PRIORITY CLAIMThis application is a divisional of U.S. patent application Ser. No. 09/924,624 filed Aug. 8, 2001, which is a continuation of U.S. patent application Ser. No. 09/564,960 filed May 4, 2000, now U.S. Pat. No. 6,350,417, which is a continuation-in-part of U.S. patent application Ser. No. 09/186,471, filed Nov. 5, 1998, now U.S. Pat. No. 6,176,977.[0001]
FIELD OF THE INVENTIONThis invention relates generally to devices that produce ozone and an electro-kinetic flow of air from which particulate matter has been substantially removed, and more particularly to cleaning the wire or wire-like electrodes present in such devices.[0002]
BACKGROUNDThe use of an electric motor to rotate a fan blade to create an air flow has long been known in the art. Unfortunately, such fans produce substantial noise, and can present a hazard to children who may be tempted to poke a finger or a pencil into the moving fan blade. Although such fans can produce substantial air flow, e.g., 1,000 ft[0003]3/minute or more, substantial electrical power is required to operate the motor, and essentially no conditioning of the flowing air occurs.
It is known to provide such fans with a HEPA-compliant filter element to remove particulate matter larger than perhaps 0.3 μm. Unfortunately, the resistance to air flow presented by the filter element may require doubling the electric motor size to maintain a desired level of airflow. Further, HEPA-compliant filter elements are expensive, and can represent a substantial portion of the sale price of a HEPA-compliant filter-fan unit. While such filter-fan units can condition the air by removing large particles, particulate matter small enough to pass through the filter element is not removed, including bacteria, for example.[0004]
It is also known in the art to produce an air flow using electro-kinetic techniques, by which electrical power is directly converted into a flow of air without mechanically moving components. One such system is described in U.S. Pat. No. 4,789,801 to Lee (1988), depicted herein in simplified form as FIGS. 1A and 1B. Lee's[0005]system10 includes an array of small area (“minisectional”)electrodes20 that is spaced-apart symmetrically from an array of larger area (“maxisectional”)electrodes30. The positive terminal of apulse generator40 that outputs a train of high voltage pulses (e.g., 0 to perhaps +5 KV) is coupled to the minisectional array, and the negative pulse generator terminal is coupled to the maxisectional array.
The high voltage pulses ionize the air between the arrays, and an[0006]air flow50 from the minisectional array toward the maxisectional array results, without requiring any moving parts.Particulate matter60 in the air is entrained within theairflow50 and also moves towards themaxisectional electrodes30. Much of the particulate matter is electrostatically attracted to the surface of the maxisectional electrode array, where it remains, thus conditioning the flow ofair exiting system10. Further, the high voltage field present between the electrode arrays can release ozone into the ambient environment, which appears to destroy or at least alter whatever is entrained in the airflow, including for example, bacteria.
In the embodiment of FIG. 1A,[0007]minisectional electrodes20 are circular in cross-section, having a diameter of about 0.003″ (0.08 mm), whereas themaxisectional electrodes30 are substantially larger in area and define a “teardrop” shape in cross-section. The ratio of cross-sectional radii of curvature between the maxisectional and minisectional electrodes is not explicitly stated, but from Lee's figures appears to exceed 10:1. As shown in FIG. 1A herein, the bulbous front surfaces of the maxisectional electrodes face the minisectional electrodes, and the somewhat sharp trailing edges face the exit direction of the air flow. The “sharpened” trailing edges on the maxisectional electrodes apparently promote good electrostatic attachment of particular matter entrained in the airflow. Lee does not disclose how the teardrop shaped maxisectional electrodes are fabricated, but presumably they are produced using a relatively expensive mold-casting or an extrusion process.
In another embodiment shown herein as FIG. 1B, Lee's maxisectional[0008]sectional electrodes30 are symmetrical and elongated in cross-section. The elongated trailing edges on the maxisectional electrodes provide increased area upon which particulate matter entrained in the airflow can attach. Lee states that precipitation efficiency and desired reduction of anion release into the environment can result from including a passive third array of electrodes70. Understandably, increasing efficiency by adding a third array of electrodes will contribute to the cost of manufacturing and maintaining the resultant system.
While the electrostatic techniques disclosed by Lee are advantageous over conventional electric fan-filter units, Lee's maxisectional electrodes are relatively expensive to fabricate. Further, increased filter efficiency beyond what Lee's embodiments can produce would be advantageous, especially without including a third array of electrodes.[0009]
The invention in applicants' parent application provided a first and second electrode array configuration electro-kinetic air transporter-conditioner having improved efficiency over Lee-type systems, without requiring expensive production techniques to fabricate the electrodes. The condition also permitted user-selection of safe amounts of ozone to be generated.[0010]
The second array electrodes were intended to collect particulate matter, and to be user-removable from the transporter-conditioner for regular cleaning to remove such matter from the electrode surfaces. The user must take care, however, to ensure that if the second array electrodes were cleaned with water, that the electrodes are thoroughly dried before reinsertion into the transporter-conditioner unit. If the unit were turned on while moisture from newly cleaned electrodes was allowed to pool within the unit, and moisture wicking could result in high voltage arcing from the first to the second electrode arrays, with possible damage to the unit.[0011]
The wire or wire-like electrodes in the first electrode array are less robust than the second array electrodes. (The terms “wire” and “wire-like” shall be used interchangeably herein to mean an electrode either made from a wire or, if thicker or stiffer than a wire, having the appearance of a wire.) In embodiments in which the first array electrodes were user-removable from the transporter-conditioner unit, care was required during cleaning to prevent excessive force from simply snapping the wire electrodes. But eventually the first array electrodes can accumulate a deposited layer or coating of fine ash-like material. If this deposit is allowed to accumulate, eventually efficiency of the conditioner-transporter will be degraded. Further, for reasons not entirely understood, such deposits can produce an audible oscillation that can be annoying to persons near the conditioner-transporter.[0012]
Thus, there is a need for a mechanism by a conditioner-transporter unit that can be protected against moisture pooling in the unit as a result of user cleaning. Further, there is a need for a mechanism by which the wire electrodes in the first electrode array of a conditioner-transporter can be periodically cleaned. Preferably such cleaning mechanism should be straightforward to implement, should not require removal of the first array electrodes from the conditioner-transporter, and should be operable by a user on a periodic basis.[0013]
The present invention provides a method and apparatus.[0014]
SUMMARYApplicants' parent application provides an electro-kinetic system for transporting and conditioning air without moving parts. The air is conditioned in the sense that it is ionized and contains safe amounts of ozone. The electro-kinetic air transporter-conditioner disclosed therein includes a louvered or grilled body that houses an ionizer unit. The ionizer unit includes a high voltage DC inverter that boosts common 110 VAC to high voltage, and a generator that receives the high voltage DC and outputs high voltage pulses of perhaps 10 KV peak-to-peak, although an essentially 100% duty cycle (e.g., high voltage DC) output could be used instead of pulses. The unit also includes an electrode assembly unit comprising first and second spaced-apart arrays of conducting electrodes, the first array and second array being coupled, respectively, preferably to the positive and negative output ports of the high voltage generator.[0015]
The electrode assembly preferably is formed using first and second arrays of readily manufacturable electrode configurations. In the embodiments relevant to this present invention, the first array included wire (or wire-like) electrodes. The second array comprised “U”-shaped or “L”-shaped electrodes having one or two trailing surfaces and intentionally large outer surface areas upon which to collect particulate matter in the air. In the preferred embodiments, the ratio between effective radii of curvature of the second array electrodes to the first array electrodes is at least about 20:1.[0016]
The high voltage pulses create an electric field between the first and second electrode arrays. This field produces an electro-kinetic airflow going from the first array toward the second array, the airflow being rich in preferably a net surplus of negative ions and in ozone. Ambient air including dust particles and other undesired components (germs, perhaps) enter the housing through the grill or louver openings, and ionized clean air (with ozone) exits through openings on the downstream side of the housing.[0017]
The dust and other particulate matter attaches electrostatically to the second array (or collector) electrodes, and the output air is substantially clean of such particulate matter. Further, ozone generated by the transporter-conditioner unit can kill certain types of germs and the like, and also eliminates odors in the output air. Preferably the transporter operates in periodic bursts, and a control permits the user to temporarily increase the high voltage pulse generator output, e.g., to more rapidly eliminate odors in the environment.[0018]
Applicants' parent application provided second array electrode units that were very robust and user-removable from the transporter-conditioner unit for cleaning. These second array electrode units could simply be slid up and out of the transporter-conditioner unit, and wiped clean with a moist cloth, and returned to the unit. However, on occasion, if electrode units are returned to the transporter-conditioner unit while still wet (from cleaning), moisture pooling can reduce resistance between the first and second electrode arrays to where high voltage arcing results.[0019]
Another problem is that over time the wire electrodes in the first electrode array become dirty and can accumulate a deposited layer or coating of fine ash-like material. This accumulated material on the first array electrodes can eventually reduce ionization efficiency. Further, this accumulated coating can also result in the transporter-conditioner unit producing 500 Hz to 5 KHz audible oscillations that can annoy people in the same room as the unit.[0020]
In a first embodiment, the present invention extends one or more thin flexible sheets of MYLAR or KAPTON type material from the lower portion of the removable second array electrode unit. This sheet or sheets faces the first array electrodes and is nominally in a plane perpendicular to the longitudinal axis of the first and second array electrodes. Such sheet material has high voltage breakdown, high dielectric constant, can withstand high temperature, and is flexible. A slit is cut in the distal edge of this sheet for each first array electrode such that each wire first array electrode fits into a slit in this sheet. Whenever the user removes the second electrode array from the transporter-conditioner unit, the sheet of material is also removed. However, in the removal process, the sheet of material is also pulled upward, and friction between the inner slit edge surrounding each wire tends to scrape off any coating on the first array electrode. When the second array electrode unit is reinserted into the transporter-conditioner unit, the slits in the sheet automatically surround the associated first electrode array electrode. Thus, there is an up and down scraping action on the first electrode array electrodes whenever the second array electrode unit is removed from, or simply moved up and down within, the transporter-conditioner unit.[0021]
Optionally, upwardly projecting pillars can be disposed on the inner bottom surface of the transporter-conditioner unit to deflect the distal edge of the sheet material upward, away from the first array electrodes when the second array electrode unit is fully inserted. This feature reduces the likelihood of the sheet itself lowering the resistance between the two electrode arrays.[0022]
In a presently preferred embodiment, the lower ends of the second array electrodes are mounted to a retainer that includes pivotable arms to which a strip of MYLAR or KAPTON type material is attached. The distal edge of each strip includes a slit, and each strip (and the slit therein) is disposed to self-align with an associated wire electrode. A pedestal extends downward from the base of the retainer, and when fully inserted in the transporter-conditioner unit, the pedestal extends into a pedestal opening in a sub-floor of the unit. The first electrode array-facing walls of the pedestal opening urge the arms and the strip on each arm to pivot upwardly, from a horizontal to a vertical disposition. This configuration can improve resistance between the electrode arrays.[0023]
Yet another embodiment provides a cleaning mechanism for the wires in the first electrode array in which one or more bead-like members surrounds each wire, the wire electrode passing through a channel in the bead. When the transporter-conditioner unit is inverted, top-for-bottom and then bottom-for-top, the beads slide the length of the wire they surround, scraping off debris in the process. The beads embodiments may be combined with any or all of the various sheets embodiments to provide mechanisms allowing a user to safely clean the wire electrodes in the first electrode array in a transporter-conditioner unit.[0024]
Other features and advantages of the invention will appear from the following description in which the preferred embodiments have been set forth in detail, in conjunction with the accompanying drawings.[0025]
BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1A is a plan, cross-sectional view, of a first embodiment of a prior art electro-kinetic air transporter-conditioner system, according to the prior art;[0026]
FIG. 1B is a plan, cross-sectional view, of a second embodiment of a prior art electrokinetic air transporter-conditioner system, according to the prior art;[0027]
FIG. 2A is a perspective view of a preferred embodiment of the present invention;[0028]
FIG. 2B is a perspective view of the embodiment of FIG. 2A, with the second array electrode assembly partially withdrawn depicting a mechanism for self-cleaning the first array electrode assembly, according to the present invention;[0029]
FIG. 3 is an electrical block diagram of the present invention;[0030]
FIG. 4A is a perspective block diagram showing a first embodiment for an electrode assembly, according to the present invention;[0031]
FIG. 4B is a plan block diagram of the embodiment of FIG. 4A;[0032]
FIG. 4C is a perspective block diagram showing a second embodiment for an electrode assembly, according to the present invention;[0033]
FIG. 4D is a plan block diagram of a modified version of the embodiment of FIG. 4C;[0034]
FIG. 4E is a perspective block diagram showing a third embodiment for an electrode assembly, according to the present invention;[0035]
FIG. 4F is a plan block diagram of the embodiment of FIG. 4E;[0036]
FIG. 5A is a perspective view of an electrode assembly depicting a first embodiment of a mechanism to clean first electrode array electrodes, according to the present invention.[0037]
FIG. 5B is a side view depicting an electrode cleaning mechanism as shown in FIG. 5A, according to the present invention;[0038]
FIG. 5C is a plan view of the electrode cleaning mechanism shown in FIG. 5B, according to the present invention;[0039]
FIG. 6A is a perspective view of a pivotable electrode cleaning mechanism, according to the present invention;[0040]
FIGS.[0041]6B-6D depict the cleaning mechanism of FIG. 6A in various positions, according to the present invention;
FIGS.[0042]7A-7E depict cross-sectional views of bead-like mechanisms to clean first electrode array electrodes, according to the present invention.
DETAILED DESCRIPTIONFIGS. 2A and 2B depict an electro-kinetic air transporter-[0043]conditioner system100 whosehousing102 includes preferably rear-located intake vents orlouvers104 and preferably front and side-located exhaust vents106, and abase pedestal108. Internal to the transporter housing is anion generating unit160, preferably powered by an AC:DC power supply that is energizable or excitable using switch S1.Ion generating unit160 is self-contained in that other than ambient air, nothing is required from beyond the transporter housing, save external operating potential, for operation of the present invention.
The upper surface of[0044]housing102 includes a user-liftable handle member112 to which is affixed asecond array240 ofelectrodes242 within anelectrode assembly220.Electrode assembly220 also comprises a first array ofelectrodes230, shown here as a single wire or wire-like electrode232. In the embodiment shown, liftingmember112 upward liftssecond array electrodes240 up and, if desired, out ofunit100, while thefirst electrode array230 remains withinunit100. In FIG. 2B, the bottom ends ofsecond array electrode242 are connected to amember113, to which is attached amechanism500 for cleaning the first electrode array electrodes, here electrode232, wheneverhandle member112 is moved upward or downward by a user. FIGS.5A-7E, described later herein, provide further details as tovarious mechanisms500 for cleaning wire or wire-like electrodes232 in thefirst electrode array230, and for maintaining high resistance between the first andsecond electrode arrays220,230 even if some moisture is allowed to pool within the bottom interior ofunit100.
The first and second arrays of electrodes are coupled in series between the output terminals of[0045]ion generating unit160, as best seen in FIG. 3. The ability to lifthandle112 provides ready access to the electrodes comprising the electrode assembly, for purposes of cleaning and, if necessary, replacement.
The general shape of the invention shown in FIGS. 2A and 2B is not critical. The top-to-bottom height of the preferred embodiment is perhaps 1 m, with a left-to-right width of perhaps 15 cm, and a front-to-back depth of perhaps 10 cm, although other dimensions and shapes may of course be used. A louvered construction provides ample inlet and outlet venting in an economical housing configuration. There need be no real distinction between[0046]vents104 and106, except their location relative to the second array electrodes, and indeed a common vent could be used. These vents serve to ensure that an adequate flow of ambient air maybe drawn into or made available to theunit100, and that an adequate flow of ionized air that includes safe amounts of O3flows out from unit130.
As will be described, when[0047]unit100 is energized with S1, high voltage output byion generator160 produces ions at the first electrode array, which ions are attracted to the second electrode array. The movement of the ions in an “IN” to “OUT” direction carries with them air molecules, thus electro kinetically producing an outflow of ionized air. The “IN” notion in FIGS. 2A and 2B denote the intake of ambient air withparticulate matter60. The “OUT” notation in the figures denotes the outflow of cleaned air substantially devoid of the particulate matter, which adheres electrostatically to the surface of the second array electrodes. In the process of generating the ionized air flow, safe amounts of ozone (O3) are beneficially produced. It maybe desired to provide the inner surface ofhousing102 with an electrostatic shield to reduces detectable electromagnetic radiation. For example, a metal shield could be disposed within the housing, or portions of the interior of the housing could be coated with a metallic paint to reduce such radiation.
As best seen in FIG. 3,[0048]ion generating unit160 includes a highvoltage generator unit170 andcircuitry180 for converting raw alternating voltage (e.g., 117 VAC) into direct current (“DC”) voltage.Circuitry180 preferably includes circuitry controlling the shape and/or duty cycle of the generator unit output voltage (which control is altered with user switch S2).Circuitry180 preferably also includes a pulse mode component, coupled to switch S3, to temporarily provide a burst of increased output ozone.Circuitry180 can also include a timer circuit and a visual indicator such as a light emitting diode (“LED”). The LED or other indicator (including, if desired, audible indicator) signals when ion generation is occurring. The timer can automatically halt generation of ions and/or ozone after some predetermined time, e.g., 30 minutes. indicator(s), and/or audible indicator(s).
As shown in FIG. 3, high[0049]voltage generator unit170 preferably comprises a lowvoltage oscillator circuit190 of perhaps 20 KHz frequency, that outputs low voltage pulses to anelectronic switch200, e.g., a thyristor or the like. Switch200 switchably couples the low voltage pulses to the input winding of a step-up transformer T1. The secondary winding of T1 is coupled to a highvoltage multiplier circuit210 that outputs high voltage pulses. Preferably the circuitry and components comprising highvoltage pulse generator170 andcircuit180 are fabricated on a printed circuit board that is mounted withinhousing102. If desired, external audio input (e.g., from a stereo tuner) could be suitably coupled tooscillator190 to acoustically modulate the kinetic airflow produced byunit160. The result would be an electrostatic loudspeaker, whose output air flow is audible to the human ear in accordance with the audio input signal. Further, the output air stream would still include ions and ozone.
Output pulses from[0050]high voltage generator170 preferably are at least 10 KV peak-to-peak with an effective DC offset of perhaps half the peak-to-peak voltage, and have a frequency of perhaps 20 KHz. The pulse train output preferably has a duty cycle of perhaps 10%, which will promote battery lifetime. Of course, different peak-peak amplitudes, DC offsets, pulse train waveshapes, duty cycle, and/or repetition frequencies may instead be used. Indeed, a 100% pulse train (e.g., an essentially DC high voltage) maybe used, albeit with shorter battery lifetime. Thus,generator unit170 may (but need not) be referred to as a high voltage pulse generator.
Frequency of oscillation is not especially critical but frequency of at least about 20 KHz is preferred as being inaudible to humans. If pets will be in the same room as the[0051]unit100, it may be desired to utilize an even higher operating frequency, to prevent pet discomfort and/or howling by the pet. As noted with respect to FIGS.5A-6E, to reduce likelihood of audible oscillations, it is desired to include at least one mechanism to clean thefirst electrode array230elements232.
The output from high voltage[0052]pulse generator unit170 is coupled to anelectrode assembly220 that comprises afirst electrode array230 and asecond electrode array240.Unit170 functions as a DC :DC high voltage generator, and could be implemented using other circuitry and/or techniques to output high voltage pulses that are input toelectrode assembly220.
In the embodiment of FIG. 3, the positive output terminal of[0053]unit170 is coupled tofirst electrode array230, and the negative output terminal is coupled tosecond electrode array240. This coupling polarity has been found to work well, including minimizing unwanted audible electrode vibration or hum. An electrostatic flow of air is created, going from the first electrode array towards the second electrode array. (This flow is denoted “OUT” in the figures.) Accordinglyelectrode assembly220 is mounted withintransporter system100 such thatsecond electrode array240 is closer to the OUT vents andfirst electrode array230 is closer to the IN vents.
When voltage or pulses from high[0054]voltage pulse generator170 are coupled across first andsecond electrode arrays230 and240, it is believed that a plasma-like field is created surroundingelectrodes232 infirst array230. This electric field ionizes the ambient air between the first and second electrode arrays and establishes an “OUT” airflow that moves towards the second array. It is understood that the IN flow enters via vent(s)104, and that the OUT flow exits via vent(s)106.
It is believed that ozone and ions are generated simultaneously by the first array electrode(s)[0055]232, essentially as a function of the potential fromgenerator170 coupled to the first array. Ozone generation maybe increased or decreased by increasing or decreasing the potential at the first array. Coupling an opposite polarity potential to the second array electrode(s)242 essentially accelerates the motion of ions generated at the first array, producing the air flow denoted as “OUT” in the figures. As the ions move toward the second array, it is believed that they push or move air molecules toward the second array. The relative velocity of this motion may be increased by decreasing the potential at the second array relative to the potential at the first array.
For example, if +10 KV were applied to the first array electrode(s), and no potential were applied to the second array electrode(s), a cloud of ions (whose net charge is positive) would form adjacent the first electrode array. Further, the relatively high 10 KV potential would generate substantial ozone. By coupling a relatively negative potential to the second array electrode(s), the velocity of the air mass moved by the net emitted ions increases, as momentum of the moving ions is conserved.[0056]
On the other hand, if it were desired to maintain the same effective outflow (OUT) velocity but to generate less ozone, the exemplary 10 KV potential could be divided between the electrode arrays. For example,[0057]generator170 could provide +4 KV (or some other fraction) to the first array electrode(s) and −6 KV (or some other fraction) to the second array electrode(s). In this example, it is understood that the +4 KV and the −6 KV are measured relative to ground. Understandably it is desired that theunit100 operate to output safe amounts of ozone. Accordingly, the high voltage is preferably fractionalized with about +4 KV applied to the first array electrode(s) and about −6 KV applied to the second array electrodes.
As noted, outflow (OUT) preferably includes safe amounts of O[0058]3that can destroy or at least substantially alter bacteria, germs, and other living (or quasi-living) matter subjected to the outflow. Thus, when switch S1 is closed and131 has sufficient operating potential, pulses from high voltagepulse generator unit170 create an outflow (OUT) of ionized air and O3. When S1 is closed, LED will visually signal when ionization is occurring.
Preferably operating parameters of[0059]unit100 are set during. manufacture and are not user-adjustable. For example, increasing the peak-to-peak output voltage and/or duty cycle in the high voltage pulses generated byunit170 can increase air flowrate, ion content, and ozone content. In the preferred embodiment, output flowrate is about 200 feet/minute, ion content is about 2,000,000/cc and ozone content is about 40 ppb (over ambient) to perhaps 2,000 ppb (over ambient). Decreasing the R2/R1 ratio below about 20:1 will decrease flow rate, as will decreasing the peak-to-peak voltage and/or duty cycle of the high voltage pulses coupled between the first and second electrode arrays.
In practice,[0060]unit100 is placed in a room and connected to an appropriate source of operating potential, typically 117 VAC. With S1 energized,ionization unit160 emits ionized air and preferably some ozone (O3) via outlet vents150. The air flow, coupled with the ions and ozone freshens the air in the room, and the ozone can beneficially destroy or at least diminish the undesired effects of certain odors, bacteria, germs, and the like. The air flow is indeed electrokinetically produced, in that there are no intentionally moving parts withinunit100. (As noted, some mechanical vibration may occur within the electrodes.) As will be described with respect to FIG. 4A, it is desirable thatunit100 actually output a net surplus of negative ions, as these ions are deemed more beneficial to health than are positive ions.
Having described various aspects of the invention in general, preferred embodiments of[0061]electrode assembly220 will now be described. In the various embodiments,electrode assembly220 will comprise afirst array230 of at least oneelectrode232, and will further comprise asecond array240 of preferably at least oneelectrode242. Understandably material(s) forelectrodes232 and242 should conduct electricity, be resilient to corrosive effects from the application of high voltage, yet be strong enough to be cleaned.
In the various electrode assemblies to be described herein, electrode(s)[0062]232 in thefirst electrode array230 are preferably fabricated from tungsten. Tungsten is sufficiently robust to withstand cleaning, has a high melting point to retard breakdown due to ionization, and has a rough exterior surface that seems to promote efficient ionization. On the other hand,electrodes242 preferably will have a highly polished exterior surface to minimize unwanted point-to-point radiation. As such,electrodes242 preferably are fabricated from stainless steel, brass, among other materials. The polished surface ofelectrodes232 also promotes ease of electrode cleaning.
In contrast to the prior art electrodes disclosed by Lee,[0063]electrodes232 and242, electrodes used inunit100 are light weight, easy to fabricate, and lend themselves to mass production. Further,electrodes232 and242 described herein promote more efficient generation of ionized air, and production of safe amounts of ozone, O3.
In[0064]unit100, a highvoltage pulse generator170 is coupled between thefirst electrode array230 and thesecond electrode array240. The high voltage pulses produce a flow of ionized air that travels in the direction from the first array towards the second array (indicated herein by hollow arrows denoted “OUT”). As such, electrode(s)232 maybe referred to as an emitting electrode, andelectrodes242 may be referred to as collector electrodes. This outflow advantageously contains safe amounts of O3, and exitsunit100 from vent(s)106.
It is preferred that the positive output terminal or port of the high voltage pulse generator be coupled to[0065]electrodes232, and that the negative output terminal or port be coupled toelectrodes242. It is believed that the net polarity of the emitted ions is positive, e.g., more positive ions than negative ions are emitted. In any event, the preferred electrode assembly, electrical coupling minimizes audible hum fromelectrodes232 contrasted with reverse polarity (e.g., interchanging the positive and negative output port connections).
However, while generation ofpositive ions is conducive to a relatively silent air flow, from a health standpoint, it is desired that the output air flow be richer in negative ions, not positive ions. It is noted that in some embodiments, however, one port (preferably the negative port) of the high voltage pulse generator may in fact be the ambient air. Thus, electrodes in the second array need not be connected to the high voltage pulse generator using wire. Nonetheless, there will be an “effective connection” between the second array electrodes and one output port of the high voltage pulse generator, in this instance, via ambient air.[0066]
Turning now to the embodiments of FIGS. 4A and 4B,[0067]electrode assembly220 comprises afirst array230 ofwire electrodes232, and asecond array240 of generally “U”-shapedelectrodes242. In preferred embodiments, the number N of electrodes comprising the first array will preferably differ by one relative to the number N2 of electrodes comprising the second array. In many of the embodiments shown, N2>N1. However, if desired, in FIG. 4A, additionfirst electrodes232 could be added at the out ends ofarray230 such that N1>N2, e.g., fiveelectrodes232 compared to fourelectrodes242.
[0068]Electrodes232 are preferably lengths of tungsten wire, whereaselectrodes242 are formed from sheet metal, preferably stainless steel, although brass or other sheet metal could be used. The sheet metal is readily formed to defineside regions244 andbulbous nose region246 for hollow elongated “U” shapedelectrodes242. While FIG. 4A depicts fourelectrodes242 insecond array240 and threeelectrodes232 infirst array230, as noted, other numbers of electrodes in each array could be used, preferably retaining a symmetrically staggered configuration as shown. It is seen in FIG. 4A that whileparticulate matter60 is present in the incoming (IN) air, the outflow (OUT) air is substantially devoid of particulate matter, which adheres to the preferably large surface area provided by the second array electrodes (see FIG. 4B).
As best seen in FIG. 4B, the spaced-apart configuration between the arrays is staggered such that each[0069]first array electrode232 is substantially equidistant from twosecond array electrodes242. This symmetrical staggering has been found to be an especially efficient electrode placement. Preferably the staggering geometry is symmetrical in thatadjacent electrodes232 oradjacent electrodes242 are spaced-apart a constant distance, Y1 and Y2 respectively. However, a non-symmetrical configuration could also be used, although ion emission and air flow would likely be diminished. Also, it is understood that the number ofelectrodes232 and242 may differ from what is shown.
In FIG. 4A, typically dimensions are as follows: diameter of[0070]electrodes232 is about 0.08 mm, distances Y1 and Y2 are each about 16 mm, distance X1 is about 16 mm, distance L is about 20 mm, and electrode heights Z1 and Z2 are each about 1 m. The width W ofelectrodes242 is preferably about 4 mm, and the thickness of the material from whichelectrodes242 are formed is about 0.5 mm. Of course other dimensions and shapes could be used. It is preferred thatelectrodes232 be small in diameter to help establish a desired high voltage field. On the other hand, it is desired that electrodes232 (as well as electrodes242) be sufficiently robust to withstand occasional cleaning.
[0071]Electrodes232 infirst array230 are coupled by aconductor234 to a first (preferably positive) output port of highvoltage pulse generator170, andelectrodes242 insecond array240 are coupled by aconductor244 to a second (preferably negative) output port ofgenerator170. It is relatively unimportant where on the various electrodes electrical connection is made toconductors234 or244. Thus, by way of example FIG. 4B depictsconductor244 making connection with someelectrodes242 internal tobulbous end246, whileother electrodes242 make electrical connection toconductor244 elsewhere on the electrode. Electrical connection to thevarious electrodes242 could also be made on the electrode external surface providing no substantial impairment of the outflow airstream results.
To facilitate removing the electrode assembly from unit[0072]100 (as shown in FIG. 2B), it is preferred that the lower end of the various electrodes fit against mating portions of wire orother conductors234 or244. For example, “cup-like” members can be affixed towires234 and244 into which the free ends of the various electrodes fit whenelectrode array220 is inserted completely intohousing102 ofunit100.
The ratio of the effective electric field emanating area of[0073]electrode232 to the nearest effective area ofelectrodes242 is at least about 15:1, and preferably is at least 20:1. Thus, in the embodiment of FIG. 4A and FIG. 4B, the ratio R2/R1≈2 mm/0.04 mm≈50:1.
In this and the other embodiments to be described herein, ionization appears to occur at the smaller electrode(s)[0074]232 in thefirst electrode array230, with ozone production occurring as a function of high voltage arcing. For example, increasing the peak-to-peak voltage amplitude and/or duty cycle of the pulses from the highvoltage pulse generator170 can increase ozone content in the output flow of ionized air. If desired, user-control S2 can be used to somewhat vary ozone content by varying (in a safe manner) amplitude and/or duty cycle. Specific circuitry for achieving such control is known in the art and need not be described in detail herein.
Note the inclusion in FIGS. 4A and 4B of at least one[0075]output controlling electrode243, preferably electrically coupled to the same potential as the second array electrodes.Electrode243 preferably defines a pointed shape in side profile, e.g., a triangle. The sharp point on electrode(s)243 causes generation of substantial negative ions (since the electrode is coupled to relatively negative high potential). These negative ions neutralize excess positive ions otherwise present in the output air flow, such that the OUT flow has a net negative charge. Electrode(s)243 preferably are stainless steel, copper, or other conductor, and are perhaps 20 mm high and about 12 mm wide at the base.
Another advantage of including pointed[0076]electrodes243 is that they may be stationarily mounted within the housing ofunit100, and thus are not readily reached by human hands when cleaning the unit. Were it otherwise, the sharp point on electrode(s)243 could easily cause cuts. The inclusion of oneelectrode243 has been found sufficient to provide a sufficient number of output negative ions, but more such electrodes may be included.
In the embodiment of FIGS. 4A and 4C, each “U”-shaped[0077]electrode242 has two trailing edges that promote efficient kinetic transport of the outflow of ionized air and O3. Note the inclusion on at least one portion of a trailing edge of apointed electrode region243′.Electrode region243′ helps promote output of negative ions, in the same fashion as was described with respect to FIGS. 4A and 4B. Note, however, the higher likelihood of a user cutting himself or herself when wipingelectrodes242 with a cloth or the like to remove particulate matter deposited thereon. In FIG. 4C and the figures to follow, the particulate matter is omitted for ease of illustration. However, from what was shown in FIGS.2A-4B, particulate matter will be present in the incoming air, and will be substantially absent from the outgoing air. As has been described,particulate matter60 typically will be electrostatically precipitated upon the surface area ofelectrodes242. As indicated by FIG. 4C, it is relatively unimportant where on an electrode array electrical connection is made. Thus,first array electrodes232 are shown connected together at their bottom regions, whereassecond array electrodes242 are shown connected together in their middle regions. Both arrays may be connected together in more than one region, e.g., at the top and at the bottom. It is preferred that the wire or strips or other inter-connecting mechanisms be at the top or bottom or periphery of thesecond array electrodes242, so as to minimize obstructing stream air movement.
Note that the embodiments of FIGS. 4C and 4D depict somewhat truncated versions of[0078]electrodes242. Whereas dimension L in the embodiment of FIGS. 4A and 4B was about 20 mm, in FIGS. 4C and 4D, L has been shortened to about 8 mm. Other dimensions in FIG. 4C preferably are similar to those stated for FIGS. 4A and 4B. In FIGS. 4C and 4D, the inclusion of point-like regions246 on the trailing edge ofelectrodes242 seems to promote more efficient generation of ionized air flow. It will be appreciated that the configuration ofsecond electrode array240 in FIG. 4C can be more robust than the configuration of FIGS. 4A and 4B, by virtue of the shorter trailing edge geometry. As noted earlier, a symmetrical staggered geometry for the first and second electrode arrays is preferred for the configuration of FIG. 4C.
In the embodiment of FIG. 4D, the outermost second electrodes, denoted[0079]242-1 and242-2, have substantially no outermost trailing edges. Dimension L in FIG. 4D is preferably about 3 mm, and other dimensions maybe as stated for the configuration of FIGS. 4A and 4B. Again, the R2/R1 ratio for the embodiment of FIG. 4D preferably exceeds about 20:1.
FIGS. 4E and 4F depict another embodiment of[0080]electrode assembly220, in which the first electrode array comprises asingle wire electrode232, and the second electrode array comprises a single pair of curved “L”-shapedelectrodes242, in cross-section. Typical dimensions, where different than what has been stated for earlier-described embodiments, are X1≈12 mm, Y1≈6 mm, Y2≈5 mm, and L1≈3 mm. The effective R2/R1 ratio is again greater than about 20:1. The fewerelectrodes comprising assembly220 in FIGS. 4E and 4F promote economy of construction, and ease of cleaning, although more than oneelectrode232, and more than twoelectrodes242 could of course be employed. This embodiment again incorporates the staggered symmetry described earlier, in which electrode232 is equidistant from twoelectrodes242.
Turning now to FIG. 5A, a first embodiment of an[0081]electrode cleaning mechanism500 is depicted. In the embodiment shown,mechanism500 comprises a flexible sheet of insulating material such as MYLAR or other high voltage, high temperature breakdown resistant material, having sheet thickness of perhaps 0.1 mm or so.Sheet500 is attached at one end to the base orother mechanism113 secured to the lower end ofsecond electrode array240.Sheet500 extends or projects out frombase113 towards and beyond the location offirst electrode array230electrodes232. The overall projection length ofsheet500 in FIG. 5A will be sufficiently long to span the distance betweenbase113 of thesecond array240 and the location ofelectrodes232 in thefirst array230. This span distance will depend upon the electrode array configuration but typically will be a few inches or so. Preferably the distal edge ofsheet500 will extend slightly beyond the location ofelectrodes232, perhaps 0.5″ beyond. As shown in FIGS. 5A and 5C, the distal edge, e.g., edge closest toelectrodes232, ofmaterial500 is formed with aslot510 corresponding to the location of anelectrode232. Preferably the inward end of the slot forms asmall circle520, which can promote flexibility.
The configuration of[0082]material500 andslots510 is such that each wire or wire-like electrode232 in thefirst electrode array230 fits snugly and friction ally within acorresponding slot510. As indicated by FIG. 5A and shown in FIG. 5C, instead of asingle sheet500 that includes a plurality ofslots510, instead one can provideindividual strips515 ofmaterial500, the distal end of each strip having aslot510 that will surround an associatedwire electrode232. Note in FIGS. 5B and 5C thatsheet500 orsheets515 maybe formed withholes119 that can attach topegs117 that project from thebase portion113 of thesecond electrode array240. Of course other attachment mechanisms could be used including glue, double-sided tape, inserting the array240-facing edge of the sheet into a horizontal slot or ledge inbase member113, and so forth.
FIG. 5A shows[0083]second electrode array240 in the process of being moved upward, perhaps by a user intending to removearray240 to remove particulate matter from the surfaces of itselectrodes242. Note that asarray240 moves up (or down), sheet510 (or sheets515) also move up (or down). This vertical movement ofarray240 produces a vertical movement insheet510 or515, which causes the outer surface ofelectrodes232 to scrape against the inner surfaces of an associatedslot510. FIG. 5A, for example, shows debris and other deposits612 (indicated by x's) onwires232 abovesheet500. Asarray240 andsheet500 move upward,debris612 is scraped off the wire electrodes, and falls downward (to be vaporized or collected as particulate matter whenunit100 is again reassembled and turned-on). Thus, the outer surface ofelectrodes232 belowsheet500 in FIG. 5A is shown as being cleaner than the surface of the same electrodes abovesheet500, where scraping action has yet to occur.
A user hearing that excess noise or humming emanates from[0084]unit100 might simply turn the unit off, and slide array240 (and thussheet500 or sheets515) up and down (as indicated by the up/down arrows in FIG. 5A) to scrape the wire electrodes in the first electrode array. This technique does not damage the wire electrodes, and allows the user to clean as required.
As noted earlier, a user may remove[0085]second electrode array240 for cleaning (thus also removingsheet500, which will have scrapedelectrodes232 on its upward vertical path). If the user cleanselectrodes242 with water and returnsarray240 tounit100 without first completely drying240, moisture might form on the upper surface of a horizontally disposedmember550 withinunit100. Thus, as shown in FIG. 5N, it is preferred that an upwardly projectingvane560 be disposed near the base of eachelectrode232 such that whenarray240 is fully inserted intounit100, the distal portion ofsheet500 or preferably sheet strips515 deflect upward. Whilesheet500 orsheets515 nominally will define an angle θ of about 90°, asbase113 becomes fully inserted intounit100, the angle θ will increase, approaching 0°, e.g., the sheet is extending almost vertically upward. If desired, a portion ofsheet500 or sheet strips515 can be made stiffer by laminating two or more layers of MYLAR or other material. For example the distal tip ofstrip515 in FIG. 5B might be one layer thick, whereas the half or so of the strip length nearestelectrode242 might be stiffened with an extra layer or two of MYLAR or similar material.
The inclusion of a projecting[0086]vane560 in the configuration of FIG. 5B advantageously disrupted physical contact betweensheet500 or sheet strips515 andelectrodes232, thus tending to preserve a high ohmic impedance between the first andsecond electrode arrays230,240. The embodiment of FIGS.6A-6D advantageously serves to pivotsheet500 or sheet strips515 upward, essentially parallel toelectrodes232, to help maintain a high impedance between the first and second electrode arrays. Note the creation of anair gap513 resulting from the upward deflection of the slit distal tip ofstrip515 in FIG. 5B.
In FIG. 6A, the lower edges of[0087]second array electrodes242 are retained byabase member113 from which projectarms677, which can pivot aboutpivot axle687. Preferablyaxle687biases arms677 into a horizontal disposition, e.g., such that θ≈90°.Arms645 project from the longitudinal axis ofbase member113 to helpmember113 align itself within anopening655 formed inmember550, described below. Preferablybase member113 andarms677 are formed from a material that exhibits high voltage breakdown and can withstand high temperature. Ceramic is a preferred material (if cost and weight were not considered), but certain plastics could also be used. The unattached tip of eacharm677 terminates in asheet strip515 of MYLAR, KAPTON, or a similar material, whose distal tip terminates in aslot510. It is seen that thepivotable arms677 and sheet strips515 are disposed such that eachslot510 will self-align with a wire or wire-like electrode232 infirst array230.Electrodes232 preferably extend frompylons627 on abase member550 that extends fromlegs565 from the internal bottom of the housing of the transporter-conditioner unit. To further help maintain high impedance between the first and second electrode arrays,base member550 preferably includes abarrier wall665 and upwardly extendingvanes675.Vanes675,pylons627, andbarrier wall665 extend upward perhaps an inch or so, depending upon the configuration of the two electrode be formed integrally, e.g., by casting, from a material that exhibits high voltage breakdown and can withstand high temperature, ceramic, or certain plastics for example.
As best seen in FIG. 6A,[0088]base member550 includes anopening655 sized to receive the lower portion of second electrodearray base member113. In FIGS. 6A and 6B,arms677 andsheet material515 are shown pivoting frombase member113 aboutaxis687 at an angle θ≈90≈. In this disposition, anelectrode232 will be within theslot510 formed at the distal tip of eachsheet material member515.
Assume that a user had removed[0089]second electrode array240 completely from the transporter-conditioner unit for cleaning, and that FIGS. 6A and 6B depictarray240 being reinserted into the unit. The coiled spring or other bias mechanism associated withpivot axle687 will urgearms677 into an approximate 0≈90° orientation as the user insertsarray240 intounit100.Side projections645help base member113 align properly such that each wire or wire-like electrode232 is caught within theslot510 of amember515 on anarm677. As the user slidesarray240 down intounit100, there will be a scraping action between the portions ofsheet member515 on either side of aslot510, and the outer surface of anelectrode232 that is essentially captured within the slot. This friction will help remove debris or deposits that may have formed on the surface ofelectrodes232. The user may slidearray240 up and down the further promote the removal of debris or deposits fromelements232.
In FIG. 6C the user has slid[0090]array240 down almost entirely intounit100. In the embodiment shown, when the lowest portion ofbase member232 is perhaps an inch or so above the planar surface ofmember550, the upward edge of avane675 will strike the a lower surface region of aprojection arm677. The result will be to pivotarm677 and the attached slit-member515 aboutaxle687 such that the angle θ decreases. In the disposition shown in FIG. 6C, θ≈45° and slit contact with an associatedelectrode232 is no longer made.
In FIG. 6D, the user has firmly urged[0091]array240 fully downward into transporter-conditioner unit100. In this disposition, as the projecting bottommost portion ofmember113 begins to enter opening655 in member550 (see FIG. 6A), contact between theinner wall657 portion ofmember550 urges eacharm677 to pivot fully upward, e.g., θ≈0°. Thus in the fully inserted disposition shown in FIG. 6D, each slitelectrode cleaning member515 is rotated upward parallel to its associatedelectrode232. As such, neitherarm677 normember515 will decrease impedance between first andsecond electrode arrays230,240. Further, the presence ofvanes675 andbarrier wall665 further promote high impedance.
Thus, the embodiments shown in FIGS.[0092]5A-6D depict alternative configurations for a cleaning mechanism for a wire or wire-like electrode in a transporter-conditioner unit.
Turning now to FIGS.[0093]7A-7E, various bead-like mechanisms are shown for cleaning deposits from the outer surface ofwire electrodes232 in afirst electrode array230 in a transporter-converter unit. In FIG. 7A asymmetrical bead600 is shown surroundingwire element232, which is passed throughbead channel610 at the time the first electrode array is fabricated.Bead600 is fabricated from a material that can withstand high temperature and high voltage, and is not likely to char, ceramic or glass, for example. While a metal bead would also work, an electrically conductive bead material would tend slightly to decrease the resistance path separating the first and second electrode arrays, e.g., by approximately the radius of the metal bead. In FIG. 7A, debris anddeposits612 onelectrode232 are depicted as “x's”. In FIG. 7A,bead600 is moving in the direction shown by the arrow relative to wire232. Such movement can result from theuser inverting unit100, e.g., turning the unit upside down. Asbead600 slides in the direction of the arrow, debris anddeposits612 scrape against the interior walls ofchannel610 and are removed. The removed debris can eventually collect at the bottom interior of the transporter-conditioner unit. Such debris will be broken down and vaporized as the unit is used, or will accumulate as particulate matter on the surface ofelectrodes242. Ifwire232 has a nominal diameter of say 0.1 mm, the diameter ofbead channel610 will be several times larger, perhaps 0.8 mm or so, although greater or lesser size tolerances may be used. Bead600 need not be circular and may instead be cylindrical as shown bybead600′ in FIG. 7A. A circular bead may have a diameter in the range of perhaps 0.3″ to perhaps 0.5″. A cylindrical bead might have a diameter of say 0.3″ and be about 0.5″ tall, although different sizes could of course be used.
As indicated by FIG. 7A, an[0094]electrode232 maybe strung through more than onebead600,600′. Further, as shown by FIGS.7B-7D, beads having different channel symmetries and orientations maybe used as well. It is to be noted that while it maybe most convenient to formchannels610 with circular cross-sections, the cross-sections could in fact be non-circular, e.g., triangular, square, irregular shape, etc.
FIG. 7B shows a[0095]bead600 similar to that of FIG. 7A, but whereinchannel610 is formed off-center to give asymmetry to the bead. An off-center channel will have a mechanical moment and will tend to slightlytension wire electrode232 as the bead slides up or down, and can improve cleaning characteristics. For ease of illustration, FIGS.7B-7E do not depict debris or deposits on or removed from wire or wire-like electrode232. In the embodiment of FIG. 7C,bead channel610 is substantially in the center ofbead600 but is inclined slightly, again to impart a different frictional cleaning action. In the embodiment of FIG. 7D,beam600 has achannel610 that is both off center and inclined, again to impart a different frictional cleaning action. In general, asymmetrical bead channel or through-opening orientations are preferred.
FIG. 7E depicts an embodiment in which a bell-shaped[0096]walled bead620 is shaped and sized to fit over apillar550 connected to ahorizontal portion560 of an interior bottom portion ofunit100.Pillar550 retains the lower end of wire or wire-like electrode232, which passes through achannel630 inbead620, and if desired, also through achannel610 in anotherbead600.Bead600 is shown in phantom in FIG. 7E to indicate that it is optional.
Friction between[0097]debris612 onelectrode232 and the mouth ofchannel630 will tend to remove the debris from the electrode asbead620 slides up and down the length of the electrode, e.g., when a user inverts transporter-conditioner unit100, to cleanelectrodes232. It is understood that eachelectrode232 will include its own bead or beads, and some of the beads may have symmetrically disposed channels, while other beads may have asymmetrically disposed channels. An advantage of the configuration shown in FIG. 7E is that whenunit100 is in use, e.g., whenbead620 surroundspillar550, with an air gap therebetween, improved breakdown resistance is provided, especially whenbead620 is fabricated from glass or ceramic or other high voltage, high temperature breakdown material that will not readily char. The presence of an air gap between the outer surface ofpillar550 and the inner surface of the bell shapedbead620 helps increase this resistance to high voltage breakdown or arcing, and to charring.
Modifications and variations maybe made to the disclosed embodiments without departing from the subject and spirit of the invention as defined by the following claims.[0098]