrangement of fluid flow channels in the honeycomb structures tends to promote uniform distribution of fluid flow through the channels and also promotes laminar flow through the channels. Uniform fluid distribution helps to assure that ionization occurs substantially uniformly; and the laminar flow helps to assure both uniformity of the ionization of the fluid and cooling of the ionizer by the flowing fluid or at least generally maintaining a substantially uniform temperature over the ionizer. The laminar flow also helps to preserve the ions out of the ionizer by providing somewhat self-insulating streams tending to preclude intermingling or mixing of the ions and, thus, grounding or discharging of the ions to themselves.
According to one aspect of the invention, an ionizer assembly includes at least two dielectric sheets, at least one flow through channel between the sheets, and a respective electrical conductor associated with each of the sheets and separated from the channel(s) by the respective associated sheet.
Another aspect relates to an ionizer formed of dielectric honeycomb material and a pair of electrodes.
Another aspect relates to use of the combination of honeycomb material and a fluid in the honeycomb material as a dielectric in an ionizer.
Another aspect relates to an ionizer subunit including a dielectric honeycomb and an electrical conductor on at least one dielectric sheet of the dielectric honeycomb.
Another aspect relates to an ionizer assembly including a stack of a plurality of ionizer subunits wherein an electrical conductor of at least one ionizer subunit is cooperative with an electrical conductor of another ionizer subunit to function as an ionizer.
Another aspect relates to a method of making an ionizer subunit including disposing a conductive material on at least one dielectric sheet of a dielectric honeycomb.
An aspect of the invention relates to an assembly including at least two dielectric sheets, at least one flow through channel between the sheets, and an electrical conductor associated with one of the sheets and separated from the channel by that sheet and adapted to cooperate with another electrode to apply voltages to a fluid in the channel to cause ionization of the fluid.
Another aspect relates to an ionizer including a pair of dielectric sheets, one or more fluid channels between the sheets, electrodes respectively at each sheet separated from the channels as not to contact fluid therein and adapted to receive electric voltage to ionize fluid in the channels, and wherein the sheets and fluid in the channels are a dielectric between the electrodes of the ionizer.
Another aspect relates to an ionizer subunit including a dielectric honeycomb and an electrical conductor at least one dielectric sheet of the dielectric honeycomb.
Another aspect relates to an ionizer including a dielectric honeycomb material having a plurality of fluid flow channels therein and an electrode at each surface of the honeycomb material, wherein the channels are of a configuration to promote laminar flow in the channels.
Another aspect relates to an electric ionizer, including a honeycomb dielectric having respective opposite generally parallel support surfaces, and a number of fluid passages in the honeycomb dielectric between said support surfaces, and an electrical conductor at each of said support surfaces, and said electrical conductors having respective portions that are in generally parallel, confronting relation separated by the honeycomb dielectric to provide electrical ionization potential to fluid in the passages.
Another aspect relates to an ionizer including a non-uniform density dielectric support having respective parallel surfaces, a pair of electrical conductors, one at one of the parallel surfaces and one at the other of the parallel surfaces and relatively positioned to provide electrical capacitance, and cooling means in the non-uniform density dielectric support.
Another aspect relates to an ionizer including electrodes, and a dielectric support for the electrodes adapted to conduct ionizable gas between the electrodes without the gas contacting the electrodes.
Another aspect relates to a method of cooling an ionizer that includes electrodes, including thermally coupling cooling fluid with the electrodes for substantially uniform cooling thereof without contact of the cooling fluid with the electrodes.
Another aspect relates to a method of making an ionizer subunit including disposing a conductive material at least one dielectric sheet of a dielectric honeycomb.
Another aspect relates to a method of operating an ionizer having a number of electrodes separated by dielectric sheets that are spaced apart by ribs providing fluid flow passages between the dielectric sheets, wherein alternating current voltage is applied to the ionizer, including directing a cooling fluid flow through the fluid flow passages.
Another aspect relates to a method of cooling an ionizer formed of a honeycomb material having respective sheet-like surfaces and a number of fluid flow channels through the honeycomb material between the surfaces, and an electrode at each surface of the honeycomb material, including directing a flow of fluid through a number of the fluid flow channels.
Another aspect relates to a method of ionizing a fluid flowing through fluid flow channels in a dielectric honeycomb having a pair of dielectric sheets that are spaced apart by ribs and a respective electrode at each sheet, including applying alternating current voltage to the electrodes at a magnitude that includes at least a portion that exceeds the break down voltage of the fluid, and directing fluid flow through the fluid flow channels at a speed such that substantially all fluid in the fluid flow channels is exposed to the break down voltage or greater for a sufficiently long duration as to be come ionized.
Another aspect relates to a method of supplying a fluid to an ionizer that includes electrodes, whereby the fluid does not contact the electrodes.
These and further features of the present invention will be apparent with reference to the following description and attached drawings. In the description and drawings, several exemplary embodiments of the invention have been disclosed in detail as being indicative of some of the ways in which the principles of the invention may be employed, but it is understood that the invention is not limited to those. Rather, the scope of the invention is determined by the claims and all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto.
Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.
These and further features of the present invention will be apparent with reference to the following description and drawings, wherein:
The present invention will now be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. Primed reference numerals may be used to designate parts similar to those designated by the same unprimed reference numeral. It will be understood that the figures are not necessarily to scale and that directions may be mentioned for convenience of the description, but are not necessarily limiting or required.
Referring initially to
The ionizer assembly 10 includes a number of ionizer subunits 11, which are assembled in a stacked relation. The ionizer subunits 11 are formed of a honeycomb structure 12 (sometimes referred to as honeycomb) that has a pair of generally planar dielectric sheets 13, 14 separated by dielectric separators 15, which may be referred to below as “ribs” or as “supports.” The honeycomb structure 12 is electrically non-conductive, e.g., made of dielectric material. An electrode 16 is between respective relatively adjacent honeycomb structures 12. In addition to a honeycomb structure 12, an ionizer subunit 11 also includes one of the electrodes. Respective pairs (or more) of electrodes 16 spaced apart by honeycomb structures 12, may be referred to as an ionizer 17. Accordingly, in assembled relation of ionizer subunits 11 to form the ionizer assembly 10, respective pairs of electrodes 16, which are separated by a honeycomb structure 12, function as ionizers 17. The ionizers 17 may be combined to provide increased production of the ionizer assembly 10, e.g., as a stack of ionizers. The honeycomb structure may provide for controlled and relatively accurate spacing of the electrodes, which are at each surface of a respective honeycomb, to provide for relatively accurate control of the voltage gradient of the ionizer assembly 10.
Dotted lines at the top of
As is seen in
As is seen in
A number of flow through channels 20 (sometimes referred to as passages, paths, pathways, flow channels, channels or the like) are in respective honeycomb structures 12 of the ionizer subunits 11. The flow through channels provide the fluid (gas) source for ion production, for cooling or other purpose, as is described below. There may be only one channel 20 or, as is illustrated in a number of the exemplary embodiments, there may be a plurality of channels 20 in an ionizer subunit 11. The channels 20 of an ionizer subunit 11 may be the space between the sheets 13, 14 and the ribs 15 of the honeycomb structure 12 of the ionizer subunits. The ribs 15 separate the dielectric sheets 13, 14 from each other and divide the space between the dielectric sheets 13, 14 into respective flow channels. The ribs 15 and dielectric sheets may be, for example, integrally formed as a single structural unit or several parts thereof may be separately formed and assembled to make the honeycomb structure 12.
A respective channel 20 may be fluidically isolated from some or all of the other channels 20, or it may be connected to one or more other channel(s), e.g., by an opening in a rib 15 between adjacent channels. A fluid may be disposed in or passed through one or more of the channels 20, for example, to effect fluid supply to the ionizer subunit to affect ion production of the ionizer subunit. In
As an example of operation of an ionizer assembly 10 of
The ion production of the ionizer assembly 10 may depend on, for example, the number of ionizer subunits 11, the size and shape of the ionizer subunits 11 and parts thereof, the size, shape and relative location of respective electrodes 16, the material used to form the electrodes 16, spacing of the electrodes as provided by the thickness of the dielectric honeycomb structure 12, electrical or dielectric characteristics of the honeycomb structures 12 and the fluids in channels 20, the electrical connections 23a, 24a of electrodes 16, to respective terminals or the like 23b, 24b of the electric circuit 22, the voltage applied to or by the electric circuit, environmental conditions, or other variables. During operation of the ionizer assembly 10, a fluid may be passed through or may be disposed in the channels 20 and may affect corona generation and thus ion production. The ions produced by the ionizer are in a sense drawn from or derived from such fluid in the channels. In operation of an embodiment at least part of the fluid becomes ionized.
An example of operating ionizer assembly 10: An electrical voltage is applied across the electrodes 16a, 16b. The honeycomb structure supports the electrodes in parallel, spaced apart, in at least partially overlapping relation. Fluid 20a is blown or pumped through the channels 20. The fluid 20a cools the ionizer assembly and respective parts thereof. The honeycomb structure 12 and the fluid 20a provide a dielectric for the ionizers 17 of the ionizer assembly 10. The honeycomb structure maintains separation of the fluid 20a from the electrodes 16 so that the fluid does not contact the electrodes or otherwise come into direct contact with the electrodes, while permitting thermal transfer from the electrodes via the honeycomb structure to the fluid. Thus, the fluid and the electrodes are thermally coupled. The fluid 20a may be freshly supplied to the ionizer assembly 10 from a separate source, e.g., ambient air; and/or the fluid may be supplied, possibly after first undergoing treatment to cool it, to ground it to remove any excess charge, and/or to dry it.
As is illustrated and described further below, the electrodes of an ionizer are not in contact with the fluid that is being ionized; a voltage applied to electrodes ionizes fluid in flow channels that are separated from and not in direct contact with the electrodes. In an embodiment the electrodes are spaced apart by a honeycomb that has flow channels for the fluid that is being ionized. In operation ionization occurs in the fluid; as there is no direct external source of electrons provided the fluid, it appears that electrons are drawn from molecules or atoms in the fluid to cause ionization of fluid. It also appears that as AC voltage is applied to the electrodes which in turn apply an electric field across the fluid, when the AC voltage and, thus, the electric field reverses, there is relatively less tendency for reversion when the fluid flows through the channels at an adequately fast speed as is described further below.
Ion reversion is the grounding of an ion after it has been generated. This can occur through contact with an ion of opposite and at least equal charge, contact with an electron donor, such as an exposed electrode that supplies electrons directly to the ion, contact with air and contact with free electrons, which may be available in the course of the ionization process. However, if the gas moves rapidly, electrons liberated in the process collect on the positive electrode side and, thus, may in view of that collecting effectively be at least somewhat removed from the ion stream and tend not to be available to effect reversion.
The flow channels in the ionizer promote laminar flow of the fluid that is directed through the ionizer. The flow rate may be controlled such that the residence time of fluid in the flow channels is at or slightly greater than one half the duty cycle of each half cycle of the applied AC voltage to the electrodes; duty cycle is referred to here as the duration that a half cycle of the applied voltage equals or exceeds the break down voltage of the fluid that would tend to cause ionization of the fluid. Such laminar flow and flow rate tend to prevent mixing of ions in the ionizer before discharge as the ionized fluid, and ozone formation within the ionizer itself is non-existent or is relatively small compared to the relatively larger amount of ozone that is generated in conventional ionizers. The laminar flow and flow rate and the non-mixing of the ions in the ionizer also are carried forward to the fluid output of the ionizer such that the ionized fluid continues to have properties of being ionized at relatively far distances from the outlet of the ionizer, e.g., in some instances has been found that this is the case at distances on the order of from about 20 feet to about 30 feet from the outlet of the ionizer.
Since the electrodes (conductors) 16 of the ionizers 17 of the ionizer assembly 10 are not in direct contact with the fluid 20 being ionized, there is no addition of metal from the electrodes to the ion stream, and there is no corrosion of the electrodes due to such a contacting of the ion stream with the electrodes. Thus, the ionized stream output is in a sense cleaner than the ionized stream output from prior ionizers, and the electrodes tend to have greater longevity.
Also, by in a sense covering the electrodes 16 to keep them from contacting the fluid 20a in the channels 20, e.g., by the separation provided by the honeycomb structure 12, the electrodes are not ion donors. Therefore, there tends to not be ion breakdown, reversion or self-grounding of the ions. As the electrodes do not contact the fluid, especially ionized fluid, the electrodes do not contribute electrons to the ions that would bring the ions back to a ground state.
From the foregoing, it will be appreciated that volumetric efficiency of the ionizer in terms of ions produced is rather substantial compared to prior ionizers.
Ionized output of the ionizer tends to be relatively efficient, in a sense tends to be maximized in its utility, by minimizing ion mixing due to the above-mentioned laminar fluid flow and flow rate as well as the post formation (production of the ions in the ionizer) grounding by contact with other ions, electrons and non-ionized fluid, e.g., air, outside of the ionizer, as laminar flow tends to be maintained for a substantial distance beyond the outlet of the ionizer.
As is described in greater detail below, if a circumstance were to occur that the ionizer assembly 10 becomes hotter than desired for desired operation, for example, due to the input electrical voltage being greater than usual, e.g., due to a power surge, due to operating at relatively high voltage and/or frequency, etc., so as to cause hot spots, excessive corona, or possibly electrical arc in the fluid channels, the fluid 20a may be used not only to cool the capacitor assembly but also to tend to blow out from a channel a hot spot, an excessive corona discharge or the electron leakage at the start of a corona discharge buildup, etc. thereby to avoid break down of the dielectric, e.g., the fluid and/or the honeycomb structure. Such capabilities of the ionizer assembly 10 leads to a robust apparatus. Also, as will be appreciated, a number of ionizer assemblies 10 may be used together to increase the output of ions therefrom. The ionizer assembly may be modular in that a number of them may be used together; similarly, the ionizer subunits 11 are modular and more or fewer of them may be used in the ionizer assembly 10. The ions/ionized fluid may be used for a number of purposes such as, for example, deodorizing, such as deodorizing a room, furniture that was smoke damaged, etc. Also, the ions/ionized fluid may be used to kill undesirable matter, such as mold, etc.
One or more of the following advantages may be obtained in an ionizer according to the invention:
No metal surface is in contact with the ionized fluid, and this avoids metal in the ionizer output and avoids degrading of the electrodes. Also, ion reversion is avoided, e.g., recombining of ions or ions with electrons to return an atom or molecule to its ground state. The honeycomb structure maintains relatively accurate spacing of the electrodes without the need for careful machining to make the honeycomb, and the honeycomb structure provides relatively large fluid flow channels that do not present such high fluid back pressure that would require a relatively high powered centrifugal blower to blow fluid through the channels, and, therefore, a relatively less expensive blower may be used. The honeycomb structure may be made of a polymer, e.g., polycarbonate, which advantageously does not promote combustion, or of other suitable material that in most instances would be less fragile/more durable than the glass tube electrodes used in one of the above-mentioned prior ionizers. The ionizer provides a relatively robust ionized output or output of ions or ionized fluid in that the ions tend not immediately to combine and revert to a nonionized state within or outside the ionizer (post ionizer); and due to the relatively unimpeded laminar flow in the channels and the robust ionized output, the output from the ionizer may be a relatively highly directed stream of ions that projects from the exit of the ionizer a substantial distance, e.g., on the order of twenty feet or more from the exit, without diffusing or mixing internally.
Referring now to
In an embodiment of the invention there are a number of channels 20 and they are relatively deep, e.g., much longer than the smaller of the respective cross sectional dimensions thereof, which straightens fluid flow and thus promotes laminar flow through the channels. In the illustrated embodiment of
In the illustrated ionizer assembly 10 the flow channels 20 are of substantially the same cross sectional size and shape and substantially the same length. This shape, size and arrangement helps to assure substantially equal flow of fluid through the flow channels or containment of fluid therein for substantially uniform corona generation, cooling, and substantially uniform electrical characteristics, etc. over the area of each respective ionizer 17, ionizer subunits 11 and the ionizer assembly 10, as may be desired.
The honeycomb structure 12 may be made from electrically non-conductive material, e.g., glass, ceramic, clay, plastic, thermoplastic, acrylic, polycarbonate, polypropylene, polyethylene, phenolic, etc. or the like. The honeycomb structure 12 may be made by any suitable method (e.g., extrusion, molding, machining, etc.). A suitable commercial example of honeycomb structure 12 is manufactured by GALLINA USA LLC of Janesville, Wis., USA and is sold under the trademark or designation “POLYCARB.” The POLYCARB multi-wall honeycomb structures are coextruded polycarbonate sheets. The sheets, which are generally parallel to the electrode 16 may be twin-wall, e.g., two layer form, as is illustrated in
The electrodes 16 of ionizer subunits 11 are on or at the external surface of a dielectric sheet 13, 14, i.e., not the internal surface of the dielectric sheet that faces directly into or forms channels 20. For a stack of ionizer subunits 11 that form the ionizer assembly 10, it will be appreciated that two electrodes 16a, 16b adjacent a respective honeycomb structure 12 are at the external surfaces of dielectric sheets 13, 14 thereof and those electrodes are relatively uniformly spaced apart from each other over their area by the honeycomb structure 12. Those electrodes 16 are not in the channels 20 and do not make contact with the fluid in the channels. The electrodes that are located between two directly adjacent ionizer subunits may be shared with the two other electrodes at the relative remotely opposite dielectric sheets of those ionizer subunits as is illustrated.
As a non-limiting example, for use with alternating current (AC) voltages in the range of from about 4000 volts to about 15,000 volts rms, a thickness of the honeycomb structure 12 may be approximately 6 millimeters as measured between the external surfaces of the sheets 13, 14. For operation using a direct current (DC) voltage, the ionizer may need a higher voltage to operate, e.g., on the order of from about 15,000 volts to about 20,000 volts. The voltages expressed herein are exemplary only and others may be used to achieve ionization of fluid by the ionizer assembly 10. Exemplary cross sectional size of the channels 20 for such honeycomb may be about 3/16 inch by about 3/16 inch. A smaller size honeycomb structure material from GALLINA USA LLC is 4.5 millimeter thick and may be used, but the smaller cross sectional size channels 20 may cause undesirable back pressure opposing the fluid flow therethrough and also may impede uniformity of fluid flow. Larger size honeycomb structures also are available and may be used.
The sizes and other values expressed herein are examples; others may be used depending on various requirements of the ionizer assembly.
Another example of coextruded twin wall (two layer) polycarbonate sheet material useful as the honeycomb structure 12 is sold under the trademark MAKROLON by Sheffield Plastics Inc. of Sheffield, Mass.; and others are available from TAP Plastics, Inc. and COEX Corporation of Wallyford, Conn. LEXAN polycarbonate material sold by General Electric Company also may be used for the honeycomb structure 12.
An advantage to using polycarbonate material for the honeycomb structure 12 is that it does not support combustion. The cooling provided by fluid in the channels, e.g., air flow or some other fluid, and the tendency for the honeycomb structure to not be combustible, tends to enhance safe operation of the ionizer assembly 10, even at high voltage and/or high frequency operating conditions or uses. Although the ionizer assembly 10 would function as an ionizer at many different voltages, the ionizer assembly is useful at relatively high AC voltages, e.g., from about 400 volts to about 15,000 volts rms or even higher voltages and standard pressure. The ionizer also may be useful at lower voltages, although less sophisticated ionizers may be more cost effective at relatively low voltages. The ionizer also is operative at many different frequencies, even for direct current (DC) circuits; exemplary frequencies are in the range of from about 60 Hertz to about 120 Hertz, but other frequencies may be used. The values mentioned herein are exemplary only and are not intended to be limiting. The ionizer may be operative using a DC voltage input or a pulsed DC voltage input.
A honeycomb structure 12 with ribs 15 providing walls separating respective flow channels 20 prevents an inadvertent or excessive corona within a fluid channel from spreading to another fluid channel. This in combination with the directed fluid flow affected by the channels helps to “blow out” any excess electrical discharge.
The honeycomb structure 12 is available in a number of thicknesses and colors. Some readily available thicknesses include, for example, 4 mm, 6 mm, 8 mm and 10 mm, as measured between the exteriors of the respective sheets 13, 14. Other thicknesses also are possible. The honeycomb structure may be colored or clear. An exemplary honeycomb structure 12 is a clear UV stabilized polycarbonate. The honeycomb structure 12 is available in large sheets and may be cut to desired dimensions. Exemplary standard sheets of the described honeycomb material are available in 4 feet by 8 feet sheets; extended lengths of 20 feet or more may be available. An example of cross-sectional size of the honeycomb structure 12 for the ionizer assembly 10 is 6 inches by 6 inches; however, such sizes are not limiting and it will be appreciated that other sizes may be used.
As is illustrated in
Substantially uniform spacing of the dielectric sheets 13, 14, and substantially uniform spacing of the ribs 15, and, if possible, spacing of the ribs such that the cross section dimensions of the channels 20 are about the same, which together tend to yield uniform channels 20, leads to substantially even fluid flow and substantially uniform cooling effect. Eliminating electrical stress points tends to minimize single point breakdown in structure, and this combination with uniform cooling tends to provide an arc or corona quenching effect, e.g., the blowing out of an electric arc, and tends to maintain even temperatures that protect the material, e.g., plastic or polymer, of which the honeycomb structure 12 is made.
In the exemplary embodiments illustrated, honeycomb structure 12 with substantially parallel, substantially planar, and overlying or stacked dielectric sheets 13, 14 is used. Though the honeycomb 12 is illustrated as having dielectric sheets 13, 14 of the same thickness, the thickness of the respective sheets 13, 14 does not necessarily have to be the same. However, the thickness of each of the honeycomb structures of the ionizer assembly 10 is substantially the same in the illustrated embodiments. The walls of the dielectric sheets 13, 14 provide in a sense a static, e.g., unchanging, dielectric as compared to the possibly changing ionization and/or dielectric characteristics of the fluid 20a flowing in channels 20. Although the honeycomb structure 12 is illustrated as having two substantially parallel dielectric sheets, honeycomb structure material with more than two dielectric sheets may be used in the ionizer assembly 10, e.g., three or more spaced apart dielectric sheets, which may be in parallel planar and overlying relation. An example of a tri-wall honeycomb structure 12b is illustrated in
The ribs 15 may be made of dielectric material and may be made of the same material used to make the dielectric sheets 13, 14. The ribs 15 may be substantially planar and arranged substantially perpendicular to the sheets 13, 14, as illustrated. It should be appreciated, however, that the ribs 15 may have alternative configurations. For example, instead of ribs 15 configured as illustrated, tubular structures formed from dielectric material may be disposed between the sheets 13, 14. In such a configuration, the interior space of the tubular structures may define a channel 20. The space exterior to the tubes and between the sheets 13, 14 also may serve as channels 20. In yet another contemplated embodiment, a thin dielectric material, may be disposed between the two substantially parallel sheets 13, 14 instead of or in addition to ribs 15. Such dielectric material may be similar to material used to form the sheets 13, 14, or may be another material. Instead of being substantially parallel to the two sheets 13, 14, however, the dielectric material may have a sinus wave shape cross section (similar to corrugated cardboard), a ‘zig-zag’ shape cross section (similar to the shape of multiple W's), or an alternative configuration. In such a manner, channels 20 may be formed between the sheets 13, 14 in the open areas provided by the ribs and sheets 13, 14. Alternatively, a piece of solid dielectric material could be provided and channels 20 could be drilled or cut in the material.
The ribs 15 tend to hold the sheets 13, 14 relatively uniformly spaced apart and the use of more than two ribs to provide relatively uniform spacing allows for the use of thinner sheets in making relatively large area honeycomb structures 12 than would be possible without more than two ribs. The use of two or more ribs in this configuration also allows for the use of thinner dielectrics or dielectric sheets for a rated voltage of the capacitor. The use of thinner dielectric material for the sheets 13, 14 also may allow for the material to be cooled more easily since the material will have less of a tendency to store heat than thicker sheets and can more easily transmit heat between the electrodes 16 and the fluid 20a, which may remove heat from and, thus, cool the ionizer assembly 10.
Separation of the flow channels 20 from each other may avoid a cumulative heat problem, for example, as follows. Ionization of gas usually occurs more easily at a higher temperature than at a relatively lower temperature, and if the ionizer assembly 10 were to generate heat, heat pockets may form; resistance to fluid flow due to a heat pocket may build in one or more flow channels 20. The fluid may begin to flow around these areas of higher fluid flow resistance and the ionizer assembly 10 may not be cooled evenly and/or efficiently. As heat builds in an area of the ionizer assembly 10, there may be a tendency for an arc to occur in that area, further raising the temperature of the fluid and the materials in that area, e.g., the honeycomb and/or the electrodes. Hence, the hot spot area may become prone to material breakdown or thermal failure, for example, crystallization, melting, pitting or burning of the electrodes 16 and/or the honeycomb structure 12. By dividing the volume of air space between the dielectric sheets 13, 14 of a honeycomb structure 12 into multiple flow channels 20 and generally maintaining even fluid flow through the flow passages, the tendency to develop such fluid flow resistance may be decreased and the ability to cool and the efficiency of cooling the ionizer assembly 10 may be increased. The fluid flow in these passages tends to be smooth and relatively turbulence free (laminar-like) which enhances cooling efficiency.
As another alternative, the fluid used to cool and/or supply the ionizer assembly 10 may be recycled. For example, the ionizer assembly 10 may be disposed in a closed case, room, closet, etc. in which a recirculating gas is contained. Dry gas, e.g., a gas that contains relatively little or no water (moisture), may be used, for example, because it has a higher ionization potential than humid air or gas. For example, in air the primary gas constituent that requires the greatest voltage for ionization (ionization potential) is nitrogen, oxygen is second, and water is third. Water acts as an electrical conductor and when it is in the gaseous state facilitates electrical conduction in air; thus to avoid conducting electricity and the possible formation of an arc discharge in air (or other fluid) flowing through the channels, it is advantageous to minimize moisture in the air. The air may be dried or another gas, e.g., nitrogen that does not contain moisture, may be used. The fluid may be directed through the channels 20 of the ionizer assembly 10, through the case where the ionized fluid may be used to do work or to have some effect, etc., and where the fluid also may be treated, e.g. cooled, dried, filtered, and electrically grounded to reduce its conductivity and potential to arc, etc., and back through the channels 20 of the ionizer assembly. The case may sink heat away from the gas and the ionizer assembly, thereby cooling the entire ionizer assembly 10 and case. Instead of using the case to sink heat, the fluid may be passed through the channels 20 and then through a fluid cooler (e.g., a heat exchanger) before recycling through the channels 20. The case also may provide for electrical grounding to discharge the fluid 20a before being recycled through the ionizer assembly 10 and/or exhausted from the ionizer assembly.
Referring now to
The electrode 16 may include an adhesive 25 to facilitate attachment to a respective sheet 13, 14 or an adhesive 25 may be located on a sheet and used to adhere the electrode to the sheet. An advantage of using adhesive backed electrically conductive tape is the cushion effect of the adhesive, which helps fill voids and, thus, enhances conformance to irregularities in the dielectric sheet. Instead or in addition to adhesive, the sheets 13, 14 may be provided with mechanical connectors that mechanically engage the electrode or reciprocal connectors on the electrode 16. Alternatively, the electrode 16 may be taped or otherwise fastened in the correct position or held in place by an adjacent ionizer subunit 11. Other possible methods of locating the electrode 16 at a sheet 13, 14 will occur to those skilled in the art and are intended to be included in the scope of the appended claims. In an optimum circumstance, for example, on the one hand the electrode 16 would be between two dielectric sheets of respective ionizer subunits 11, and there would be no voids or space, etc. between the confronting surfaces of those two dielectric sheets; by avoiding such voids or space, the likelihood of corona discharge or electric arc formation therein is avoided.
In the illustrated embodiment of
As is seen in several drawing figures, the electrode 16 is positioned in spaced apart relation from three of the side edges 28 of the honeycomb structure 12, as is represented by space 28a, to avoid electrical leakage from one electrode to another electrode around the edge of the honeycomb dielectric 12.
Referring now to
Instead of folding the excess material portion 26 at this point, a plurality of ionizer subunits 11 may be assembled in overlying relation, e.g., as is seen in
Each ionizer subunit 11 may be made in the same manner and with the same configuration. This would facilitate production of the ionizer subunits and may help increase overall quality and consistency of the ionizer subunits and the ionizer assemblies 10.
Referring now to
A plurality of ionizer subunits 11 is shown. In the illustrated exemplary ionizer assembly 10, six ionizer subunits 11 are provided. Starting at the top of
Thus, it will be appreciated that the respective electrodes 16a and their associated tabs 18a may be exposed at one part of the ionizer assembly 10 and the respective electrodes 16b and their associated tabs 18b may be exposed at another part of the ionizer assembly 10, not in direct electrical connection with the electrodes 16a. In this way it is relatively easy to electrically couple respective electrodes 16a together and to the electrical circuit 19 and respective electrodes 16b together and to the electrical circuit 19.
In the illustrated embodiment of
As shown in
As shown in
As shown in
Referring now to
As is seen in
As shown in
In the embodiment of FIGS. 12 and 13A-13D the notch 34 is rectangular cross section. In the embodiment of
According to the illustrated embodiment of
After the ionizer assembly 10′ components are in their appropriate configuration (orientation), they may be mechanically and electrically connected to form a functioning ionizer assembly 10′. Threaded rods 33 are provided for this purpose. If desired, around at least a portion of the rod 33 there may be placed an electrically conductive engaging material 41. This conductive engaging material may be, for example, a piece of conductive foil or a conductive sleeve. The threaded rod 33 is inserted through the sleeve 41 and the assembly is pushed into the notches 34 formed in the base 11b, the top 11t and the ionizer subunits 11′. As illustrated in
If desired, electrically conductive material 41a, e.g., some slightly crushed aluminum foil (
In the illustrated exemplary embodiment the threaded rod 33 approximately is the same height as the ionizer assembly 10′, as shown. A washer 42 and a nut 43 may be attached to each end of the rod 33 to join and hold the ionizer assembly 10′ together in operational relation. The rod may be a bolt to hold the stacked ionizer subunits together between the bolt head at one end and washer and nut at the other end. Other devices, such as clamps, rivets, tape, bands, etc., e.g., as are described herein, alternatively or additionally may be used to hold the parts of the ionizer assembly 10′ together. The use of rod 33, sleeve 41, washer 42 and nut 43 can be suitably tightened to hold the parts of the ionizer assembly 10′ securely together, e.g., to press or to squeeze these together, to tend to minimize air or other fluid in areas where not desired, e.g., between an electrode and the sheet material of a honeycomb structure or between sheet material of respectively adjacent honeycomb materials and between the top and bottom ionizer subunits and the top and base of the ionizer assembly 10′.
A recess 44 in the base 11b allows for recessing the end of the threaded rod 33, the washer 42 and the nut 43 from the surface of the base and allow for a flat surface on the bottom of the ionizer assembly 10′. In the illustrated embodiment, the recess is formed by making a groove approximately ¼″ (one fourth inch) deep and about 7/16″ (seven sixteenths inch) wide across the base 11b in a straight line from approximately the midpoint of one side to the midpoint of the opposite side of the base. The groove is centered over the notches 34 or 34v. Using a groove, instead of a more traditional recess such as, for example, a wide hole around the washer and nut, allows for lower tolerances since the rod can shift in toward the center of the ionizer assembly 10′ (providing improved electrical contact with ionizer electrodes) or out toward the edge without having to adjust the recess location. The recessed nut and bolt allow the base to be flat to rest securely on another surface on which it is placed, if desired.
The ionizer assembly is self-supporting structure even by its own dielectric, e.g., the honeycomb structure and/or in that the components are retained together as described and also the top and base facilitate supporting the ionizer assembly on a surface, in a case, etc., and stacking of capacitor assemblies, as well as side-by-side placement.
The rod 33 and, if used, the conductive engaging material 41 are selected so the outer diameter of the rod and engaging material is approximately equal to the width of the notches 34. When the rod and engaging material firmly engage the notch and the ionizer components in stacked relation, no or extremely limited movement is possible in the vertical and horizontal directions, keeping the entire ionizer assembly 10′ in the illustrated operational configuration. Also, the base 11b and top 11t members protect the ionizer from physical damage, electrically insulate the top and bottom, and may facilitate securing the ionizer assembly 10′ in a machine or other support structure, case, etc., without damaging what may be more fragile material of the respective ionizer subunits 11′.
In
Referring now to
As shown in
As shown in
As shown in
In
Referring now to
The ionizer assembly 10, 10′ may function as an ionizer or as a capacitor, which may be determined by adjusting the flow rate of air 20a (or other fluid) flowing through channels 20. Whether the ionizer assembly 10, 10′, functions as an ionizer or as a capacitor may be determined by adjusting the flow rate (one complete replenishment of air in the flow channels 20) relative to the duty cycle. The time it takes for one complete replenishing of air (or other fluid) in the flow channels also may be referred to as the residence time. If the flow rate is approximately equal to or greater than the duty cycle, the unit 10, 10′ functions as a capacitor by blowing out the electrical arc or corona discharge, e.g., because the electrical arc or corona discharge or the start of fluid breakdown and, thus the tendency to create an electrical arc or corona discharge in the fluid quickly is blown out of the flow channels 20. If the flow rate is less than the duty cycle, the unit 10, 10′ functions as an ionizer by creating or promoting corona discharge in the fluid 20a and, thus, ionizing the fluid or at least some of the fluid in the flow channels 20.
Other factors that may determine whether the ionizer assembly functions as an ionizer or as a capacitor may include, for example, voltages, duty cycle, and/or frequency of the input power supply to the ionizer assembly, the thickness of the honeycomb 12, the material of which the honeycomb is made, the dielectric characteristics of the honeycomb and/or the fluid 20a, the material used for the electrodes 16, and possibly other factors.
Referring now to
As is illustrated schematically in
The control 62 may be a digital control, computer control, other electronic circuitry, programmed logic device, etc. to determine operation of at least part of the ionizer system 60, for example, as is described below. It will be appreciated that the description with regard to
It is possible that during operation of the ionizer assembly 10, as is illustrated in
In operation of the ionizer assembly 10, as illustrated in
In the present invention, if it were desired to eliminate arcing in fluid in the flow passages 20 and/or at least to try to reduce or to minimize the occurrence of such arcing, the blower output may be adjusted, e.g., increased to ensure that the flow rate of fluid in the flow through channels 20 is relatively fast at or near flow required to fill ionizer volume for one half duty cycle so that any electrical arc that would tend to occur in the channel would be blown out of the channel before a substantial amount of charring damage, etc. has occurred. As an example, since the electrical input to the ionizer assembly 10 ordinarily would be an alternating current (AC) signal (voltage) of a given frequency, it would be advantageous to avoid or to tend to minimize arcing of fluid in the channels 20 by using a flow rate through the channels that is at least as fast as one half the duty cycle of the mentioned AC signal. According to this example, if the AC signal were at 60 Hertz, one half cycle requires about eight milliseconds; so the flow through the channels 20 would be at a speed that takes approximately less than 8 milliseconds to change the air in each channel or faster to tend to minimize the exposure of fluid in the channels 20 to a voltage that is at or above the breakdown voltage of the dielectric.
With further reference to
Briefly referring to
Although the invention is shown and described with respect to certain illustrated embodiments, equivalent alterations and modifications will be obvious to others skilled in the art as they read and thus come to understand this specification and the annexed drawings. Dimensions, materials, weights, etc., described herein are only exemplary and others may be used in the cases provided in accordance with the invention. In particular regard to the various functions performed by the above described components, the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one of the several embodiments, such features generally can be combined with one or more other features of any other embodiment as may be desired and advantageous for any given or particular application.
Although particular embodiments of the invention have been described in detail, it is understood that the invention is not limited correspondingly in scope, but includes all changes, modifications and equivalents coming within the spirit and terms of the claims appended hereto.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/886,612, filed Jan. 25, 2007, the entire disclosure of which is hereby incorporated by reference.
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