Fiberglass dielectric barrier ionization discharge device
09597424 ยท 2017-03-21
Assignee
Inventors
Cpc classification
Y02A50/20
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B01D2259/4508
PERFORMING OPERATIONS; TRANSPORTING
B03C3/38
PERFORMING OPERATIONS; TRANSPORTING
Y10T29/49144
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B01D2259/818
PERFORMING OPERATIONS; TRANSPORTING
Y10T29/49002
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B01D2257/90
PERFORMING OPERATIONS; TRANSPORTING
Y10T29/49149
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24F8/192
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
B01D53/32
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A bipolar ionization device in which fiberglass is used as the dielectric. In one embodiment, a fiberglass board is used, with the anode on one side of the board and the cathode on the other side of the board. A number of flat boards can be stacked, with spacing between them to allow air flow to scavenge ions, with stanchions providing both mounting and electrical connections to the ionization devices. In another embodiment, a fiberglass tube is used, with the cathode inside the tube and the anode outside the tube.
Claims
1. A bipolar ionization tube, comprising: a fiberglass tube with a first end and a second end; a cathode positioned within and being circumscribed by an interior surface wall of said fiberglass tube; an anode circumscribing an exterior surface of said fiberglass tube, said anode configured for electrical connectivity with a first conducting terminal of a power supply; an electrically insulated end cap sized for receiving the first end of said fiberglass tube, said end cap being secured to said fiberglass tube with at least one sealant; an elongated conducting terminal having a first portion extending through said end cap and configured for electrical connectivity with a second conducting terminal of said power supply, and a second portion extending into said fiberglass tube and configured for electrical connectivity with said cathode; and a seal cap sized for receiving the second end of said fiberglass tube, said seal cap being secured to said fiberglass tube with the at least one sealant.
2. The bipolar ionization tube of claim 1, wherein said cathode is cylindrically shaped and fabricated from solid aluminum alloy.
3. The bipolar ionization tube of claim 1, wherein said anode is cylindrically shaped and fabricated from a stainless steel mesh.
4. The bipolar ionization tube of claim 3, wherein the second portion of said elongated conducting terminal comprises a conductive current distributor member for providing current to said cathode.
5. The bipolar ionization tube of claim 4, wherein said conductive current distributor member includes a plurality of tines for contacting said cathode.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Further advantages and features of the present invention will become apparent from the detailed description of a preferred embodiment of the invention with reference to the accompanying drawings, in which:
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(14) To facilitate understanding of the invention, identical reference numerals have been used, when appropriate, to designate the same or similar elements that are common to the figures. Further, unless stated otherwise, the drawings shown and discussed in the figures are not drawn to scale, but are shown for illustrative purposes only.
DETAILED DESCRIPTION OF THE INVENTION
(15) One embodiment of the present invention is a ionization device for removing impurities, such as dust, pollen, mold, compounds producing noxious odors, among other undesirable particles from the air, that manifest themselves, illustratively, in ventilation systems of buildings, although such environment is not considered as being limiting.
(16) Among the improvements in the tube of the present invention is the improvement in overall structural integrity.
(17) Both the flat fiberglass board ionization device and the fiberglass tube ionization device provide for an anode and cathode which increase the ion output of the ionization tube. The mesh or grid used to form the anode is fabricated with a tightly woven mesh, which allows for more contact points to produce ions.
(18) In addition to other benefits, the embodiment of the flat fiberglass ionization device results in a reduction in the resistance to airflow, allowing for a more efficient HVAC system.
(19) Reference will now be made in detail to implementations of the invention, examples of which are illustrated in the accompanying drawings.
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(21) As
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(23) In an embodiment such as shown in
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(25) For corrosion resistance, solid copper face 320 is preferably provided with tinning. In an alternative embodiment, cathode 310 can be provided with a conductive material other than copper. In other alternative embodiments, cathode 310 can use a mesh or perforated metal in lieu of the solid face 320 shown.
(26) With reference to
(27) The board 110 can be purchased from a manufacturer with copper already applied to both sides, and the copper can then be removed from unwanted areas by various subtractive methods leaving only the desired copper traces. Alternatively, the board 110 can be produced using an additive method where traces are adding to the bare substrate by electroplating methods.
(28) In one embodiment, screen 150, shown in
(29) Ion and ozone outputs are affected by the thickness of the dielectric and the spacing of the screen 150 from the dielectric; by adjusting these two variables, ion and ozone outputs can be tailored to suit the application. Thus in another embodiment, not shown, conductive spacers are provided between tracing 210 and screen 150, and between attachment dots 280 and screen 150. In a preferred embodiment, the conductive spacers will add 7 mil spacing.
(30) With reference to
(31) Ionization device 100 is powered by a high voltage alternating current (ac). In a preferred embodiment, ionization devices 100 will be powered by 2000-3,000 volts ac, which can be supplied by a power transformer that raises a branch circuit from 120 or 220 volts ac up to 3,000 volts ac. Cathode 310 thus experiences one polarity from first stanchion 420 while anode 115 experiences the opposite polarity from second stanchion 430. This leads to opposite charges to build-up on each side of the dielectric barrier, with the resultant electric field generating discharges in the form of plasma filamentary and surface dielectric barrier discharges (DBD).
(32) As air flows over the ionization device 100 and the molecules in the air interact with the generated plasma, electrons are transferred between molecules, generating both positive and negative ions that propagate quickly, thus ionizing the air. Ionization of the air helps clean the air by breaking down organic chemicals and removing their associated odors, as well as reducing the levels of particulate matter through agglomeration.
(33) In this preferred embodiment, the first and second stanchions provide HV+ and HV voltage to the side of the board 110 indicated by width 140. In a preferred embodiment, on cathode 310, border 330 is interrupted at the intersection 350 of notch 250 and first stanchion 420. Instead, solid copper face 320 extends to the edge of cathode 310 and over the edge, onto the side of the board 110 indicated by width 140, making contact with the HV+ terminal of the power supply through the conductor of first stanchion 420. Similarly, on the anode 115, border 220 is interrupted at the intersection 270 of notch 240 and second stanchion 430. Instead, trace 210 extends to the edge of anode 115 and over the edge, onto the side of the board 110 indicated by width 140, making contact with the HV terminal of the power supply through the conductor of second stanchion 430.
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(37) A stanchion has a minimum of two modular insulators 510, to retain a single board 110, but by varying the height of central conductor 520 and the number of modular insulators 510, a stanchion can be built to support any of a plurality of boards 110. The threaded rod that forms the central conductor and structural support is cut to the appropriate length, depending on the number of modular insulators 510. For five modular insulators, the rod would be approximately 80 mm long. It is envisioned that up to ten modular insulators can be accommodated. The Insulator 510 is Noryl plastic or equivalent. At the base of the stack of modular insulators, the threaded rod penetrates the baseplate on the enclosure. At the top of the stack of modular insulators, washers and nuts are used to retain top modular insulator 510 in place vertically.
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(39) With reference to
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(41) The fiberglass tube 910 has an elongated cylindrical shape, with a wall of substantially uniform cross-section, forming an interior surface and an exterior surface. The fiberglass tube 910 has a first end and a second end. In a preferred embodiment, fiberglass tube 910 is preferably rated FR-4 grade. In one embodiment the outer diameter of the fiberglass tube can be approximately 0.75 to 1.625 inches, and is preferably about 1.375 inches. The thickness of the fiberglass wall forming the tube 910 is preferably 0.125 inches to 0.140 inches. In a preferred embodiment, the overall length of the fiberglass tube is 7 inches to 21 inches, although such lengths are not considered limiting. A person of ordinary skill in the art will appreciate that the dimensions of the fiberglass tube 910 are associated with the desired overall ion output and are not considered as limiting. The edge at the first end of the fiberglass tube 910 is seated into the end cap 950, while the edge at the second end of the fiberglass tube 910 is seated into the seal cap 970. End cap 950 and seal cap 970 are formed of an insulating material, such as vinyl.
(42) Arranged against the inner wall of the fiberglass tube 910 is the cathode 920. Preferably, the cathode 920 is formed from solid aluminum alloy and is cylindrical in shape. In a preferred embodiment, the alloy is 1100 H0 series. Although the cathode 920 is described as being fabricated from aluminum, a person of ordinary skill in the art will appreciate that other conductive metals or metal alloys can be utilized to form the cathode 920, such as stainless steel and the like, and in lieu of a solid form, a mesh or perforated form can be used. A thin film of metal can also be created through a version of deposition, such as sputtering, chemical vapor deposition (CVD), etc.
(43) The cathode 920 is sized to cover the interior surface of the fiberglass tube 910, to about - from the edge of the first and second ends of the fiberglass tube 910, allowing enough space at the edges of the fiberglass tube 910 so that the edge of the first end of fiberglass tube 910 may properly fit into the end cap 950 and that the edge of the second end of fiberglass tube 910 may properly fit into seal cap 970. In a preferred embodiment, the cathode 920 has a thickness of approximately 0.010 inches.
(44) The anode 930 is arranged on the outer wall of fiberglass tube 910. The anode 930 is cylindrical in shape and fabricated from a stainless steel mesh, which covers the exterior surface of the fiberglass tube 910. Preferably, the anode 930 is approximately the same or slightly larger that the length of the cathode 920. Although the anode 930 is described as being fabricated from stainless steel, a person of ordinary skill in the art will appreciate that other conductive metals or metal alloys can be utilized to form the cathode 920, such as aluminum and the like.
(45) In a preferred embodiment, the anode 930 has a thickness of approximately 0.14 inches, and 225 openings per square inch. Alternatively, the anode 930 can have a thickness in the range of 0.01 to 0.015 inches, and 180 to 290 openings (i.e., perforations) per square inch.
(46) The anode 930 is electrically connected to a high voltage alternating current power supply with an electrical conductor (not shown), such as a stainless steel clip, wire, or other well-known electrical conductor. In one embodiment, a stainless steel clip extends from the HV+ lead of the high voltage power supply and is positioned to securely contact the outer surface area of the anode 930.
(47) The conducting terminal 960 includes a power input terminal 962, a current distributor 940 with two tines 980, fastener 966 and anti-rotation tab 965 for securing the current distributor 940 to the power input terminal 962, and fastener 964 for securing the assembled conducting terminal 960 to end cap 950.
(48) The power input terminal 962 is made of a conductive metal, such as #304 stainless steel. The power input terminal 962 extends through a bore formed through the floor of the end cap 950. The power input terminal 962 is mechanically and electrically connected to the current distributor 940. In one embodiment, the bottom portion of the current distributor 940 includes a smooth bore sized to receive a threaded end of the power input terminal 962. Fastener 966 for securing current distributor 940 to power input terminal 962 can be a nut, though different methods of fastening may be used, such as welding or screws in various configurations. Likewise, fastener 964 for securing the assembled conducting terminal 960 to end cap 950 can be a nut, though different methods of fastening may be used.
(49) The power input terminal 962 extends a sufficient length from the external surface of the bottom portion of the end cap 950 to allow for connection to the separate high voltage alternating current power supply. The external end of the power input terminal 962 can be a threaded, as illustratively shown, although such terminal connector is not considered as limiting. For example, the power input terminal 962 can be of a plug-in or stab-on type connector, amongst other well-known connectors.
(50) The current distributor 940 is shaped as a U-shaped tuning fork with two tines 980 that extend outward to contact cathode 920. Current distributor 940 is fabricated from a conductive metal, such as stainless steel, aluminum, copper, among other conductive metals or metal alloys.
(51) Similarly to the flat fiberglass board ionization device 100, the bipolar ionization tube 900 can be installed, for example, in a heating, ventilation and cooling (HVAC) duct. During operation, the bipolar ionization tube 900 is connected to a suitable power source, such as a high voltage AC power supply. One polarity is supplied to current distributor 940 and is distributed to the cathode 920 by the current distributor 940 through its tines 980. The opposite polarity is provided to anode 930, such as by a conductive wire or clip provided between the anode and the power source. As described earlier, this leads to opposite charges to build up on each side of the dielectric barrier.
(52) As air flows over the ionization device and the molecules in the air interact with the generated plasma, electrons are transferred between molecules generating both positive and negative ions that propagate quickly; thus ionizing the air. Ionization of the air helps clean the air by breaking down organic chemicals and removing their associated odors, as well as reducing the levels of particulate matter.
(53) It is noted that the design of the anode and cathode, which includes the metals used for fabrication, as well as the increase in the number of perforations per square inch of the stainless steel anode mesh, are specifically directed towards increasing the ionization output in the surrounding air over the prior art. Likewise, the type of dielectric and its thickness, and the spacing between the dielectric and the anode are important in optimizing the ionization output. Advantageously, energy costs to operate the ionization tube 900 of the present invention can be reduced as compared to the tubes of the prior art, since the enhancements to the anode and cathode increase the overall ion production of the tube 900.
(54) Referring to
(55) At step 1015, fiberglass board 110 is provided with first notch 250, second notch 240, and third notch 260, to facilitate mounting of fiberglass board 110, as well as to provide high voltage alternating current to the anode and cathode via electrical connections at 240 and 250.
(56) At step 1020, either subtractive or additive methods are used to create copper cathode 310 on the bottom of fiberglass board 110, except for a partial border around the perimeter of the bottom of fiberglass board 110. At first notch 250, the border is omitted and the copper continues to the edge of fiberglass board 110 and over the edge, covering part of the intersection of first notch 250 with the side of fiberglass board 110.
(57) In step 1025, either subtractive or additive methods are used to create copper trace 210 on the top of fiberglass board 110 inside of a partial border 220 around the perimeter of the top of fiberglass board 110. At second notch 240, the border 220 is omitted and the copper trace 210 continues to the edge of fiberglass board 110 and over the edge, covering part of the intersection of second notch 240 with the side of fiberglass board 110.
(58) In step 1027, copper cathode 310 is provided with tinning, with heavy tinning where the copper continues over the edge at first notch 250. In addition, copper trace 210 is provided with tinning, with heavy tinning where the copper continues over the edge at second notch 240.
(59) At step 1030, screen 150 is tack soldered to attachment dots 280 and to copper trace 210 at small attachment dots 285, completing construction of anode 115 of the top of fiberglass board 110.
(60) The method 1000 then proceeds to step 1030, where the method ends and any testing of the assembled ionization tube is provided.
(61) Referring to
(62) At step 1115, solid aluminum alloy cathode 920 is inserted into the interior of the fiberglass tube 910. The cathode 920 is positioned such that the upper and lower edges of the cathode 920 are about - from the edge of the first and second ends of the fiberglass tube 910. As previously discussed for the apparatus, other conductive metals or metal alloys can be utilized to form the cathode 920, such as stainless steel and the like, and in lieu of a solid form, a mesh or perforated form can be used. A thin film of metal can also be created through a version of deposition, such as sputtering, chemical vapor deposition (CVD), etc.
(63) At step 1120, conducting terminal 960 is assembled and installed on end cap 950.
(64) In step 1125, a layer of sealant is applied to the circumference around the bottom of the inside of end cap 950. Depending on the type of sealant, the sealant can be allowed to partially cure prior to proceeding to step 1130.
(65) At step 1130, the first end of fiberglass tube 910 is slid over the conducting terminal 960 and slid downwards towards the end cap 950 until the peripheral edge of the tube 910 is firmly seated at the bottom of the inside of end cap 950. The tines 980 of the current distributor 940 make contact with cathode 920.
(66) At step 1135, the cylindrical stainless steel mesh anode 930 is slid over the second end of the fiberglass tube 910. The upper and lower edges of the anode 930 are aligned to coincide with the respective upper and lower edges of the cathode 920.
(67) In step 1140, a layer of sealant is applied to the circumference around the bottom of the inside of seal cap 970. Depending on the type of sealant, the sealant can be allowed to partially cure prior to proceeding to step 1145.
(68) At step 1145 the peripheral edge of the second end of fiberglass tube 910 is firmly seated at the bottom of the inside of seal cap 970.
(69) The method 1100 then proceeds to step 1150, where the method ends and any additional curing of the sealants and testing of the assembled ionization tube is provided.
(70) A person of ordinary skill in the art will appreciate that the specific order of the steps of method 1100 is not considered limiting.
(71) Although an exemplary description of the invention has been set forth above to enable those of ordinary skill in the art to make and use the invention, that description should not be construed to limit the invention, and various modifications and variations may be made to the description without departing from the scope of the invention, as will be understood by those with ordinary skill in the art, and the scope thereof is determined by the claims that follow.