Patent Application
20120061251
The present invention is an electrolytic cell structure and associated process, preferably used for hydrolyzing water from a saline solution into a plurality of mixed oxidant solutions.
Electrolyzed oxidizing water (“EOW or “EO”), also known as electrolyzed water, electrolyzed oxidizing water, electro-activated water, or electro-chemically activated water solution, is formed by adding a small amount of sodium chloride (NaCl) to water and conducting a current across an anode and cathode, and through the NaCl solution, typically within a reactor apparatus. The cathode produces alkaline, reducing water, which is often referred to as the catholyte; whereas the anode produces acidic, oxidizing water, which is often referred to as the anolyte.
Most typically, the reactor within which this electrolytic process occurs further provides for at least some degree of separation of the catholyte and anolyte. The extent to which the electro-chemical reactions are allowed to proceed, along with the degree of separation or mixing of the catholyte and anolyte, will define the composition and properties of the resulting solution(s), including pH.
In many reactions, the principal byproduct solutions are sodium hydroxide (NaOH), the catholyte; and hypochlorous acid (HClO), the anolyte. Mixing of the catholyte and anolyte may further yield a solution of sodium hypochlorite (NaOCl). The composition and properties of the resulting solution(s) may then be used to determine an appropriate application for which the solution(s) may be used.
In use, electrolyzed water has been subject to claims for effectiveness in purging toxins from animal and human bodies, to hydrate the body, to attract and neutralize free radicals, to restore balance to body chemistry, to enhance the delivery of nutrients, to make acidic foods and beverages more alkaline, and to support the immune system, amongst other qualities and uses.
Such claims notwithstanding, sodium hydroxide, sodium hypochlorite, and hypochlorous acid are all known to be disinfecting agents, and electrolyzed water is known to kill a variety of spores, viruses, and bacteria. Accordingly, electrolyzed water may be useful in a variety of mainstream applications, including for medical products, disinfection, cleaning, and decontamination. The acidic form of electrolyzed water may be used for rinsing food-preparation equipment and surfaces, and for washing fruits and vegetables, since electrolyzed water may be effective as a seed surface disinfectant and as a contact bactericide.
Currently available EOW reactors are most often constructed utilizing a cylindrical design. Within the cylindrical reactor housing is located one or more cylindrical ceramic tubes. In operation, the ceramic tube allows ionic exchange through the ceramic material, while limiting passage of liquids and gases.
Designs utilizing such ceramic tubes, however, are known to be difficult to construct and to maintain. For example, ceramic tubes are relatively more difficult and expensive to produce than, for example, a flat ceramic plate. Thus, scaling the size of such a cylindrical EOW reactor to meet commercial specifications may be limited by the ability to scale the size of the associated ceramic tubes. Ceramic tubes are also easily cracked and broken; therefore, cylindrical reactors must be handled carefully to avoid such damage, since the cost of ceramic tube replacement and/or maintenance can be high. Additionally, it has been reported that electrolyte flow rates through such devices can be difficult to maintain for a variety of reasons. Thus, it would be advantageous to be able to produce and use an EOW reactor that does not make use of ceramic, tubular components.
Accordingly, it is to the resolution and/or reduction of these noted deficiencies, utilizing an EOW reactor that does not make use of tubular ceramic components, that the present invention has been developed and is directed.
The present invention, in a preferred embodiment, is a non-cylindrical electrolytic cell structure with a preferably rectilinear, ceramic or other membrane, which is useful for hydrolyzing water from a saline solution into a plurality of mixed oxidant, anolyte and catholyte streams.
In a preferred embodiment, a first half of an electrode stack is represented, in order of construction, by a PVC plate, a rubber gasket plate, a titanium metal cathode plate, a rubber gasket plate, a PVC frame carrying a ceramic or other membrane, a rubber gasket plate, and a precious metal coated titanium anode plate.
A second half of an electrode stack comprises a mirror image of the first half; however, using a common precious metal coated titanium anode plate. Thus, the common precious metal coated titanium anode plate preferably comprises two precious metal coated titanium plates, which are bonded and held together by use and application of a clear silicone adhesive.
According to the preferred construction, then, the common precious metal coated titanium anode plate is followed by a rubber gasket plate, a PVC frame carrying a ceramic or other membrane, a rubber gasket plate, a titanium metal cathode plate, a rubber gasket plate, and a PVC plate.
Thus, in accordance with the design, construction, and operation of the electrolytic cell structure and electrode stack, positively charged sodium ions (Na+) within the liquid electrolyte pass from the electrolyte in the cathode compartment, through ceramic or other membrane, and to the negatively charged cathode plate; while, essentially simultaneously, negatively charged chloride ions (Cl−) pass from the liquid electrolyte in the anode compartment, through ceramic or other membrane, to the positively charged anode plate.
In use, a saline electrolyte solution, typically maintained at approximately 5000 ppm, is passed into the electrolytic cell structure. A DC voltage is applied to the electrolytic cell structure, either prior to or after passing the saline electrolyte solution into electrolytic cell structure, depending upon known electrical, steady-state, and other constraints and considerations attendant the use and operation of such a system.
The saline electrolyte solution passes through the electrolytic cell structure, wherein an anolyte and a catholyte are produced. Typically, the anolyte product is taken off to an anolyte storage means. The catholyte, on the other hand, is recirculated through the electrolytic cell structure, preferably through use of a PVC tee. The PVC tee preferably serves to reduce hydrogen gas carry-over into the anode compartments of the electrolytic cell structure. A first branch of the PVC tee allows the catholyte to recirculate through the electrolytic cell structure. A second branch of the PVC tee, operated in conjunction with a control valve, allows the catholyte product to be taken off to a catholyte storage means. The control valve preferably may be used to vary the flow rate of the catholyte product in relation to the flow of the anolyte product as a proportion of total flow through electrolytic cell structure.
In order to support the use and operation just described, the electrolytic cell structure might also be configured within a system preferably including a DC power supply and a mini programmable logic controller (“PLC Controller”). Certain other system elements are also optionally, but preferably, included, such as, without limitation, a conductivity measurement and control subsystem, a DC current limiting control subsystem, preferably-automatic pH control means for adjusting the pH of the anolyte solution produced by the electrolytic cell structure of the present invention, a water softener cylinder subsystem, interconnecting pipe work, one or more pumps, one or more salt tanks for the water softener subsystem and for the electrolytic cell structure of the present invention, mounting means preferably comprising a portable rig which supports all associated pipe work, associated instrumentation, DC power supply, water softener, salt tank(s), and the electrolytic cell structure of the present invention. Through the use of such additional system elements in association with the electrolytic cell structure of the present invention, uniform and high quality anolyte and catholyte streams can be produced at steady state, commercial flow rates, maintained (within shelf-life limits), and stored.
These and other objects, features, and advantages of the invention will become more apparent to those ordinarily skilled in the art after reading the following Detailed Description and Claims in light of the accompanying drawing Figures.
Accordingly, the present invention will be understood best through consideration of, and reference to, the following drawing Figures, viewed in conjunction with the Detailed Description of Illustrative Embodiments referring thereto, in which like reference numbers throughout the various Figures designate like structure and in which:
It is to be noted that the drawings presented are intended solely for the purpose of illustration and that they are, therefore, neither desired nor intended to limit the invention to any or all of the exact details of construction shown, except insofar as they may be deemed essential to the claimed invention.
In describing preferred embodiments of the present invention illustrated in the Figures, specific terminology is employed for the sake of clarity. The invention, however, is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner to accomplish a similar purpose.
In that form of the preferred embodiment of the present invention chosen for purposes of illustration, FIGS. 1 and 3-21 show non-cylindrical electrolytic cell structure 100 and associated features and component parts for hydrolyzing water from a saline solution into a plurality of mixed oxidant solutions. Accordingly, electrolytic cell structure 100, when assembled in final form, may be referred to as an EOW reactor.
As will be described in greater detail below, non-cylindrical electrolytic cell structure 100 of the present invention preferably comprises a preferably rectilinear, ceramic or other membrane used to produce separate anolyte and catholyte streams from an input saline/brine solution.
In the following detailed description of construction and component parts, it is assumed that electrolytic cell structure 100 is constructed in a horizontal orientation. Accordingly, each primary component of electrolytic cell structure 100 will be described, starting from a bottom and working upward.
It is noted that polyvinyl chloride (PVC) materials are preferably utilized in constructing individual elements of electrolytic cell structure 100, as and where indicated. PVC materials have been found useful for such applications due to their inherent, beneficial properties and characteristics, some of which include relative inertness with respect to the chemicals with which they are used, non-degradation in the humid environments in which they are used, ease of forming and machining, toughness and durability, resistance to impact, dimensional stability under a wide range of temperatures and conditions, market availability and ease of procurement, and relative low cost, to name but a few.
Similarly, certain individual elements of electrolytic cell structure 100 are preferably fabricated from a rubber material, as and where indicated. Rubber materials have been found useful for constructing such elements due to their relative inertness with respect to the chemicals with which they are used, non-degradation in the humid environments in which they are used, ease of formability, cutting, and punching, flexibility, durability, resistance to impact, ability to effectuate and maintain appropriate seals, dimensional stability under a wide range of temperatures and conditions, market availability and ease of procurement, and relative low cost, to name but a few.
Notwithstanding a preference for the use of PVC and rubber materials, as and where indicated, other materials meeting one or more of these properties and/or characteristics may also be used and/or substituted, where appropriate to the application of use and any associated specifications, without departing from the scope, disclosure, and spirit of the present invention.
In the preferred embodiment, electrolytic cell structure 100 further comprises non-cylindrical electrode stack 110. A preferred construction of electrolytic cell structure 100 and electrode stack 110 begins with PVC plate 120a. In the embodiment shown in the Figures, PVC plate 120a comprises approximate dimensions of 538 mm×160 mm×25.4 mm. PVC plate 120a further carries two inlet ports 112a, 112b located on one end. At the opposite end, PVC plate 120a carries two outlet ports 114a, 114b. In the embodiment shown in the Figures, ten holes 116 are located around the periphery of PVC plate 120a to accommodate matched bolt, washer, and nut sets 118.
PVC plate 120a is one of two PVC plates 120a, 120b which, when bolted together with sets 118 at the extremities of electrode stack 110, prevent any significant, unwanted electrolyte leakage from electrolytic cell structure 100 or electrode stack 110, using alternately positioned rubber gasket plates 140, 180, 220 within electrode stack 110.
Next in order of construction is rubber gasket plate 140. Rubber gasket plate 140 preferably comprises approximate dimensions of 475 mm×100×3.2 mm. Holes 142 are punched out of, or otherwise formed within, rubber gasket plate 140 to provide for electrolyte flow to the catholyte and anolyte compartments.
In design, construction, and operation, rubber gasket plate 140 serves as both a gasket, to prevent significant leakage from the overall electrolytic cell structure 100 and electrode stack 110, and as a conduit for electrolyte flow.
Next in order of construction is metal cathode plate 160, preferably constructed from a metal such as titanium. Titanium metal cathode plate 160 comprises approximate dimensions of 475 mm×100 mm×1 mm. Holes 162 are punched out of, or otherwise formed within, titanium metal cathode plate 160 for electrolyte flow to the catholyte and anolyte compartments. Further punched out of, or otherwise formed within, titanium metal cathode plate 160 are alignment holes 164 for cell stack assembly rods 166. Titanium metal cathode plate 160 preferably carries tab 168 and hole 170 for DC power connection cable 172a.
In design, construction, and operation, titanium metal cathode plate 160 serves both as a functional cathode in electrode stack 110 and as one of the boundary walls of the cathode compartment.
Next in order of construction is rubber gasket plate 180. Rubber gasket plate 180 comprises approximate dimensions 475 mm×100 mm×3.2 mm, and further internal cut-out features 182a, 182b, as shown.
In design, construction, and operation, rubber gasket plate 180 serves as both a gasket, to prevent significant leakage from the overall electrolytic cell structure 100 and electrode stack 110, and as a preformed cathode compartment space 184 through which catholyte will flow in a generally upward direction through electrode stack 110.
Next in order of construction is PVC frame 200. PVC frame 200 comprises approximate dimensions of 475 mm×100 mm×3.2 mm. Importantly, PVC frame 200 contains and supports ceramic or other membrane 210, comprising approximate dimensions of 375 mm×65 mm×2.0 mm. Ceramic or other membrane 210 is affixed and held within a cut out of PVC frame 200 preferably with clear silicone adhesive 212.
In design, construction, and operation, ceramic or other membrane 210 acts as a partition between catholyte and anolyte compartments of electrode stack 110. It should be noted that ceramic or other membrane 210 is essentially impervious to the flow of both liquids and gases, but permits ionic exchanges therethrough.
It is noted that, at present, the preferred material for membrane construction is ceramic; however, the inventor hereof is experimenting with one or more other materials which may provide certain technical and economic benefits. For example, in an alternate embodiment, a proprietary material produced by W. L. Gore & Associates, Inc. (Elkton, Md.), Part No. TBP, may provide certain benefits as a membrane material. Preliminary data has suggested that such a membrane material may require only approximately one-half the voltage, as compared with the voltage requirements of a ceramic material, to drive an equivalent ion density through the membrane, and while still providing certain other required attributes, such as impermeability to liquids and gases, and inertness to chemical attack. Such materials may also be easier to produce, may be cheaper, and may be easier to form, use, and maintain within electrolytic cell structure 100 and electrode stack 110. Use of any and all such materials are, therefore, contemplated as being within the scope, disclosure, and spirit of the present invention.
Thus, in accordance with the design, construction, and operation of electrolytic cell structure 100 and electrode stack 110, positively charged sodium ions (Na+) within the liquid electrolyte pass from the electrolyte in the cathode compartment, through ceramic or other membrane 210, and to negatively charged cathode plate 160; while, essentially simultaneously, negatively charged chloride ions (Cl−) pass from the liquid electrolyte in the anode compartment, through ceramic or other membrane 210, to positively charged anode plate 240.
Next in order of construction is rubber gasket plate 220. Rubber gasket plate 220 comprises approximate dimensions 475 mm×100 mm×3.2 mm, and further internal cut-out features 222a, 222b, as shown.
In design, construction, and operation, rubber gasket plate 220 serves as both a gasket, to prevent significant leakage from the overall electrolytic cell structure 100 and electrode stack 110, and as a preformed anode compartment space 224 through which anolyte will flow in a generally upward direction through electrode stack 110.
Next in order of construction is a precious metal coated, preferably titanium anode plate 240 comprising approximate dimensions of 475 mm×100 mm×1 mm. Holes 242 are punched out of, or otherwise formed within, precious metal coated titanium anode plate 240 for electrolyte flow to the catholyte and anolyte compartments. Further punched out of, or otherwise formed within, precious metal coated titanium anode plate 240 are alignment holes 244 for cell stack assembly rods 166. Precious metal coated titanium anode plate 240 preferably carries tab 246 and hole 248 for DC power connection cable 172b.
In design, construction, and operation, precious metal coated titanium anode plate 240 serves both as a functional anode in electrode stack 110 and as one of the boundary walls of the anode compartment.
With consideration to the design, construction, and operation of electrolytic cell structure 100 and electrode stack 110, it is here noted that a first half of electrode stack 110 is represented by PVC plate 120a, rubber gasket plate 140, titanium metal cathode plate 160, rubber gasket plate 180, PVC frame 200 carrying ceramic or other membrane 210, rubber gasket plate 220, and precious metal coated titanium anode plate 240.
A second half of electrode stack 110 comprises a mirror image of the first half; however, using a common precious metal coated titanium anode plate. Thus, the common precious metal coated titanium anode plate preferably comprises two precious metal coated titanium plates 240, which are bonded and held together by use and application of clear silicone adhesive 212. According to the preferred construction, then, the common precious metal coated titanium anode plate is followed by rubber gasket plate 220, PVC frame 200 carrying ceramic or other membrane 210, rubber gasket plate 180, titanium metal cathode plate 160, rubber gasket plate 140, and PVC plate 120b.
In use and operation, electrolytic cell structure 100, constructed according to the preferred embodiment set forth above, hydrolyzes water from a saline solution into a plurality of mixed oxidant solutions. In order to support such use and operation, electrolytic cell structure 100 might also be configured into a system preferably including a DC power supply and a mini programmable logic controller (“PLC Controller”).
Because electrolyzed water breaks down and/or disproportionates relatively quickly, it may be advantageous to locate the EOW reactor proximate the intended location of use of the electrolyzed water. As such, the relative size and footprint of the EOW reactor and supporting system components may, in some circumstances or applications, be of importance.
Accordingly, whether in support of an EOW reactor, such as electrolytic cell structure 100, located proximate the intended location of use of the electrolyzed water, or in support of an EOW reactor, such as electrolytic cell structure 100, producing commercial quantities of electrolyzed water, certain other system elements may, optionally, but preferably, be utilized. Such system elements may include, without limitation, a conductivity measurement and control subsystem, a DC current limiting control subsystem, preferably-automatic pH control means for adjusting the pH of the anolyte solution produced by electrolytic cell structure 100 of the present invention, a water softener cylinder subsystem, interconnecting pipe work, one or more pumps, one or more salt tanks for the water softener subsystem and for electrolytic cell structure 100 of the present invention, mounting means preferably comprising a portable rig which supports all associated pipe work, associated instrumentation, DC power supply, water softener, salt tank(s), and electrolytic cell structure 100 of the present invention.
It will be appreciated by those of ordinary skill in the art that electrolytic cell structure 100 described hereinabove may be provided, in an appropriate case, in unitary, integral, or single piece construction. Similarly, the elements, pieces, parts, and assemblies of the invention described herein, and methods of construction, operation, and use thereof, may be varied, reconfigured, and rearranged to meet the function, and achieve the benefits of the present invention. It will be further apparent to those of ordinary skill in the art that electrolytic cell structure 100, and associated system elements, easily may be scaled to meet commercial specifications, and at reasonable cost in comparison to prior art EOW reactor systems.
Similarly, in an appropriate case, mixed oxidant electrolytic cell structure 100 of the present invention, or a legal equivalent thereof, may be used in association with such other ionic solution compositions, and for such other purposes, as may produce a useful, beneficial result.
In use, a saline electrolyte solution, typically maintained at approximately 5000 ppm, is passed into electrolytic cell structure 100. A DC voltage is applied to electrolytic cell structure 100, either prior to or after passing the saline electrolyte solution into electrolytic cell structure 100, depending upon known electrical, steady-state, and other constraints and considerations attendant the use and operation of such a system.
The saline electrolyte solution passes through electrolytic cell structure 100, wherein an anolyte and a catholyte are produced. Typically, the anolyte product is taken off to an anolyte storage means. The catholyte, on the other hand, is recirculated through electrolytic cell structure 100, preferably through use of approximately 50 mm diameter PVC tee 260. PVC tee 260 preferably serves to reduce hydrogen gas carry-over into the anode compartments of electrolytic cell structure 100. A first branch of PVC tee 260 allows the catholyte to recirculate through electrolytic cell structure 100. A second branch of PVC tee 260, operated in conjunction with control valve 270, allows the catholyte product to be taken off to a catholyte storage means. Control valve 270 preferably may be used to vary the flow rate of the catholyte product in relation to the flow of the anolyte product as a proportion of total flow through electrolytic cell structure 100.
As set forth above, in order to support the use and operation just described, electrolytic cell structure 100 might also be configured within a system preferably including a DC power supply and a mini programmable logic controller (“PLC Controller”). Certain other system elements are also optionally, but preferably, included, such as, without limitation, a conductivity measurement and control subsystem, a DC current limiting control subsystem, preferably-automatic pH control means for adjusting the pH of the anolyte solution produced by electrolytic cell structure 100 of the present invention, a water softener cylinder subsystem, interconnecting pipe work, one or more pumps, one or more salt tanks for the water softener subsystem and for electrolytic cell structure 100 of the present invention, mounting means preferably comprising a portable rig which supports all associated pipe work, associated instrumentation, DC power supply, water softener, salt tank(s), and electrolytic cell structure 100 of the present invention. Through the use of such additional system elements in association with electrolytic cell structure 100 of the present invention, uniform and high quality anolyte and catholyte streams can be produced at steady state, commercial flow rates, maintained (within shelf-life limits), and stored.
It further will be appreciated by those of ordinary skill in the art that the process and associated steps for using electrolytic cell structure 100 as described hereinabove, or the legal equivalents thereof, may be varied, reconfigured, and rearranged to meet the function, and achieve the benefits of, the present invention. It will be further apparent to those of ordinary skill in the art that electrolytic cell structure 100, and associated system elements and process steps, easily may be scaled to meet commercial specifications, and at reasonable cost in comparison to prior art EOW reactor systems.
Having, thus, described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the within disclosures are exemplary only and that various other alternatives, adaptations, and modifications may be made within the scope, disclosure, and spirit of the present invention. Accordingly, the present invention is not limited to the specific embodiments as illustrated herein, but is only limited by the following claims.
This application claims priority under 35 U.S.C §119(e) to U.S. provisional patent application Ser. No. 61/310,618, filed on Mar. 4, 2010, entitled “Mixed Oxidant Electrolytic Cell,” which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61310618 | Mar 2010 | US |
