Embodiments of the invention relate generally to liquid disinfectant devices that rely on the introduction of copper and/or silver ions into a water stream.
Certain metal ions, for example copper and silver ions, can be used for disinfecting a liquid. In one arrangement, a group of copper-silver alloy electrodes are aligned in a flow cell with a DC current and voltage applied to the electrodes, so that ions are released into the liquid that flows through the cell and promotes killing of microorganisms.
The emissions of an ionization process include surface-active cations, which provide a potent biocide. The disinfection action is attributable to the positively-charged copper and silver ions which form electrostatic bonds with negatively charged sites on microorganism cell walls. These electrostatic bonds create stresses which lead to distorted cell wall permeability, reducing the normal intake of life-sustaining nutrients. This action, coupled with protein denaturation, leads to cell lysis and death. Bacteria are killed rather than merely suppressed as in the case with alternative control methods. These ions eradicate or minimize various microorganisms in liquids, including but not necessarily limited to: Legionella, E. coli, Salmonella, M. avium, Listeria, Staphylococcus and Pseudomonas aeriginosa.
In one embodiment, the invention is a liquid purification apparatus, including a flow cell having an opening at each end for conducting a liquid therethrough. The liquid purification apparatus also includes a pair of electrode plates disposed within the flow cell, each electrode plate comprising an elongated rectangle having a length, width, and thickness, the length and width defining a face of each electrode plate, the width being greater than the thickness. The electrode plates are arranged such that the faces of the electrode plates are parallel and opposite one another with a gap therebetween.
In another embodiment, the invention is a method of disinfecting a liquid. The method includes providing a flow cell having an opening at each end for conducting a liquid therethrough. The method also includes disposing a pair of electrode plates disposed within the flow cell, each electrode plate comprising an elongated rectangle having a length, width, and thickness, the length and width defining a face of each electrode plate, the width being greater than the thickness. The electrode plates are arranged such that the faces of the electrode plates are parallel and opposite one another with a gap therebetween. The method also includes applying a voltage to the electrode plates and contacting the electrode plates with the liquid.
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
Certain metal ions, such as copper and silver ions, can be used for liquid purification. A typical electrode arrangement is one wherein copper and silver alloyed or compounded bars are in the form of elongate electrodes that are square in cross section. The present invention can be used with alloys having various compositions, including various materials in varying percentages, but in one embodiment the alloy has 30% silver and 70% copper. The electrodes are disposed within a flow cell so that ions are released into the liquid passing through. A flow cell typically includes a cylindrical housing (although other shapes are possible) having an opening at each end through which a liquid (usually water) passes. The flow cell generally includes connectors or is otherwise adapted at each end to be joined to a flow system. In one embodiment, the flow cell is constructed from C-PVC plastic. In various embodiments, the flow cell and other components of the liquid disinfecting system described herein are made from materials that are approved by the National Sanitation Foundation (NSF).
In the prior art system, the electrode bars are arranged in the flow cell as a subassembly of juxtaposed pairs, such that two pairs of juxtaposed pairs, totaling four in number, are arranged with the longitudinal axes of the bars being parallel to direction of liquid flow. In some cases, two such subassemblies are used, arranged end to end, so that there are four pairs of electrodes arranged with their longitudinal axes being parallel to each other and parallel to the direction of liquid flow. A typical dimension for the individual bars is one inch square by seven inches long. Electrodes of this arrangement are described in U.S. Pat. Nos. 6,126,820 and 6,325,944, each incorporated herein by reference in its entirety.
In normal operation the electrodes are sacrificially consumed under the influence of what is typically a direct-current (DC) electric voltage applied across the electrodes. One of the electrodes serves as cathode and the other as anode. In some embodiments, the polarity of the applied DC voltage is reversed occasionally (i.e. the electrode that was cathode becomes the anode, and vice versa). The system can include a controller with a power supply that can apply up to 100 volts DC at up to 10 amps of current, although other power levels are also possible. The DC voltage applied to the electrodes in turn influences an electric current that passes through the water from one electrode to the other. It is expected that in normal operation the electrodes will be consumed (since ions are released from the electrodes into the liquid) and will eventually need replacement.
Although sacrificial consumption of the electrodes is expected, the consumption experienced in the current conventional electrode configuration has been an ongoing problem presenting a number of undesirable product and operational situations. Among the problems are: (i) the electrodes have a reduced useful life; (ii) the electrodes erode in a manner which rounds off the corners of the confronting, or opposed, electrode surfaces, producing a crowned surface on each electrode, which reduces the active surface area and therefore ion generation and/or degrades the effectiveness of operation; and (iii) the rounding and crowning of electrodes leads to a need for early replacement, resulting in an inordinate amount of electrode material scrap.
The electrodes may also be subject to erosion by the water that is running through the flow cell and being treated. Erosion is caused by the water flow over and past the electrodes and is in addition to, and is to be distinguished from, the sacrificial phenomena inherent in normal operation.
Yet another problem with the prior art electrode arrangements is that the electrodes become coated with calcium, magnesium, and other minerals that are present in the water being treated. This can be detrimental to effective ion generation and, thus, to operation of the flow cell disinfectant system. The presence of a mineral coating requires periodic cleaning and/or replacement of the electrodes.
The asymmetrical wearing (e.g. rounded corners) and coating can have a negative impact on the electrical qualities of the system. The amount of voltage available at most building or other sites where the disinfectant system may be installed is limited, typically to about 100 volts DC. As wear and/or coating progress, the amount of voltage required to achieve desired ion generation increases, ultimately reaching the upper limit of available voltage, at which point the efficacy of the system begins to diminish. Furthermore, operating at higher voltage levels increases the heat that is generated in and around the electrodes.
Extended, continuous system operation is the goal of an efficient treatment system. The problems discussed above run contrary to that desired objective.
Thus, objects of the present invention include extending the life of the electrodes, reducing the amount of scrap material remaining when an electrode has reached the end of its useful life, and improving the basic operation of the system.
A brief description of a typical prior art arrangement will assist in the understanding of advances achieved by this invention. In
The prior art electrodes are square bars, for example one inch by one inch in cross-section and seven inches in length. Thus, each electrode provides seven square inches of operative surface area, or a total of twenty-eight square inches of operative surface, when four pairs of electrodes are used. When four pairs of electrodes are used, the electrodes may be arranged in the flow cell in two groups of four electrodes arranged end to end in the direction of water flow.
A reference point for electrode orientation is selected as the longitudinal axis X-X′ of the flow cell illustrated in perspective in
After use in a typical water system the electrodes 16a and 20a become rounded as illustrated in
The operational significance of the dome shape is that the current flow influenced through the water by a voltage applied across the electrodes will seek the shortest path. This concentrates the current between the outermost portions of the domed surfaces, i.e. along line 30 in
Using fresh electrodes, current will flow between the opposed electrode surfaces across the entire operative surface. That exposes considerably more electrode surface to electric energy and thus results in greater ion generation for a given voltage across the electrodes compared to the amount of ion generation that will result from the current being concentrated at the outermost tip of the domed electrodes (
With reference to
As the just-described coating increases and rounding of the electrode progresses, an increasing amount of voltage is required to maintain ion generation. Eventually the upper limit of voltage available for application across the electrodes (typically 100 V) may be reached, such that no more voltage is available for application to the electrodes, and ion generation falls off. As this condition progresses the electrodes may need to have the mineral coating periodically cleaned off. As coating/cleaning and rounding of the electrodes progresses, a point will be reached where the operational surface area of the electrodes may become too small and the electrodes may have to be replaced.
This invention proposes an electrode configuration where a pair of wider electrodes 40 and 42 are arranged in the flow chamber, see
In one embodiment of this invention, the individual electrodes are each two and a half inches wide, five-eighths of an inch thick, and fourteen inches long. This provides an operative surface area of thirty-five square inches if two electrodes are used and seventy square inches if two sets of such electrodes are used. With reference to
The electrodes 40 and 42 have lateral faces 56, 58 and 60, 62, respectively. Faces 56 and 60 are adjacent to a portion of an inner wall of the flow cell and the other faces 58 and 62 are adjacent an inner wall portion of the flow cell that is diametrically opposite to the inner wall portion of the flow cell to which edges 56, 60 are adjacent. Therefore, the electrodes extend continuously from one edge to the other, defining a continuous ion generating electrode operating surface across the flow cell. This defines a water flow passage between the flat, planar electrode operating surfaces. The operating surfaces extend from adjacent one interior portion of the flow cell wall continuously across the center line of the flow cell (axis X) to a diametrically opposite portion of the internal flow cell wall. Relative to water flow this defines a flow passage between the operating surfaces of the electrodes that is continuous and uninterrupted, and which encompasses the mid portion of the flow cell (axis X) and extensions on both sides of that mid portion up to portions of diametrically opposite portions of inner walls of the flow cell.
Similarly, and with reference to
It has been observed that the electrodes configured in accordance with this invention have operated over time with the following improved characteristics.
Erosion of the electrode material, to the extent this is present, is relatively uniform across the operational surfaces, eliminating the rounding or domed effect of the prior art configuration. The sacrificial consumption of the electrodes is also uniform across the operational surfaces of electrodes. This provides consistent ion generation within available voltage sources. It results in consumption of virtually the entire amount of available electrode material. The criteria determining when the electrodes have to be replaced becomes not when the electrodes cannot function adequately in response to the electrical power available but when it consumed beyond its physical, structural integrity. This also means little of the electrode material is left to scrap.
Another advantage which has been observed is the electrodes of the present invention, over extended periods of usage, are not subjected to the coating of minerals from the water being treated. This can be seen, for example, in
Accordingly, the deleterious effects of uneven wear due to erosion or material sacrificing, and uneven coating with impurities, have each been reduced or eliminated. The electrodes of this invention are capable of extended, uninterrupted usage and continue to operate well within the voltage available from conventional power sources.
Whereas the prior art arrangements usually required cleaning on a monthly basis or more frequently and usually had to be replaced when substantial electrode material was still present, electrodes of this invention have operated without requiring cleaning for a period of months and the electrodes when discarded will have been substantially consumed and not left to scrap.
It is understood that the improved operation is the result of several unexpected operational phenomena.
Because the electrodes present a continuous surface to the water from one wall of the flow cell across the mid point of the cell (longitudinal axis X) to an opposite portion the wall of the flow cell, the turbulence that was present with the prior art is substantially reduced. The prior art arrangement of four electrodes within the center of the flow cell, as opposed to two electrodes in the same space as in the present invention, presented an interrupted flow passage producing turbulence in the areas of electrodes. Other prior art arrangements in which two sets of four electrodes were arranged along the axis of flow, with space between the two sets, generates even more turbulence.
The configuration of the present invention provides quiet, substantially laminar flow and no deleterious turbulence, giving a better flow dynamic for the effective operation of the electrodes. Turbulence is believed to have contributed to both the uneven erosion and rounding of operational surfaces in known systems as well as to the coating of the electrodes with impurities such as mineral deposits.
The electrodes of this invention also operate at consistently lower temperature than the prior art electrodes. Elimination of the rounding effect and coating allows the electrodes to operate at a lower voltage, thereby generating less heat.
Also, the thinner, uninterrupted electrode configuration provides one which dissipates the heat that is generated more readily. In summary, the inventive electrodes run more electrically efficient and cooler overall.
Other thickness, width and length combinations are possible so long as the opposed, continuous operating surfaces extending across the full width of the flow passage are maintained. Some such combinations are set forth below.
Another measure for defining the configuration of the improved electrode configuration is, whereas the ratio of width to thickness in the prior art electrodes was 1:1, the ratio of width to thickness in accordance with some embodiments the present invention is in the range of 4:1. In various embodiments, the ratio of the width to the thickness is 1.1:1, 1.25:1, 1.5:1, 2:1, 3:1, 5:1, 10:1, or greater. In still other embodiments, the ratio is that which is embodied in the dimensions of the electrodes set forth below as alternative embodiments.
In some embodiments the fasteners protrude from the surfaces of the electrodes into the gap between the adjacent electrodes. However, in other embodiments, the opposing faces 48, 50 of the electrodes 40, 42 are substantially flat and free of any protrusions related to fasteners or other sources (e.g.
In some embodiments (e.g.
In other embodiments (e.g.
In some embodiments (e.g.
In other embodiments (
In still other embodiments, the support blocks 100 are diamond-shaped (
The support blocks 100 typically have openings to accommodate fasteners 150 (
In one embodiment, the invention provides for a replacement or retrofit kit for a flow cell. The kit can include a pair of electrode plates, one or more support blocks for mounting the electrode plates to the flow cell, and one or more fasteners for attaching the electrode plates and support blocks to the flow cell.
Priority is hereby claimed to U.S. Provisional Patent App. No. 61/069,112 filed on Mar. 12, 2008, the entire contents of which are incorporated herein by reference.
Number | Date | Country | |
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61069112 | Mar 2008 | US |