U.S. patent application number 12/488301 was filed with the patent office on 2009-12-24 for electrolysis cell having conductive polymer electrodes and method of electrolysis.
This patent application is currently assigned to TENNANT COMPANY. Invention is credited to Bruce F. Field.
Application Number | 20090314657 12/488301 |
Document ID | / |
Family ID | 41105205 |
Filed Date | 2009-12-24 |
United States Patent
Application |
20090314657 |
Kind Code |
A1 |
Field; Bruce F. |
December 24, 2009 |
ELECTROLYSIS CELL HAVING CONDUCTIVE POLYMER ELECTRODES AND METHOD
OF ELECTROLYSIS
Abstract
A method and apparatus are provided for performing electrolysis
with an electrolysis cell. The cell includes an anode electrode and
a cathode electrode. At least one of the anode electrode or the
cathode electrode is at least partially formed of conductive
polymer.
Inventors: |
Field; Bruce F.; (Golden
Valley, MN) |
Correspondence
Address: |
WESTMAN CHAMPLIN & KELLY, P.A.
SUITE 1400, 900 SECOND AVENUE SOUTH
MINNEAPOLIS
MN
55402
US
|
Assignee: |
TENNANT COMPANY
Minneapolis
MN
|
Family ID: |
41105205 |
Appl. No.: |
12/488301 |
Filed: |
June 19, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61074059 |
Jun 19, 2008 |
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61077001 |
Jun 30, 2008 |
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61077005 |
Jun 30, 2008 |
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61084460 |
Jul 29, 2008 |
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61092586 |
Aug 28, 2008 |
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61083046 |
Jul 23, 2008 |
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Current U.S.
Class: |
205/770 ;
204/227; 204/252 |
Current CPC
Class: |
C02F 2201/4615 20130101;
C02F 2209/006 20130101; C02F 2307/02 20130101; B08B 3/08 20130101;
Y02E 60/36 20130101; C02F 2001/4619 20130101; C02F 2201/003
20130101; C02F 2201/4613 20130101; C02F 2001/46152 20130101; C02F
2201/46115 20130101; C02F 2201/4617 20130101; C02F 2209/04
20130101; A47L 13/26 20130101; C02F 1/4618 20130101; A61L 2/035
20130101; A61L 2/22 20130101; C02F 2001/46157 20130101; C02F
2201/46135 20130101; C02F 2001/46133 20130101; C02F 2201/46125
20130101; Y02E 60/366 20130101; C02F 2001/46185 20130101; C02F
2201/008 20130101; C02F 2201/4618 20130101; C02F 2001/46119
20130101 |
Class at
Publication: |
205/770 ;
204/227; 204/252 |
International
Class: |
C25B 9/00 20060101
C25B009/00 |
Claims
1. An electrolysis cell comprising: an anode electrode; and a
cathode electrode, wherein at least one of the anode electrode and
the cathode electrode are at least partially formed of conductive
polymer.
2. The electrolysis cell of claim 1 and further comprising an ion
selective membrane disposed between the anode electrode and the
cathode electrode and which defines a respective anode chamber and
cathode chamber.
3. The electrolysis cell of claim 1, wherein both the anode
electrode and the cathode electrode are at least partially formed
of conductive polymer.
4. The electrolysis cell of claim 1, wherein the anode electrode
and the cathode electrode each consist solely of conductive
polymer.
5. The electrolysis cell of claim 1, wherein the conductive polymer
has a surface resistivity of 10.sup.0 to 10.sup.12 ohm/sq.
6. The electrolysis cell of claim 1, wherein the conductive polymer
has a surface resistivity of 10.sup.1 to 10.sup.6 ohm/sq.
7. The electrolysis cell of claim 1, wherein the anode electrode
and cathode electrode are cylindrical and are coaxial with one
another.
8. The electrolysis cell of claim 1 and further comprising: an ion
selective membrane disposed between the anode electrode and the
cathode electrode and which defines a respective anode chamber and
cathode chamber; an inlet, which directs a received liquid into the
anode chamber and the cathode chamber; and an outlet, which
receives a combined flow of liquid from the anode chamber and the
cathode chamber.
9. A mobile surface cleaner comprising the electrolysis cell of
claim 1, a mobile body configured to travel over a surface; a
source of a liquid; a liquid dispenser; and a flow path that passes
from the liquid source, through the electrolysis cell, to the
liquid dispenser.
10. A hand-held spray bottle comprising: a liquid reservoir; a
liquid outlet; an electrolysis cell carried by the bottle and
fluidically coupled between the reservoir and the liquid outlet,
wherein the electrolysis cell comprises an anode electrode and a
cathode electrode, and wherein at least one of the anode electrode
or the cathode electrode is at least partially formed of conductive
polymer; and a switch actuated between first and second states by a
hand trigger, wherein the switch energizes the electrolysis cell in
the first state and de-energizes the electrolysis cell in the
second state.
11. The hand-held spray bottle of claim 10 and further comprising:
a power supply carried by the bottle, wherein the switch couples
the electrolysis cell to the power supply in the first state and
de-couples the electrolysis cell from the power supply in the
second state.
12. The hand-held spray bottle of claim 10 and further comprising
an ion selective membrane disposed between the anode electrode and
the cathode electrode and which defines a respective anode chamber
and cathode chamber.
13. The hand-held spray bottle of claim 10, wherein the anode
electrode and the cathode electrode each consist solely of
conductive polymer.
14. The hand-held spray bottle of claim 10, wherein the conductive
polymer has a surface resistivity of 10.sup.0 to 10.sup.12
ohm/sq.
15. The hand-held spray bottle of claim 10, wherein the conductive
polymer has a surface resistivity of 10.sup.1 to 10.sup.6
ohm/sq.
16. The hand-held spray bottle of claim 10, wherein the anode
electrode and cathode electrode are cylindrical and are coaxial
with one another.
17. The hand-held spray bottle of claim 10 and wherein the
electrolysis cell further comprises: an ion selective membrane
disposed between the anode electrode and the cathode electrode and
which defines a respective anode chamber and cathode chamber; an
inlet, which directs a received liquid into the anode chamber and
the cathode chamber; and an outlet, which receives a combined flow
of liquid from the anode chamber and the cathode chamber.
18. A method comprising electrolyzing a liquid using an
electrolysis cell, which comprises at least one conductive polymer
electrode.
19. The method of claim 18, wherein the method comprises:
introducing a first part of the liquid into a first electrolysis
chamber comprising a first electrode; introducing a second part of
the liquid into a second electrolysis chamber comprising a second
electrode, wherein the second electrolysis chamber is separated
from the first electrolysis chamber by an ion selective membrane
and wherein at least one of the first or second electrodes
comprises a conductive polymer; and applying a voltage across the
first and second electrodes to electrochemically activate the first
and second parts of the liquid.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is based on and claims the benefit
of the following applications: [0002] 1) U.S. Provisional Patent
Appln. No. 61/074,059, filed Jun. 19, 2008, entitled ELECTROLYSIS
CELL HAVING CONDUCTIVE POLYMER ELECTRODES AND METHOD OF
ELECTROLYSIS; [0003] 2) U.S. Provisional Patent Appln. No.
61/077,001, filed Jun. 30, 2008, entitled HAND-HELD SPRAY BOTTLE
ELECTROLYSIS CELL AND DC-DC CONVERTER; [0004] 3) U.S. Provisional
Patent Appln. No. 61/077,005, filed Jun. 30, 2008, entitled
ELECTROLYSIS CELL HAVING ELECTRODES WITH VARIOUS-SIZED/SHAPED
APERTURES; [0005] 4) U.S. Provisional Patent Appln. No. 61/083,046,
filed Jul. 23, 2008, entitled ELECTROLYSIS DE-SCALING METHOD WITH
CONSTANT OUTPUT; [0006] 5) U.S. Provisional Patent Appln. No.
61/084,460, filed Jul. 29, 2008, entitled TUBULAR ELECTROLYSIS CELL
AND CORRESPONDING METHOD; and [0007] 6) U.S. Provisional Patent
Appln. No. 61/092,586, filed Aug. 28, 2008, entitled APPARATUS
HAVING ELECTROLYSIS CELL AND INDICATOR LIGHT ILLUMINATING THROUGH
LIQUID; the contents of which are hereby incorporated by reference
in their entirety.
FIELD OF THE DISCLOSURE
[0008] The present disclosure relates to electrochemical activation
of fluids and, more particularly, to electrolysis cells and
corresponding methods.
BACKGROUND
[0009] Electrolysis cells are used in a variety of different
applications for changing one or more characteristics of a fluid.
For example, electrolysis cells have been used in
cleaning/sanitizing applications, medical industries, and
semiconductor manufacturing processes. Electrolysis cells have also
been used in a variety of other applications and have had different
configurations.
[0010] For cleaning/sanitizing applications, electrolysis cells are
used to create anolyte electrochemically activated (EA) liquid and
catholyte EA liquid. Anolyte EA liquids have known sanitizing
properties, and catholyte EA liquids have known cleaning
properties. Examples of cleaning and/or sanitizing systems are
disclosed in Field et al. U.S. Publication No. 2007/0186368 A1,
published Aug. 16, 2007.
SUMMARY
[0011] An aspect of the disclosure relates to an electrolysis cell.
The cell includes an anode electrode and a cathode electrode. At
least one of the anode electrode or the cathode electrode is at
least partially formed of conductive polymer.
[0012] Another aspect of the disclosure relates to a hand-held
spray bottle. The bottle includes a liquid reservoir, a liquid
outlet and an electrolysis cell carried by the bottle and
fluidically coupled between the reservoir and the liquid outlet.
The electrolysis cell has an anode electrode and a cathode
electrode. At least one of the anode electrode or the cathode
electrode is at least partially formed of conductive polymer. The
bottle further includes a switch actuated between first and second
states by a hand trigger, wherein the switch energizes the
electrolysis cell in the first state and de-energizes the
electrolysis cell in the second state.
[0013] Another aspect of the disclosure relates to a method, which
includes electrolyzing a liquid using an electrolysis cell having
at least one conductive polymer electrode.
[0014] For example, the method includes the steps of: introducing a
first part of the liquid into a first electrolysis chamber
comprising a first electrode; introducing a second part of the
liquid into a second electrolysis chamber comprising a second
electrode, wherein the second electrolysis chamber is separated
from the first electrolysis chamber by an ion selective membrane
and wherein at least one of the first or second electrodes includes
a conductive polymer; and applying a voltage across the first and
second electrodes to electrochemically activate the first and
second parts of the liquid.
[0015] This Summary is provided to introduce a selection of
concepts in a simplified form that are further described below in
the Detailed Description. This Summary is not intended to identify
key features or essential features of the claimed subject matter,
nor is it intended to be used as an aid in determining the scope of
the claimed subject matter. The claimed subject matter is not
limited to implementations that solve any or all disadvantages
noted in the background.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a simplified, schematic diagram of a hand-held
spray bottle according to an exemplary aspect of the present
disclosure.
[0017] FIG. 2 illustrates an example of an electrolysis cell having
an ion-selective membrane.
[0018] FIG. 3 illustrates an electrolysis cell having no
ion-selective membrane according to a further example of the
disclosure.
[0019] FIG. 4A is a fragmentary view of a conductive polymer
electrode having a plurality of rectilinear apertures in a regular
grid pattern according to an aspect of the disclosure.
[0020] FIG. 4B is a fragmentary view of a conductive polymer
electrode having a plurality of curvilinear apertures of different
sizes in a regular grid pattern according to another example.
[0021] FIG. 4C is a fragmentary view of a conductive polymer
electrode having a plurality of irregular and regular shaped
apertures having a variety of different shapes and sizes according
to another example.
[0022] FIG. 5 illustrates an example of an electrolysis cell having
a tubular shape according to one illustrative example.
[0023] FIG. 6 is a waveform diagram illustrating the voltage
pattern applied to the anode and cathode according to an exemplary
aspect of the present disclosure.
[0024] FIG. 7 is a block diagram of a system having an indicator
according to an embodiment of the disclosure, which can be
incorporated into any of the embodiments disclosed herein, for
example.
[0025] FIG. 8A is a perspective view of a spray bottle having an
indicator light that illuminates through liquid carried by the
bottle.
[0026] FIG. 8B is a perspective view of a spray bottle having an
indicator light that illuminates through liquid carried by the
bottle, according to an alternative embodiment of the
disclosure.
[0027] FIG. 8C is a rear, perspective view of a head of the bottle
shown in FIG. 8B.
[0028] FIGS. 9A and 9B are perspective views of a left-hand side
housing, and FIG. 9C is a perspective view of a right-hand side
housing of the bottle shown in FIG. 8B.
[0029] FIG. 10 illustrates various components installed in the
left-hand side housing.
[0030] FIGS. 11A and 11B illustrate a liquid container carried by
the bottle shown in FIG. 8B.
[0031] FIG. 12A illustrates a fragmentary, close-up view of a
pump/cell assembly installed in a barrel of the housing.
[0032] FIG. 12B is a perspective view of the pump/cell assembly
removed from the housing.
[0033] FIG. 12C is a bottom, perspective view of the pump/cell
assembly with the trigger removed.
[0034] FIG. 13 illustrates an exploded, perspective view of a
mounting bracket of the assembly shown in FIGS. 12A-12C.
[0035] FIGS. 14A and 14B are perspective views of a trigger of the
bottle shown in FIG. 8B.
[0036] FIGS. 15A and 15B are perspective views of a trigger boot,
which overlies the trigger.
[0037] FIG. 16A illustrates lower compartments of a housing half in
greater detail.
[0038] FIG. 16B illustrates a circuit board and batteries mounted
within the compartments shown in FIG. 16A.
[0039] FIG. 17 is a perspective view of a mobile cleaning machine,
which implements an electrolysis cell according to an example of
the present disclosure.
[0040] FIG. 18 is a simplified block diagram of an electrolysis
cell that is mounted to a platform according to another
embodiment.
[0041] FIG. 19 is a perspective view of an all-surface cleaner
according to another embodiment of the disclosure.
[0042] FIG. 20 is a block diagram illustrating a control circuit
for controlling the various components within the hand-held spray
bottle shown in FIGS. 8-16 according to an illustrating example of
the disclosure.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0043] An aspect of the present disclosure is directed to a method
and apparatus for electrolyzing liquids.
1. Hand-Held Spray Bottle
[0044] Electrolysis cells can be used in a variety of different
applications and housed in a variety of different types of
apparatus, which can be hand-held, mobile, immobile, wall-mounted,
motorized or non-motorized cleaning/sanitizing vehicle, wheeled,
etc, for example. In this example, an electrolysis cell is
incorporated in a hand-held spray bottle.
[0045] FIG. 1 is a simplified, schematic diagram of a hand-held
spray bottle 10 according to an exemplary aspect of the present
disclosure. Spray bottle 10 includes a reservoir 12 for containing
a liquid to be treated and then dispensed through a nozzle 14. In
an example, the liquid to be treated includes an aqueous
composition, such as regular tap water.
[0046] Spray bottle 10 further includes an inlet filter 16, one or
more electrolysis cells 18, tubes 20 and 22, pump 24, actuator 26,
switch 28, circuit board and control electronics 30 and batteries
32. Although not shown in FIG. 1, tubes 20 and 22 may be housed
within a neck and barrel, respectively of bottle 10, for example. A
cap 34 seals reservoir 12 around the neck of bottle 10. Batteries
32 can include disposable batteries and/or rechargeable batteries,
for example, and provide electrical power to electrolysis cell 18
and pump 24 when energized by circuit board and control electronics
30.
[0047] In the example shown in FIG. 1, actuator 26 is a
trigger-style actuator, which actuates momentary switch 28 between
open and closed states. For example, when the user "squeezes" the
hand trigger to a squeezed state, the trigger actuates the switch
into the closed state. When the user releases the hand trigger,
trigger actuates the switch into the open state. However, actuator
26 can have other styles in alternative embodiments and can be
eliminated in further embodiments. In embodiments that lack a
separate actuator, switch 28 can be actuated directly by the user.
When switch 28 is in the open, non-conducting state, control
electronics 30 de-energizes electrolysis cell 18 and pump 24. When
switch 28 is in the closed, conducting state, control electronics
30 energizes electrolysis cell 18 and pump 24. Pump 24 draws liquid
from reservoir 12 through filter 16, electrolysis cell 18, and tube
20 and forces the liquid out tube 22 and nozzle 14. Depending on
the sprayer, nozzle 14 may or may not be adjustable, so as to
select between squirting a stream, aerosolizing a mist, or
dispensing a spray, for example.
[0048] Switch 28, itself, can have any suitable actuator type, such
as a push-button switch as shown in FIG. 1, a toggle, a rocker, any
mechanical linkage, and/or any non-mechanical sensor such as
capacitive, resistive plastic, thermal, inductive, etc. Switch 28
can have any suitable contact arrangement, such as momenary,
single-pole single throw, etc.
[0049] In an alternative embodiment, pump 24 is replaced with a
mechanical pump, such as a hand-triggered positive displacement
pump, wherein actuator trigger 26 acts directly on the pump by
mechanical action. In this embodiment, switch 28 could be
separately actuated from the pump 24, such as a power switch, to
energize electrolysis cell 18. In a further embodiment, batteries
32 are eliminated and power is delivered to spray bottle 10 from an
external source, such as through a power cord, plug, and/or contact
terminals.
[0050] The arrangement shown in FIG. 1 is provided merely as a
non-limiting example. Spray bottle 10 can have any other structural
and/or functional arrangement. For example, pump 24 can be located
downstream of cell 18, as shown in FIG. 1, or upstream of cell 18
with respect to the direction of fluid flow from reservoir 12 to
nozzle 14.
[0051] As described in more detail below, the spray bottle contains
a liquid to be sprayed on a surface to be cleaned and/or sanitized.
In one non-limiting example, electrolysis cell 18 converts the
liquid to an anolyte EA liquid and a catholyte EA liquid prior to
being dispensed from the bottle as an output spray. The anolyte and
catholyte EA liquids can be dispensed as a combined mixture or as
separate spray outputs, such as through separate tubes and/or
nozzles. In the embodiment shown in FIG. 1, the anolyte and
catholyte EA liquids are dispensed as a combined mixture. With a
small and intermittent output flow rate provided the spray bottle,
electrolysis cell 18 can have a small package and be powered by
batteries carried by the package or spray bottle, for example.
2. Electrolysis Cells
[0052] An electrolysis cell includes any fluid treatment cell that
is adapted to apply an electric field across the fluid between at
least one anode electrode and at least one cathode electrode. An
electrolysis cell can have any suitable number of electrodes, any
suitable number of chambers for containing the fluid, and any
suitable number of fluid inputs and fluid outputs. The cell can be
adapted to treat any fluid (such as a liquid or gas-liquid
combination). The cell can include one or more ion-selective
membranes between the anode and cathode or can be configured
without any ion selective membranes. An electrolysis cell having an
ion-selective membrane is referred to herein as a "functional
generator".
[0053] Electrolysis cells can be used in a variety of different
applications and can have a variety of different structures, such
as but not limited to a spray bottle as discussed with reference to
FIG. 1, and/or the structures disclosed in Field et al. U.S. Patent
Publication No. 2007/0186368, published Aug. 16, 2007. Thus,
although various elements and processes relating to electrolysis
are described herein relative to the context of a spray bottle,
these elements and processes can be applied to, and incorporated
in, other, non-spray bottle applications.
3. Electrolysis Cell Having a Membrane
3.1 Cell Structure
[0054] FIG. 2 is a schematic diagram illustrating an example of an
electrolysis cell 50 that can be used in the spray bottle shown in
FIG. 1, for example. Electrolysis cell 50 and which receives liquid
to be treated from a liquid source 52. Liquid source 52 can include
a tank or other solution reservoir, such as reservoir 12 in FIG. 1,
or can include a fitting or other inlet for receiving a liquid from
an external source.
[0055] Cell 50 has one or more anode chambers 54 and one or more
cathode chambers 56 (known as reaction chambers), which are
separated by an ion exchange membrane 58, such as a cation or anion
exchange membrane. One or more anode electrodes 60 and cathode
electrodes 62 (one of each electrode shown) are disposed in each
anode chamber 54 and each cathode chamber 56, respectively. The
anode and cathode electrodes 60, 62 can be made from any suitable
material, such as a conductive polymer, titanium and/or titanium
coated with a precious metal, such as platinum, or any other
suitable electrode material. In one example, at least one of the
anode or cathode is at least partially or wholly made from a
conductive polymer. The electrodes and respective chambers can have
any suitable shape and construction. For example, the electrodes
can be flat plates, coaxial plates, rods, or a combination thereof.
Each electrode can have, for example, a solid construction or can
have one or more apertures. In one example, each electrode is
formed as a mesh. In addition, multiple cells 50 can be coupled in
series or in parallel with one another, for example.
[0056] The electrodes 60, 62 are electrically connected to opposite
terminals of a conventional power supply (not shown). Ion exchange
membrane 58 is located between electrodes 60 and 62. The power
supply can provide a constant DC output voltage, a pulsed or
otherwise modulated DC output voltage, and/or a pulsed or otherwise
modulated AC output voltage to the anode and cathode electrodes.
The power supply can have any suitable output voltage level,
current level, duty cycle or waveform.
[0057] For example in one embodiment, the power supply applies the
voltage supplied to the plates at a relative steady state. The
power supply (and/or control electronics) includes a DC/DC
converter that uses a pulse-width modulation (PWM) control scheme
to control voltage and current output. Other types of power
supplies can also be used, which can be pulsed or not pulsed and at
other voltage and power ranges. The parameters are
application-specific.
[0058] During operation, feed water (or other liquid to be treated)
is supplied from source 52 to both anode chamber 54 and cathode
chamber 56. In the case of a cation exchange membrane, upon
application of a DC voltage potential across anode 60 and cathode
62, such as a voltage in a range of about 5 Volts (V) to about 28V,
cations originally present in the anode chamber 54 move across the
ion-exchange membrane 58 towards cathode 62 while anions in anode
chamber 54 move towards anode 60. However, anions present in
cathode chamber 56 are not able to pass through the cation-exchange
membrane, and therefore remain confined within cathode chamber
56.
[0059] As a result, cell 50 electrochemically activates the feed
water by at least partially utilizing electrolysis and produces
electrochemically-activated water in the form of an acidic anolyte
composition 70 and a basic catholyte composition 72.
[0060] If desired, the anolyte and catholyte can be generated in
different ratios to one another through modifications to the
structure of the electrolysis cell, for example. For example, the
cell can be configured to produce a greater volume of catholyte
than anolyte if the primary function of the EA water is cleaning.
Alternatively, for example, the cell can be configured to produce a
greater volume of anolyte than catholyte if the primary function of
the EA water is sanitizing. Also, the concentrations of reactive
species in each can be varied.
[0061] For example, the cell can have a 3:2 ratio of cathode plates
to anode plates for producing a greater volume of catholyte than
anolyte. Each cathode plate is separated from a respective anode
plate by a respective ion exchange membrane. Thus, there are three
cathode chambers for two anode chambers. This configuration
produces roughly 60% catholyte to 40% anolyte. Other ratios can
also be used.
3.2 Example Reactions
[0062] In addition, water molecules in contact with anode 60 are
electrochemically oxidized to oxygen (O.sub.2) and hydrogen ions
(H.sup.+) in the anode chamber 54 while water molecules in contact
with the cathode 62 are electrochemically reduced to hydrogen gas
(H.sub.2) and hydroxyl ions (OH.sup.-) in the cathode chamber 56.
The hydrogen ions in the anode chamber 54 are allowed to pass
through the cation-exchange membrane 58 into the cathode chamber 56
where the hydrogen ions are reduced to hydrogen gas while the
oxygen gas in the anode chamber 54 oxygenates the feed water to
form the anolyte 70. Furthermore, since regular tap water typically
includes sodium chloride and/or other chlorides, the anode 60
oxidizes the chlorides present to form chlorine gas. As a result, a
substantial amount of chlorine is produced and the pH of the
anolyte composition 70 becomes increasingly acidic over time.
[0063] As noted, water molecules in contact with the cathode 62 are
electrochemically reduced to hydrogen gas and hydroxyl ions
(OH.sup.-) while cations in the anode chamber 54 pass through the
cation-exchange membrane 58 into the cathode chamber 56 when the
voltage potential is applied. These cations are available to
ionically associate with the hydroxyl ions produced at the cathode
62, while hydrogen gas bubbles form in the liquid. A substantial
amount of hydroxyl ions accumulates over time in the cathode
chamber 56 and reacts with cations to form basic hydroxides. In
addition, the hydroxides remain confined to the cathode chamber 56
since the cation-exchange membrane does not allow the negatively
charged hydroxyl ions pass through the cation-exchange membrane.
Consequently, a substantial amount of hydroxides is produced in the
cathode chamber 56, and the pH of the catholyte composition 72
becomes increasingly alkaline over time.
[0064] The electrolysis process in the functional generator 50
allow concentration of reactive species and the formation of
metastable ions and radicals in the anode chamber 54 and cathode
chamber 56.
[0065] The electrochemical activation process typically occurs by
either electron withdrawal (at anode 60) or electron introduction
(at cathode 62), which leads to alteration of physiochemical
(including structural, energetic and catalytic) properties of the
feed water. It is believed that the feed water (anolyte or
catholyte) gets activated in the immediate proximity of the
electrode surface where the electric field intensity can reach a
very high level. This area can be referred to as an electric double
layer (EDL).
[0066] While the electrochemical activation process continues, the
water dipoles generally align with the field, and a proportion of
the hydrogen bonds of the water molecules consequentially break.
Furthermore, singly-linked hydrogen atoms bind to the metal atoms
(e.g., platinum atoms) at cathode electrode 62, and single-linked
oxygen atoms bind to the metal atoms (e.g., platinum atoms) at the
anode electrode 60. These bound atoms diffuse around in two
dimensions on the surfaces of the respective electrodes until they
take part in further reactions. Other atoms and polyatomic groups
may also bind similarly to the surfaces of anode electrode 60 and
cathode electrode 62, and may also subsequently undergo reactions.
Molecules such as oxygen (O.sub.2) and hydrogen (H.sub.2) produced
at the surfaces may enter small cavities in the liquid phase of the
water (i.e., bubbles) as gases and/or may become solvated by the
liquid phase of the water. These gas-phase bubbles are thereby
dispersed or otherwise suspended throughout the liquid phase of the
feed water.
[0067] The sizes of the gas-phase bubbles may vary depending on a
variety of factors, such as the pressure applied to the feed water,
the composition of the salts and other compounds in the feed water,
and the extent of the electrochemical activation. Accordingly, the
gas-phase bubbles may have a variety of different sizes, including,
but not limited to macrobubbles, microbubbles, nanobubbles, and
mixtures thereof. In embodiments including macrobubbles, examples
of suitable average bubble diameters for the generated bubbles
include diameters ranging from about 500 micrometers to about one
millimeter. In embodiments including microbubbles, examples of
suitable average bubble diameters for the generated bubbles include
diameters ranging from about one micrometer to less than about 500
micrometers. In embodiments including nanobubbles, examples of
suitable average bubble diameters for the generated bubbles include
diameters less than about one micrometer, with particularly
suitable average bubble diameters including diameters less than
about 500 nanometers, and with even more particularly suitable
average bubble diameters including diameters less than about 100
nanometers.
[0068] Surface tension at a gas-liquid interface is produced by the
attraction between the molecules being directed away from the
surfaces of anode electrode 60 and cathode electrode 62 as the
surface molecules are more attracted to the molecules within the
water than they are to molecules of the gas at the electrode
surfaces. In contrast, molecules of the bulk of the water are
equally attracted in all directions. Thus, in order to increase the
possible interaction energy, surface tension causes the molecules
at the electrode surfaces to enter the bulk of the liquid.
[0069] In the embodiments in which gas-phase nanobubbles are
generated, the gas contained in the nanobubbles (i.e., bubbles
having diameters of less than about one micrometer) are also
believed to be stable for substantial durations in the feed water,
despite their small diameters. While not wishing to be bound by
theory, it is believed that the surface tension of the water, at
the gas/liquid interface, drops when curved surfaces of the gas
bubbles approach molecular dimensions. This reduces the natural
tendency of the nanobubbles to dissipate.
[0070] Furthermore, nanobubble gas/liquid interface is charged due
to the voltage potential applied across membrane 58. The charge
introduces an opposing force to the surface tension, which also
slows or prevents the dissipation of the nanobubbles. The presence
of like charges at the interface reduces the apparent surface
tension, with charge repulsion acting in the opposite direction to
surface minimization due to surface tension. Any effect may be
increased by the presence of additional charged materials that
favor the gas/liquid interface.
[0071] The natural state of the gas/liquid interfaces appears to be
negative. Other ions with low surface charge density and/or high
polarizability (such as Cl.sup.-, ClO.sup.-, HO.sub.2.sup.-, and
O.sub.2.sup.-) also favor the gas/liquid interfaces, as do hydrated
electrons. Aqueous radicals also prefer to reside at such
interfaces. Thus, it is believed that the nanobubbles present in
the catholyte (i.e., the water flowing through cathode chamber 56)
are negatively charged, but those in the anolyte (i.e., the water
flowing through anode chamber 54) will possess little charge (the
excess cations cancelling out the natural negative charge).
Accordingly, catholyte nanobubbles are not likely to lose their
charge on mixing with the anolyte.
[0072] Additionally, gas molecules may become charged within the
nanobubbles (such as O.sub.2.sup.-), due to the excess potential on
the cathode, thereby increasing the overall charge of the
nanobubbles. The surface tension at the gas/liquid interface of
charged nanobubbles can be reduced relative to uncharged
nanobubbles, and their sizes stabilized. This can be qualitatively
appreciated as surface tension causes surfaces to be minimized,
whereas charged surfaces tend to expand to minimize repulsions
between similar charges. Raised temperature at the electrode
surface, due to the excess power loss over that required for the
electrolysis, may also increase nanobubble formation by reducing
local gas solubility.
[0073] As the repulsion force between like charges increases
inversely as the square of their distances apart, there is an
increasing outwards pressure as a bubble diameter decreases. The
effect of the charges is to reduce the effect of the surface
tension, and the surface tension tends to reduce the surface
whereas the surface charge tends to expand it. Thus, equilibrium is
reached when these opposing forces are equal. For example, assuming
the surface charge density on the inner surface of a gas bubble
(radius r) is .PHI.(e.sup.-/meter.sup.2), the outwards pressure
("P.sub.out"), can be found by solving the NavierStokes equations
to give:
P.sub.out=.PHI..sup.2/2D.epsilon..sub.0 (Equation 1)
where D is the relative dielectric constant of the gas bubble
(assumed unity), ".epsilon..sub.0" is the permittivity of a vacuum
(i.e., 8.854 pF/meter). The inwards pressure ("P.sub.in") due to
the surface tension on the gas is:
P.sub.in=2 g/r P.sub.out (Equation 2)
where "g" is the surface tension (0.07198 Joules/meter.sup.2 at
25.degree. C.). Therefore if these pressures are equal, the radius
of the gas bubble is:
r=0.28792 .epsilon..sub.0/.PHI..sup.2. (Equation 3)
[0074] Accordingly, for nanobubble diameters of 5 nanometers, 10
nanometers, 20 nanometers, 50 nanometers, and 100 nanometers the
calculated charge density for zero excess internal pressure is
0.20, 0.14, 0.10, 0.06 and 0.04 e.sup.-/nanometer.sup.2 bubble
surface area, respectively. Such charge densities are readily
achievable with the use of an electrolysis cell (e.g., electrolysis
cell 18). The nanobubble radius increases as the total charge on
the bubble increases to the power 2/3. Under these circumstances at
equilibrium, the effective surface tension of the fuel at the
nanobubble surface is zero, and the presence of charged gas in the
bubble increases the size of the stable nanobubble. Further
reduction in the bubble size would not be indicated as it would
cause the reduction of the internal pressure to fall below
atmospheric pressure.
[0075] In various situations within the electrolysis cell (e.g.,
electrolysis cell 18), the nanobubbles may divide into even smaller
bubbles due to the surface charges. For example, assuming that a
bubble of radius "r" and total charge "q" divides into two bubbles
of shared volume and charge (radius r1/2=r/2.sup.1/3, and charge
q.sub.1/2=q/2), and ignoring the Coulomb interaction between the
bubbles, calculation of the change in energy due to surface tension
(.DELTA.E.sub.ST) and surface charge (.DELTA.E.sub.q) gives:
.DELTA.E.sub.ST=+2(4.pi..gamma.r.sub.1/2.sup.2)-4.pi..gamma.r.sup.2=4.pi-
..gamma.r.sup.2(2.sup.1/3-1) (Equation 3)
and
.DELTA. E q = - 2 ( 1 2 .times. ( q / 2 ) 2 4 .pi. 0 r 1 / 2 ) - 1
2 .times. q 2 4 .pi. 0 r = q 2 8 .pi. 0 r ( 1 - 2 - 2 / 3 ) (
Equation 4 ) ##EQU00001##
[0076] The bubble is metastable if the overall energy change is
negative which occurs when .DELTA.E.sub.ST+.DELTA.E.sub.q is
negative, thereby providing:
q 2 8 .pi. 0 r ( 1 - 2 - 2 / 3 ) + 4 .pi. .gamma. r 2 ( 2 1 / 3 - 1
) .ltoreq. 0 ( Equation 5 ) ##EQU00002##
which provides the relationship between the radius and the charge
density (.PHI.):
.phi. = q 4 .pi. r 2 .gtoreq. ( 2 .gamma. 0 r ( 2 1 / 3 - 1 ) ( 1 -
2 - 2 / 3 ) ) ( Equation 6 ) ##EQU00003##
[0077] Accordingly, for nanobubble diameters of 5 nanometers, 10
nanometers, 20 nanometers, 50 nanometers, and 100 nanometers the
calculated charge density for bubble splitting 0.12, 0.08, 0.06,
0.04 and 0.03 e.sup.-/nanometer.sup.2 bubble surface area,
respectively. For the same surface charge density, the bubble
diameter is typically about three times larger for reducing the
apparent surface tension to zero than for splitting the bubble in
two. Thus, the nanobubbles will generally not divide unless there
is a further energy input.
[0078] The above-discussed gas-phase nanobubbles are adapted to
attach to dirt particles, thereby transferring their ionic charges.
The nanobubbles stick to hydrophobic surfaces, which are typically
found on typical dirt particles, which releases water molecules
from the high energy water/hydrophobic surface interface with a
favorable negative free energy change. Additionally, the
nanobubbles spread out and flatten on contact with the hydrophobic
surface, thereby reducing the curvatures of the nanobubbles with
consequential lowering of the internal pressure caused by the
surface tension. This provides additional favorable free energy
release. The charged and coated dirt particles are then more easily
separated one from another due to repulsion between similar
charges, and the dirt particles enter the solution as colloidal
particles.
[0079] Furthermore, the presence of nanobubbles on the surface of
particles increases the pickup of the particle by micron-sized
gas-phase bubbles, which may also be generated during the
electrochemical activation process. The presence of surface
nanobubbles also reduces the size of the dirt particle that can be
picked up by this action. Such pickup assist in the removal of the
dirt particles from floor surfaces and prevents re-deposition.
Moreover, due to the large gas/liquid surface area-to-volume ratios
that are attained with gas-phase nanobubbles, water molecules
located at this interface are held by fewer hydrogen bonds, as
recognized by water's high surface tension. Due to this reduction
in hydrogen bonding to other water molecules, this interface water
is more reactive than normal water and will hydrogen bond to other
molecules more rapidly, thereby showing faster hydration.
[0080] For example, at 100% efficiency a current of one ampere is
sufficient to produce 0.5/96,485.3 moles of hydrogen (H.sub.2) per
second, which equates to 5.18 micromoles of hydrogen per second,
which correspondingly equates to 5.18.times.22.429 microliters of
gas-phase hydrogen per second at a temperature of 0.degree. C. and
a pressure of one atmosphere. This also equates to 125 microliters
of gas-phase hydrogen per second at a temperature of 20.degree. C.
and a pressure of one atmosphere. As the partial pressure of
hydrogen in the atmosphere is effectively zero, the equilibrium
solubility of hydrogen in the electrolyzed solution is also
effectively zero and the hydrogen is held in gas cavities (e.g.,
macrobubbles, microbubbles, and/or nanobubbles).
[0081] Assuming the flow rate of the electrolyzed solution is 0.12
U.S. gallons per minute, there is 7.571 milliliters of water
flowing through the electrolysis cell each second. Therefore, there
are 0.125/7.571 liters of gas-phase hydrogen within the bubbles
contained in each liter of electrolyzed solution at a temperature
of 20.degree. C. and a pressure of one atmosphere. This equates to
0.0165 liters of gas-phase hydrogen per liter of solution less any
of gas-phase hydrogen that escapes from the liquid surface and any
that dissolves to supersaturate the solution.
[0082] The volume of a 10 nanometer-diameter nanobubble is
5.24.times.10.sup.-22 liters, which, on binding to a hydrophobic
surface covers about 1.25.times.10.sup.-16 square meters. Thus, in
each liter of solution there would be a maximum of about
3.times.10.sup.-19 bubbles (at 20.degree. C. and one atmosphere)
with combined surface covering potential of about 4000 square
meters. Assuming a surface layer just one molecule thick, this
provides a concentration of active surface water molecules of over
50 millimoles. While this concentration represents a maximum
amount, even if the nanobubbles have greater volume and greater
internal pressure, the potential for surface covering remains
large. Furthermore, only a small percentage of the dirt particles
surfaces need to be covered by the nanobubbles for the nanobubbles
to have a cleaning effect.
[0083] Accordingly, the gas-phase nanobubbles, generated during the
electrochemical activation process, are beneficial for attaching to
dirt particles so transferring their charge. The resulting charged
and coated dirt particles are more readily separated one from
another due to the repulsion between their similar charges. They
will enter the solution to form a colloidal suspension.
Furthermore, the charges at the gas/water interfaces oppose the
surface tension, thereby reducing its effect and the consequent
contact angles. Also, the nanobubbles coating of the dirt particles
promotes the pickup of larger buoyant gas-phase macrobubbles and
microbubbles that are introduced. In addition, the large surface
area of the nanobubbles provides significant amounts of higher
reactive water, which is capable of the more rapid hydration of
suitable molecules.
4. Ion Exchange Membrane
[0084] As mentioned above, the ion exchange membrane 58 can include
a cation exchange membrane (i.e., a proton exchange membrane) or an
anion exchange membrane. Suitable cation exchange membranes for
membrane 38 include partially and fully fluorinated ionomers,
polyaromatic ionomers, and combinations thereof. Examples of
suitable commercially available ionomers for membrane 38 include
sulfonated tetrafluorethylene copolymers available under the
trademark "NAFION" from E.I. du Pont de Nemours and Company,
Wilmington, Del.; perfluorinated carboxylic acid ionomers available
under the trademark "FLEMION" from Asahi Glass Co., Ltd., Japan;
perfluorinated sulfonic acid ionomers available under the trademark
"ACIPLEX" Aciplex from Asahi Chemical Industries Co. Ltd., Japan;
and combinations thereof. However, any ion exchange membrane can be
used in other examples.
5. Dispenser
[0085] The anolyte and catholyte EA liquid outputs can be coupled
to a dispenser 74, which can include any type of dispenser or
dispensers, such as an outlet, fitting, spigot, spray head, a
cleaning/sanitizing tool or head, etc. In the example shown in FIG.
1, dispenser 34 includes spray nozzle 14. There can be a dispenser
for each output 70 and 72 or a combined dispenser for both
outputs.
[0086] In one example, the anolyte and catholyte outputs are
blended into a common output stream 76, which is supplied to
dispenser 74. As described in Field et al. U.S. Patent Publication
No. 2007/0186368, it has been found that the anolyte and catholyte
can be blended together within the distribution system of a
cleaning apparatus and/or on the surface or item being cleaned
while at least temporarily retaining beneficial cleaning and/or
sanitizing properties. Although the anolyte and catholyte are
blended, they are initially not in equilibrium and therefore
temporarily retain their enhanced cleaning and/or sanitizing
properties.
[0087] For example, in one embodiment, the catholyte EA water and
the anolyte EA water maintain their distinct electrochemically
activated properties for at least 30 seconds, for example, even
though the two liquids are blended together. During this time, the
distinct electrochemically activated properties of the two types of
liquids do not neutralize immediately. This allows the advantageous
properties of each liquid to be utilized during a common cleaning
operation. After a relatively short period of time, the blended
anolyte and catholyte EA liquid on the surface being cleaned
quickly neutralize substantially to the original pH and ORP of the
source liquid (e.g., those of normal tap water). In one example,
the blended anolyte and catholyte EA liquid neutralize
substantially to a pH between pH6 and pH8 and an ORP between .+-.50
mV within a time window of less than 1 minute from the time the
anolyte and catholyte EA outputs are produced by the electrolysis
cell. Thereafter, the recovered liquid can be disposed in any
suitable manner.
[0088] However, in other embodiments, the blended anolyte and
catholyte EA liquid can maintain pHs outside of the range between
pH6 and pH8 and ORPs outside the range of .+-.50 mV for a time
greater than 30 seconds, and/or can neutralize after a time range
that is outside of 1 minute, depending on the properties of the
liquid.
6. Electrolysis Cell With No Ion-Selective Membrane
[0089] FIG. 3 illustrates an electrolysis cell 80 having no
ion-selective membrane according to a further example of the
disclosure. Cell 80 includes a reaction chamber 82, an anode 84 and
a cathode 86. Chamber 82 can be defined by the walls of cell 80, by
the walls of a container or conduit in which electrodes 84 and 86
are placed, or by the electrodes themselves, for example. Anode 84
and cathode 86 may be made from any suitable material or a
combination of materials, such as a conductive polymer, titanium
and/or titanium coated with a precious metal, such as platinum.
Anode 84 and cathode 86 are connected to a conventional electrical
power supply, such as batteries 32 shown in FIG. 1. In one
embodiment, electrolytic cell 80 includes its own container that
defines chamber 82 and is located in the flow path of the liquid to
be treated, such as within the flow path of a hand-held spray
bottle or mobile floor cleaning apparatus.
[0090] During operation, liquid is supplied by a source 88 and
introduced into reaction chamber 82 of electrolysis cell 80. In the
embodiment shown in FIG. 3, electrolysis cell 80 does not include
an ion exchange membrane that separates reaction products at anode
84 from reaction products at cathode 86. In the example in which
tap water is used as the liquid to be treated for use in cleaning,
after introducing the water into chamber 82 and applying a voltage
potential between anode 84 and cathode 86, water molecules in
contact with or near anode 84 are electrochemically oxidized to
oxygen (O.sub.2) and hydrogen ions (H.sup.+) while water molecules
in contact or near cathode 86 are electrochemically reduced to
hydrogen gas (H.sub.2) and hydroxyl ions (OH.sup.-). Other
reactions can also occur and the particular reactions depend on the
components of the liquid. The reaction products from both
electrodes are able to mix and form an oxygenated fluid 89 (for
example) since there is no physical barrier, for example,
separating the reaction products from each other. Alternatively,
for example, anode 84 can be separated from cathode 84 by using a
dielectric barrier such as a non-permeable membrane (not shown)
disposed between the anode and cathode.
7. Electrode Pattern Examples
[0091] As mentioned above, at least one of the anode or cathode
electrodes can be formed at least partially or wholly of a
conductive polymer, such as those used for static dissipating
devices. Examples of suitable conductive polymers are commercially
available from RTP Company of Winona, Minn., USA. For example, the
electrodes can be formed of a conductive plastic compound having a
surface resistivity of 10.sup.0 to 10.sup.12 ohm/sq, such as
10.sup.1 to 10.sup.6 ohm/sq. However, electrodes having surface
resistivities outside those ranges can be used in other
examples.
[0092] With conductive polymer, the electrodes can be easily molded
or otherwise formed in any desired shape. For example, the
electrodes can be injection molded. As mentioned above, one or more
of the electrodes can form a mesh, with regular-sized rectangular
openings in the form of a grid. However, the openings or apertures
can have any shape, such as circular, triangular, curvilinear,
rectilinear, regular and/or irregular. Curvilinear apertures have
at least one curved edge. When injection molded, for example, the
shapes and sizes of the apertures can be easily tailored to a
particular pattern. However, these patterns can also be formed in
metallic electrodes in other examples of the present
disclosure.
[0093] The apertures can be sized and positioned to increase the
surface area of the electrode for electrolysis and thereby promote
generation of gas bubbles in the liquid being treated.
[0094] FIG. 4A is a fragmentary view of a conductive polymer
electrode 100 having a plurality of rectilinear (e.g., rectangular)
apertures 102 in a regular grid pattern according to an aspect of
the disclosure.
[0095] FIG. 4B is a fragmentary view of a conductive polymer
electrode 104 having a plurality of curvilinear (e.g., circular)
apertures 106 of different sizes in a regular grid pattern
according to another example. The use of differently sized
apertures in the same electrode may promote generation of
differently sized gas bubbles along the edges of the apertures
during electrolysis.
[0096] FIG. 4C is a fragmentary view of a conductive polymer
electrode 108 having a plurality of irregular and regular shaped
apertures 110 having a variety of different shapes and sizes
according to another example. In this example, various apertures
110 define various opening areas. One or more of the apertures 110
can include one or more internal points, such as points 112, that
are believed to promote further gas bubble and reactive species
generation during electrolysis. These apertures form polygons
having at least one internal angle (e.g., at point 112) that is
greater than 180 degrees. In an alternative embodiment, the
apertures have a plurality of internal angles greater than 180
degrees.
[0097] In addition, the electrodes can be formed with one or more
other non-uniform features, such as spikes or burs that further
increase the electrode surface area. The spikes can be arranged in
a regular pattern or an irregular pattern and can have the same
sizes and shapes or can have different sizes and/or shapes.
[0098] For example, an electrolysis cell can be constructed to
include an anode and a cathode, wherein at least one of the anode
electrode or the cathode electrode comprises a first plurality of
apertures having a first size (and/or shape) and a second plurality
of apertures having a second, different size (and/or shape). In one
example, the electrolysis cell also includes an ion selective
membrane disposed between the anode electrode and the cathode
electrode and which defines a respective anode chamber and cathode
chamber.
[0099] In a further example, at least two apertures of a set
comprising the first and second plurality of apertures have
different shapes (and/or sizes) than one another. In a further
example, at least three apertures of a set comprising the first and
second plurality of apertures have different shapes (and/or sizes)
than one another.
[0100] The first and second plurality of apertures can have polygon
shapes and/or curvilinear shapes formed of at least one curved
edge. At least one of the first plurality or the second plurality
of apertures can be arranged in a regular pattern or in an
irregular pattern.
[0101] At least one aperture of the first plurality or the second
plurality of apertures can have a polygon shape with at least one
internal angle that is greater than 180 degrees.
[0102] In a further example, the electrodes shown in FIGS. 4A-4C
are fabricated of a conductive metallic material. For example as
shown in FIG. 4A, the electrode 100 can be formed of a metallic
mesh, which can be plated with another material such as platinum or
can be unplated.
8. Tubular Electrode Example
[0103] The electrodes themselves can have any suitable shape, such
as planar, coaxial plates, cylindrical rods, or a combination
thereof. FIG. 5 illustrates an example of an electrolysis cell 200
having a tubular shape according to one illustrative example.
Portions of cell 200 are cut away for illustration purposes. In
this example, cell 200 is an electrolysis cell having a tubular
housing 202, a tubular outer electrode 204, and a tubular inner
electrode 206, which is separated from the outer electrode by a
suitable gap, such as 0.040 inches. Other gap sizes can also be
used, such as but not limited to gaps in the range of 0.020 inches
to 0.080 inches. Either of the inner or outer electrode can serve
as the anode/cathode, depending upon the relative polarities of the
applied voltages.
[0104] In one example, outer electrode 204 and inner electrode 206
have conductive polymer constructions with apertures such as those
shown in FIGS. 4A-4C, for example. However, one or both electrodes
can have a solid construction in another example.
[0105] The electrodes 206 and 206 can be made from any suitable
material, such as a conductive polymer, titanium and/or titanium
coated with a precious metal, such as platinum, or any other
suitable electrode material. In addition, multiple cells 200 can be
coupled in series or in parallel with one another, for example.
[0106] In a specific example, at least one of the anode or cathode
electrodes is formed of a metallic mesh, with regular-sized
rectangular openings in the form of a grid. In one specific
example, the mesh is formed of 0.023-inch diameter T316 stainless
steel having a grid pattern of 20.times.20 grid openings per square
inch. However, other dimensions, arrangements and materials can be
used in other examples.
[0107] An ion-selective membrane 208 is positioned between the
outer and inner electrodes 204 and 206. In one specific example,
the ion-selective membrane includes a "NAFION" from E.I. du Pont de
Nemours and Company, which has been cut to 2.55 inches by 2.55
inches and then wrapped around inner tubular electrode 206 and
secured at the seam overlap with a contact adhesive, for example,
such as a #1357 adhesive from 3M Company. Again, other dimensions
and materials can be used in other examples.
[0108] In this example, the volume of space within the interior of
tubular electrode 206 is blocked by a solid inner core 209 to
promote liquid flow along and between electrodes 204 and 206 and
ion-selective membrane 208. This liquid flow is conductive and
completes an electrical circuit between the two electrodes.
Electrolysis cell 200 can have any suitable dimensions. In one
example, cell 200 can have a length of about 4 inches long and an
outer diameter of about 3/4 inch. The length and diameter can be
selected to control the treatment time and the quantity of bubbles,
e.g., nanobubbles and/or microbubbles, generated per unit volume of
the liquid.
[0109] Cell 200 can include a suitable fitting at one or both ends
of the cell. Any method of attachment can be used, such as through
plastic quick-connect fittings. For example, one fitting can be
configured to connect to the output tube 20 shown in FIG. 1.
Another fitting can be configured to connect to the inlet filter 16
or an inlet tube, for example. In another example, one end of cell
200 is left open to draw liquid directly from reservoir 12 in FIG.
1.
[0110] In the example shown in FIG. 5, cell 200 produces anolyte EA
liquid in the anode chamber (between one of the electrodes 204 or
206 and ion-selective membrane 208) and catholyte EA liquid in the
cathode chamber (between the other of the electrodes 204 or 206 and
ion-selective membrane 208). The anolyte and catholyte EA liquid
flow paths join at the outlet of cell 200 as the anolyte and
catholyte EA liquids enter tube 20 (in the example shown in FIG.
1). As a result, spray bottle 10 dispenses a blended anolyte and
catholyte EA liquid through nozzle 14.
[0111] In one example, the diameters of tubes 20 and 22 are kept
small so that once pump 24 and electrolysis cell 18 (e.g., cell 200
shown in FIG. 5) are energized, tubes 20 and 22 are quickly primed
with electrochemically-activated liquid. Any non-activated liquid
contained in the tubes and pump are kept to a small volume. Thus,
in the embodiment in which the control electronics 30 activate pump
and electrolysis cell in response to actuation of switch 28, spray
bottle 10 produces the blended EA liquid at nozzle 14 in an "on
demand" fashion and dispenses substantially all of the combined
anolyte and catholyte EA liquid (except that retained in tubes 20,
22 and pump 24) from the bottle without an intermediate step of
storing the anolyte and catholyte EA liquids. When switch 28 is not
actuated, pump 24 is in an "off" state and electrolysis cell 18 is
de-energized. When switch 28 is actuated to a closed state, control
electronics 30 switches pump 24 to an "on" state and energizes
electrolysis cell 18. In the "on" state, pump 24 pumps water from
reservoir 12 through cell 18 and out nozzle 14.
[0112] Other activation sequences can also be used. For example,
control circuit 30 can be configured to energize electrolysis cell
18 for a period of time before energizing pump 24 in order to allow
the feed water to become more electrochemically activated before
dispensing.
[0113] The travel time from cell 18 to nozzle 14 can be made very
short. In one example, spray bottle 10 dispenses the blended
anolyte and catholyte liquid within a very small period of time
from which the anolyte and catholyte liquids are produced by
electrolysis cell 18. For example, the blended liquid can be
dispensed within time periods such as within 5 seconds, within 3
seconds, and within 1 second of the time at which the anolyte and
catholyte liquids are produced.
9. Control Circuit
[0114] Referring back to FIG. 1, control electronics 30 can include
any suitable control circuit, which can be implemented in hardware,
software, or a combination of both, for example.
[0115] Control circuit 30 includes a printed circuit board
containing electronic devices for powering and controlling the
operation of pump 24 and electrolysis cell 18. In one example,
control circuit 30 includes a power supply having an output that is
coupled to pump 24 and electrolysis cell 18 and which controls the
power delivered to the two devices. Control circuit 30 also
includes an H-bridge, for example, that is capable of selectively
reversing the polarity of the voltage applied to electrolysis cell
18 as a function of a control signal generated by the control
circuit. For example, control circuit 30 can be configured to
alternate polarity in a predetermined pattern, such as every 5
seconds with a 50% duty cycle. In another example, described in
more detail below, control circuit 30 is configured to apply a
voltage to the cell with primarily a first polarity and
periodically reverse the polarity for only very brief periods of
time. Frequent reversals of polarity can provide a self-cleaning
function to the electrodes, which can reduce scaling or build-up of
deposits on the electrode surfaces and can extend the life of the
electrodes.
[0116] In the context of a hand-held spray bottle, it is
inconvenient to carry large batteries. Therefore, the available
power to the pump and cell is somewhat limited. In one example, the
driving voltage for the cell is in the range of about 8 Volts to
about 28 Volts. But since typical flow rates through the spray
bottle and electrolysis cell are fairly low, only relatively small
currents are necessary to effectively activate the liquid passing
through the cell. With low flow rates, the residence time within
the cell is relatively large. The longer the liquid resides in the
cell while the cell is energized, the greater the electrochemical
activation (within practical limits). This allows the spray bottle
to employ smaller capacity batteries and a DC-to-DC converter,
which steps the voltage up to the desired output voltage at a low
current.
[0117] For example, the spray bottle can carry one or more
batteries having an output voltage of about 3-9 Volts. In one
particular example, the spray bottle can carry four AA batteries,
each having a nominal output voltage of 1.5 Volts at about 500
milliampere-hours to about 3 ampere-hours. If the batteries are
connected in series, then the nominal output voltage would be about
6V with a capacity of about 500 milliampere-hours to about 3
ampere-hours. This voltage can be stepped up to the range of 18
Volts to 28 Volts, for example, through the DC-to-DC converter.
Thus, the desired electrode voltage can be achieved at a sufficient
current.
[0118] In another particular example, the spray bottle carries 10
nickel-metal hydride batteries, each having a nominal output
voltage of about 1.2 Volts. The batteries are connected in series,
so the nominal output voltage is about 10V to 12.5V with a capacity
of about 1800 milliampere-hours. This voltage is stepped up/down to
a range of 8 Volts to at least 28 Volts, for example, through the
DC-to-DC converter. Thus, the desired electrode voltage can be
achieved at a sufficient current.
[0119] The ability to produce a large voltage and a suitable
current through the cell can be beneficial for applications in
which regular tap water is fed through the cell to be converted
into a liquid having enhanced cleaning and/or sanitizing
properties. Regular tap water has a relatively low electrical
conductivity between the electrodes of the cell.
[0120] Examples of suitable DC-to-DC converters include the Series
A/SM surface mount converter from PICO Electronics, Inc. of Pelham,
N.Y., U.S.A. and the NCP3064 1.5A Step-Up/Down/Inverting Switching
regulator from ON Semiconductor of Phoenix, Ariz., U.S.A, connected
in a boost application.
[0121] In one example, the control circuit controls the DC-to-DC
converter based on a sensed current drawn from the electrolysis
cell so that the DC-to-DC converter outputs a voltage that is
controlled to achieve a current draw through the cell that is
within a predetermined current range. For example, the target
current draw is about 400 milliamperes in one specific example. In
another example, the target current is 350 milliamperes. Other
currents and ranges can be used in alternative embodiments. The
desired current draw may depend on the geometry of the electrolysis
cell, the properties of the liquid being treated and the desired
properties of the resulting electrochemical reaction.
[0122] Block diagrams illustrating examples of the control
electronics are described in more detail below with respect to
FIGS. 7 and 20.
10. Driving Voltage for Electrolysis Cell
[0123] As described above, the electrodes of the electrolysis cell
can be driven with a variety of different voltage and current
patterns, depending on the particular application of the cell. It
is desirable to limit scaling on the electrodes by periodically
reversing the voltage polarity that is applied to the electrodes.
Therefore, the terms "anode" and "cathode" and the terms "anolyte"
and "catholyte" as used in the description and claims are
respectively interchangeable. This tends to repel
oppositely-charged scaling deposits.
[0124] In one example, the electrodes are driven at one polarity
for a specified period of time (e.g., about 5 seconds) and then
driven at the reverse polarity for approximately the same period of
time. Since the anolyte and catholyte EA liquids are blended at the
outlet of the cell, this process produces essentially one part
anolyte EA liquid to one part catholyte EA liquid.
[0125] In another example, the electrolysis cell is controlled to
produce a substantially constant anolyte EA liquid or catholyte EA
liquid from each chamber without complicated valving. In prior art
electrolysis systems, complicated and expensive valving is used to
maintain constant anolyte and catholyte through respective outlets
while still allowing the polarity to be reversed to minimize
scaling. For example, looking at FIG. 2, when the polarity of the
voltage applied to the electrodes is reversed, the anode 60 becomes
a cathode, and the cathode 62 becomes an anode. Outlet 70 will
deliver catholyte instead of anolyte, and outlet 72 will deliver
anolyte instead of catholyte. Therefore, with the prior art
approach, valving could be used to connect outlet 70 to cathode
chamber 56 and outlet 72 to anode chamber 54 when the voltage is
reversed. This results in a constant anolyte or catholyte flow
through each output. Instead of using this complicated valving, one
example of the present disclosure achieves substantially constant
outputs through the voltage pattern supplied to the electrodes.
[0126] FIG. 6 is a waveform diagram illustrating the voltage
pattern applied to the anode and cathode according to an exemplary
aspect of the present disclosure. A substantially constant,
relatively positive voltage is applied to the anode, while a
substantially constant, relatively negative voltage is applied to
the cathode. However, periodically each voltage is briefly pulsed
to a relatively opposite polarity to repel scale deposits. In this
example, a relatively positive voltage is applied to the anode and
a relatively negative voltage is applied to the cathode from times
t0-t1, t2-t3, t4-t5 and t6-t7. During times t1-t2, t3-t4, t5-t6 and
t7-t8, the voltages applied to each electrode is reversed. The
reversed voltage level can have the same magnitude as the
non-reversed voltage level or can have a different magnitude if
desired.
[0127] The frequency of each brief polarity switch can be selected
as desired. As the frequency of reversal increases, the amount of
scaling decreases. However, the electrodes may loose small amounts
of platinum (in the case of platinum coated electrodes) with each
reversal. As the frequency of reversals decreases, scaling may
increase. In one example, the time period between reversals, as
shown by arrow 300, is in the range of about 1 second to about 600
seconds. Other periods outside this range can also be used.
[0128] The time period at which the voltages are reversed can also
be selected as desired. In one example, the reversal time period,
represented by arrow 302, is in the range of about 50 milliseconds
to about 100 milliseconds. Other periods outside this range can
also be used. In this example, time period of normal polarity 303,
such as between times t2 and t3, is at least 900 milliseconds.
[0129] Also, the voltage can be selectively reversed periodically
or non-periodically. In one particular example, the time period 300
between reversals is 1 second, and during each period of the
waveform, the voltage between the electrodes is applied with the
normal polarity for 900 milliseconds and then with the reversed
polarity for 100 milliseconds.
[0130] With these ranges, for example, each anode chamber produces
a substantially constant anolyte EA liquid output, and each cathode
chamber produces a substantially constant catholyte EA output
without requiring valving.
[0131] If the number of anode electrodes is different than the
number of cathode electrodes, e.g., a ratio of 3:2, or if the
surface area of the anode electrode is different than the surface
area of the cathode electrode, then the applied voltage pattern can
be used in the above-manner to produce a greater amount of either
anolyte or catholyte to emphasize cleaning or sanitizing properties
of the produced liquid. For example, if cleaning is to be
emphasized, then a greater number of electrodes can be driven to
the relatively negative polarity (to produce more catholyte) and a
lesser number of electrodes can be driven to the relatively
positive polarity (to produce less anolyte). If sanitizing is to be
emphasized, then a greater number of electrodes can be driven to
the relatively positive polarity (to produce more anolyte) and a
lesser number of electrodes can be driven to the relatively
negative polarity (to produce less catholyte).
[0132] If the anolyte and catholyte outputs are blended into a
single output stream prior to dispensing, then the combined anolyte
and catholyte output liquid can be tailored to emphasize cleaning
over sanitizing or to emphasize sanitizing over cleaning. In one
embodiment, the control circuit includes a further switch, which
allows the user to select between cleaning and sanitizing modes.
For example, in the embodiment shown in FIG. 1, spray bottle 10 can
include a user-operable cleaning/sanitizing mode switch that is
mounted to the bottle.
[0133] In one exemplary embodiment of the disclosure, a hand-held
spray bottle such as those shown in FIGS. 1 and 8 carries tubular
electrolysis cell such as cell 200 shown in FIG. 5. The
electrolysis cell is driven with a voltage to emphasize enhanced
cleaning properties by generating a greater amount of catholyte EA
liquid than anolyte EA liquid per unit of time. In cell 200, outer
cylindrical electrode 204 has a greater diameter and therefore a
greater surface area than inner cylindrical electrode 206. To
emphasize enhanced cleaning properties, the control circuit drives
cell 200 so that, for the majority of period of the driving voltage
pattern, outer electrode 204 serves as the cathode and inner
electrode 206 serves as the anode. Since the cathode has a larger
surface area than the anode, cell 200 will generate more catholyte
than anolyte per unit of time through the combined outlet of the
cell. Referring to FIG. 6, in this example, the control circuit
applies a relatively positive voltage to the anode (electrode 206)
and a relatively negative voltage to the cathode (electrode 204)
from times t0-t1, t2-t3, t4-t5 and t6-t7. During times t1-t2,
t3-t4, t5-t6 and t7-t8, applied to each electrode is briefly
reversed.
[0134] In this example, the spray bottle is filled with regular tap
water only. Thus the liquid that is pumped through and
electrochemically activated with cell 200 consists solely of
regular tap water. The tap water is electrochemically activated, as
discussed herein, and dispensed as a blended anolyte and catholyte
stream through the spray nozzle. The spray output therefore has
enhanced cleaning properties, wherein the amount of catholyte
exceeds the amount of anolyte in the blended stream. Enhanced
sanitizing properties can be emphasized in an alternative
embodiment by making electrode 204 primarily an anode and electrode
206 primarily a cathode using the waveforms shown in FIG. 6, for
example.
[0135] It has been found that such frequent, brief polarity
reversals for de-scaling the electrodes may have a tendency also to
shed materials often used for plating the electrodes, such as
platinum, from the electrode surface. Thus in one embodiment,
electrodes 204 and 206 comprise unplated electrodes, such as
metallic electrodes or conductive plastic electrodes. For example,
the electrodes can be unplated metallic mesh electrodes.
11. Status Indicator Light Illuminating Through Liquid
11.1 Control Circuit for Bottles Shown in FIGS. 1 and 8-16
[0136] Another aspect of the present disclosure relates to
providing a humanly-perceptible indicator, which indicates a
functional status of the electrolysis cell, such as the
oxidation-reduction potential of the EA liquid. The spray bottle
and/or other devices disclosed herein can be modified to include a
visual indicator of the output liquid's oxidation-reduction
potential.
[0137] The level of power consumed by the electrolysis cell can be
used to determine whether the cell is operating correctly and
therefore whether the liquid (sparged water, EA anolyte, and/or EA
catholyte) produced by the cell is electrochemically activated to a
sufficient level. Power consumption below a reasonable level can
reflect various potential problems such as use of ultra-pure feed
water or feed water having a generally low electrolyte content
(e.g., low sodium/mineral content) such that the water does not
conduct a sufficient level of electrical current within the
functional generator. The current consumption can therefore also
indicate high or low levels of oxidation-reduction potential, for
example. Also, the current drawn by the pump may be used to
indicate whether the pump is operating correctly or whether there
is a problem, such as the pump being stalled.
[0138] FIG. 7 is a block diagram of a system 400 having an
indicator according to an embodiment of the disclosure, which can
be incorporated into any of the embodiments disclosed herein, for
example. System 400 includes power supply (such as a battery) 402,
control electronics 404, electrolysis cell 406, pump 408, current
sensors 410 and 412, indicator lights 414 and 416, switch 418 and
trigger 420. For simplicity, the liquid inputs and outputs of
electrolysis cell 404 are not shown in FIG. 7. All elements of
system 400 can be powered by the same power supply 402 or by two or
more separate power supplies, for example.
[0139] Control electronics 404 are coupled to control the operating
state of electrolysis cell 406, pump 408 and indicator lights 414
and 416 based on the present operating mode of system 400 and user
control inputs, such as trigger 420. In this example, switch 418 is
coupled in series between power supply 402 and control electronics
404 and serves to couple and decouple power supply 402 to and from
power inputs of control electronics 404 depending on the state of
trigger 420. In one embodiment, switch 418 includes a momentary,
normally-open switch that closes when trigger 420 is depressed and
opens when trigger 420 is released.
[0140] In an alternative example, switch 418 is configured as an
on/off toggle switch, for example, that is actuated separately from
trigger 420. Trigger 420 actuates a second switch that is coupled
to an enable input of control electronics 404. Other configurations
can also be used.
[0141] In both embodiments, when trigger 420 is depressed, control
electronics 404 is enabled and generates appropriate voltage
outputs for driving electrolysis cell 406 and pump 408. For
example, control electronics 404 can produce a first voltage
pattern for driving the electrolysis cell 406, such as those
patterns described herein, and a second voltage pattern for driving
pump 408. When trigger 420 is released, control electronics is
powered off and/or otherwise disabled from producing the output
voltages to cell 406 and pump 408.
[0142] Current sensors 410 and 412 are coupled in electrical series
with electrolysis cell 406 and pump 408, respectively, and each
provide a signal to control electronics 404 that is representative
of the respective electrical current drawn through cell 406 or pump
406. For example, these signals can be analog or digital
signals.
[0143] In one particular example, system 400 includes a sensor 410
for sensing the current drawn by electrolysis cell 406, but no
sensor 412 for sensing current drawn by pump 408. The control
electronics 404 includes a microcontroller, such as an
MC9S08SH4CTG-ND Microcontroller available from Digi-Key Corporation
of Thief River Falls, Minn., U.S.A., which controls a DRV8800 full
bridge motor driver circuit available from Texas Instruments
Corporation of Dallas, Tex., U.S.A. The driver circuit has an
H-switch that drives the output voltage to electrolysis cell 406
according to a voltage pattern controlled by the microcontroller.
The H-switch has a current sense output that can be used by the
microcontroller to sense the current drawn by cell 406.
[0144] Control electronics 404 compares the sensor outputs to
predetermined threshold current levels or ranges and then operates
indicators 414 and 416 as a function of one or both of the
comparisons. The threshold current levels or ranges can be selected
to represent predetermined power consumption levels, for
example.
[0145] Indicators 414 and 416 each can include any visually
perceptible indicator, such as an LED. In one example, indicator
lights 414 and 416 have different colors to indicate different
operating states. For example, indicator light 414 might be green,
which when illuminated indicates a normal, properly functioning
electrolysis cell and/or pump, and indicator 416 might be red,
which when illuminated indicates a problem in the operating state
of the electrolysis cell and/or pump. In a particular example, the
bottle contains four green LEDs 414 and four red LEDs 416 for a
strong illumination of the liquid contained in the bottle.
[0146] In the example shown in FIG. 7, control electronics 404
operate the indicator lights 414 and 416 as a function of the
current levels sensed by current sensors 410 and/or 412. For
example, control electronics 404 can turn off (or alternatively,
turn on) one or both of the indicator lights as a function of
whether the current level sensed is above or below a threshold
level or within a range. Indicator lights 414 and 416 can be
operated by separate power signals and a common ground, for
example, provided by control electronics 404.
[0147] In one embodiment, control electronics 404 illuminates the
green indicator light 414 in a steady "on" state and turns off the
red indicator light 416 when the sensed current level the cell 406
is above the respective threshold level (or within the predefined
range). In contrast, control electronics 404 illuminates the red
indicator light 416 in a steady "on" state and the green indicator
light 414 in a steady "off" state when the sensed current level of
cell 406 is below the respective threshold level.
[0148] The control electronics 404 modulates the green indicator
light 414 between the on and off states when the current drawn by
pump 408 is outside of a predetermined range. Any suitable range
can be used for the pump current, such as between 1.5 Amps and 0.1
Amps. Other ranges can also be used. In a further example, control
electronics 404 illuminates the green indicator light 414 in a
steady "on" state and turns off the red indicator light 416 when
the sensed current levels of both the cell 406 and the pump 408 are
within their respective predetermined, and if not, illuminates the
red indicator light 416 and turns off the green indicator light
414.
[0149] In another embodiment, one or more indicator lights are
operated in a steady "on" state when the sensed current level is
above the threshold level, and are cycled between the "on" state
and "off" state at a selected frequency to indicate a problem when
the sensed current level of electrolysis cell 406 is below the
threshold level. Multiple threshold levels and frequencies can be
used in other embodiments. Also, a plurality of
separately-controlled indicator lights can be used, each indicating
operation within a predefined range. Alternatively or in addition,
the control electronics can be configured to alter the illumination
level of one or more indicator lights as a function of the sensed
current level relative to one or more thresholds or ranges, for
example. In a further example, separate indicator lights can be
used for separately indicating the operating state of the
electrolysis cell and the pump. Other configurations can also be
used.
11.2 Illumination Through the Liquid
[0150] As described in more detail below, indicator lights 414
and/or 416 can be positioned on the apparatus (such as on the spray
bottle) to illuminate the liquid itself, either prior to treatment
by electrolysis cell 404 and/or after treatment. For example, the
indicator light, when illuminated, generates luminous flux in the
visible wavelength range that is visually perceptible through the
liquid from a viewpoint that is exterior to the apparatus. For
example, the liquid may diffuse at least a portion of the light,
giving a visual impression that the liquid, itself, is illuminated.
In one embodiment, the apparatus comprises a container, lumen or
other element that contains the liquid and comprises a material
and/or portion that is at least translucent and positioned to
transmit at least some of the light produced by indicator 414
and/or 416 when illuminated. This container, lumen or other element
is at least partially visible from an exterior of the
apparatus.
[0151] The term "at least translucent" includes translucent,
semi-transparent, fully transparent, and any term that means at
least some of the light illuminating from the indicator is humanly
perceptible through the material.
[0152] FIGS. 8-16 illustrate examples of a hand-held spray bottle
500 and 500' having an electrolysis cell and at least one indicator
light, wherein at least some of the light illuminating from the
indicator is humanly perceptible from a viewpoint that is external
to the bottle. The particular bottle configurations and
constructions shown in the drawings are provided as non-limiting
examples only. The same reference numerals are used in FIGS. 8-16
for the same or similar elements.
[0153] Referring to FIG. 8A, bottle 500 includes a housing 501
forming a base 502, a neck 504, and a barrel or head 506. The tip
of barrel 506 includes a nozzle 508 and a drip/splash guard 509.
Drip/splash guard 509 also serves as a convenient hook for hanging
bottle 500 on a utility cart, for example. As shown in more detail
below, housing 501 has a clamshell-type construction with
substantially symmetrical left and right hand sides attached
together, such as by screws. Base 502 houses a container 510, which
serves as a reservoir for liquid to be treated and then dispensed
through nozzle 508. Container 510 has a neck and threaded inlet
(with a screw cap) 512 that extends through base 502 to allow
container 510 to be filled with a liquid. Inlet 512 is threaded to
receive a cap seal.
[0154] In this example, the side walls of housing base 502 have a
plurality of openings or windows 520 about its circumference
through which container 510 is visible. In this example, the
openings 520 are formed by an absence of the housing material
within the opening. In another example, the openings are formed by
a material that is at least translucent. In another example, shown
in FIG. 8B, the entire housing or a portion of the housing is at
least translucent.
[0155] Similarly, container 510 is formed of a material that is at
least translucent. For example, container 510 can be fabricated as
a blow mold of a clear polyester material. As explained in more
detail below, housing 501 also contains a circuit board carrying a
plurality of LED indicator lights 594, 596 (corresponding to lights
414 and 416 shown in FIG. 7). The lights are positioned beneath the
base of container 510 to transmit light through a base wall of
container 510 and into any liquid contained in the container. The
liquid diffuses at least a portion of the light, giving an
appearance of the liquid being illuminated. This illumination is
visible from a viewpoint external to housing 501, through openings
520. The color of the light and/or other illumination
characteristics such as on/off modulation, intensity, etc. that are
controlled by the control electronics are observable through
openings 510 to give the user an indication of the functional
status of the bottle. Arrows 522 represent illumination from the
indicator light that is transmitted through the liquid in container
510 and visible from an exterior of the bottle, through openings
520 in housing 501.
[0156] For example, the liquid can be illuminated with a green LED
to indicate that the electrolysis cell and/or pump are functioning
properly. Thus, the user can be assured that the treated liquid
dispensed from nozzle 508 has enhanced cleaning and/or sanitizing
properties as compared to the source liquid contained in container
510. Also, illumination of the source liquid in container 510,
although not yet treated, gives an impression that the liquid is
"special" and has enhanced properties.
[0157] Similarly, if the electrolysis cell and/or pump are not
functioning properly, the control electronics illuminates the red
LED, giving the source liquid a red appearance. This gives the user
an impression that there is a problem and that the dispensed liquid
may not have enhanced cleaning and/or sanitizing properties.
[0158] Although in the example shown in FIG. 8A the illumination is
visible through container 510, the indicator lights can be
positioned to illuminate any portion of the flow path from a liquid
inlet to the bottle and nozzle 508, including any elements upstream
and/or downstream of the electrolysis cell. The housing can be
modified in any manner to allow this illumination to be visible by
a user. For example, the liquid can be illuminated in a delivery
tube extending from the output of the electrolysis cell to the
nozzle 508. Barrel 506 can be modified to include an opening to
expose the delivery tube, or a portion of the tube can extend along
the exterior of barrel 506, for example.
[0159] FIG. 8B is a perspective view of a bottle 500' which lacks
the windows 520 if the embodiment shown in FIG. 8A. In this
example, the entire housing 501 or a portion of the housing is at
least translucent. For example, housing 501 can be fabricated of
polycarbonate. The same reference numerals are used in FIG. 8B as
were used in FIG. 8A for the same or similar elements. Although not
expressly shown in FIG. 8B, with a translucent housing, the
internal components of bottle 500' are visible through housing 501
from a viewpoint that is external to the housing. For example, the
container 510 (shown in phantom) and the liquid contained therein
are visible through housing 501. In this example, there are four
red LEDs 594 and four green LEDs 596 (also shown in phantom),
arranged in pairs in each corner of the bottle. Thus, when LEDs 594
and/or 596 are illuminated, the liquid diffuses at least a portion
of the light, giving an appearance of the liquid being illuminated.
This illumination is visible from a viewpoint external to housing
501 in the same manner as shown in FIG. 8A, except illumination
would not be limited to the "windows" 520.
[0160] FIG. 8C is a perspective view of the back end of the barrel
(or head) 506 of bottle 501', which illustrates an electrical power
jack 523 for connecting to the cord of a battery charger (not
shown). In the example in which bottle 500' carries rechargeable
batteries, these batteries can be recharged through jack 523.
[0161] FIGS. 9-16 illustrate further details of the particular
bottle 500' shown in FIG. 8B.
[0162] FIGS. 9A and 9B are perspective views of the left-hand side
501A of housing 501, and FIG. 9C is a perspective view of the
right-hand side 501B of housing 501.
[0163] The left and right hand sides 501A and 501B, when attached
to one another form a plurality of compartments for containing
various elements of the bottle. For example, housing base 502
includes a first compartment 531 for containing liquid container
510 (shown in FIGS. 8A, 8B), a second compartment 532 for
containing a circuit board supporting the control electronics, and
a third compartment 533 for containing a plurality of batteries to
power the control electronics. Barrel 506 includes a compartment
534 for containing the electrolysis cell and pump.
[0164] FIG. 10 illustrates various components installed in the
left-hand side 501A of housing 501. Container 510 is installed in
compartment 531, circuit board 540 is installed in compartment 532,
batteries 542 are installed in compartment 533, and pump/cell
assembly 544 is installed in compartment 534. The various tubes
that connect container 510, pump/cell assembly and nozzle 508 are
not shown in FIG. 10.
[0165] FIGS. 11A and 11B illustrate container 510 in greater
detail. FIG. 11A is a perspective view of container 510, and FIG.
11B is a fragmentary, cross-sectional view of the inlet 512 of
container 510 installed in housing 501A. An o-ring 548 seals the
outer diameter surface of the neck of inlet 512 within housing
501A. The threads on inlet 512 receive a cap (not shown) to seal
the inlet opening. Container 510 further includes an outlet 549 for
receiving a tube (not shown) for drawing liquid from container 510.
The tube may include an inlet filter as described with reference to
FIG. 1, for example.
[0166] FIG. 12A illustrates a fragmentary, close-up view of
pump/cell assembly 544 installed in the barrel 506 of housing half
501A. FIG. 12B is a perspective view of pump/cell assembly 544
removed from the housing. FIG. 12C shows a bottom, perspective view
of the assembly with the trigger 570 removed.
[0167] Pump/cell assembly 544 includes a pump 550 and an
electrolysis cell 552 mounted within a bracket 554. The pump 550
has a first port 555 that is fluidically coupled to the tube (not
shown) extending from the outlet 549 of container 510 and a second
port 555 that is fluidically coupled through another tube (also not
shown) to the inlet 556 of electrolysis cell 552.
[0168] Electrolysis cell 552 has an outlet 557 that is fluidically
coupled to nozzle 508. In one example, electrolysis cell 552
corresponds to the tubular electrolysis cell 200 discussed with
reference to FIG. 5. However, any suitable electrolysis cell can be
used in alternative embodiments, and the cell can have any shape
and/or geometry. For example, the cell can have electrodes that are
cylindrical as shown in FIG. 5 or substantially planar, parallel
plates. O-ring 560 provides a seal about the nozzle 508 for housing
501.
[0169] Bottle 500' further includes a trigger 570, which actuates a
momentary push-button on/off switch 572. Trigger 570 actuates about
pivot 574 when depressed by a user. A spring 576 (shown in FIG.
12C) biases trigger 570 in a normally released state and thus
switch 572 in an off state. Switch 572 has electrical leads 578 for
connecting to the control electronics on circuit board 540, shown
in FIG. 10.
[0170] As described with reference to the block diagram shown in
FIG. 7, when trigger 570 is depressed, switch 572 actuates to the
"on" state, thereby providing electrical power to the control
electronics, which energizes pump 550 and electrolysis cell 552.
When energized, pump 550 draws liquid from container 510 and pumps
the liquid through electrolysis cell 552, which delivers a combined
anolyte and catholyte EA liquid to nozzle 508. When pump 550 and/or
electrolysis cell 552 are functioning properly, the control
electronics also illuminate the liquid within container 510 with
the LEDs installed on the circuit board or another location in or
on bottle 500'.
[0171] FIG. 13 illustrates bracket 554 in greater detail.
[0172] FIGS. 14A and 14B are perspective views of trigger 570.
Trigger 570 has a set of apertures 580 for receiving a pin or pins
that define the pivot point of the trigger.
[0173] FIGS. 15A and 15B are perspective views of a trigger boot
584, which overlies trigger 570. Boot 584 provides a protective
layer for trigger 570 and seals the edges of housing 501 about the
trigger.
[0174] FIG. 16A illustrates compartments 532 and 533 of housing
half 501A in greater detail. FIG. 16B illustrates the circuit board
540 mounted within compartment 532 and batteries 542 mounted within
compartment 533.
[0175] In addition, circuit board 540 includes a plurality of
light-emitting diodes (LEDs) 594 and 596. In this example, the LEDs
are positioned on the top surface of circuit board 540 such that
light radiating from the LEDs illuminates the liquid in container
510 through the base of the container. Other arrangements can also
be used. The LEDs can have different colors and be controlled
separately, as described above, to indicate different operating
states or characteristics, for example.
12. Illumination Through the Liquid in Other Apparatus
[0176] The features and methods described herein, such as those of
the electrolysis cell and the indicator light(s), can be used in a
variety of different apparatus, such as on a spray bottle, a mobile
surface cleaner, and/or a free-standing or wall-mount electrolysis
platform. For example, they can be implemented onboard (or
off-board) a mobile surface cleaner, such as a mobile hard floor
surface cleaner, a mobile soft floor surface cleaner or a mobile
surface cleaner that is adapted to clean both hard and soft floors
or other surfaces, for example.
[0177] Field et al. U.S. Publication No. 2007/0186368 A1 discloses
various apparatus in which the features and methods described
herein can be used, such as a mobile surface cleaner having a
mobile body configured to travel over a surface. The mobile body
has a tank for containing a cleaning liquid, such as tap water, a
liquid dispenser and a flowpath from the tank to the liquid
dispenser. An electrolysis cell is coupled in the flowpath. The
electrolysis cell has an anode chamber and a cathode chamber
separated by an ion exchange membrane and electrochemically
activates tap water that has passed through the functional
generator.
[0178] The functional generator converts the tap water into an
anolyte EA liquid and a catholyte EA liquid. The anolyte EA liquid
and the catholyte EA liquid can be separately applied to the
surface being cleaned and/or sanitized, or can be combined on-board
the apparatus to form a combination anolyte and catholyte EA liquid
and dispensed together through a cleaning head, for example.
[0179] Field et al. U.S. Publication No. 2007/0186368 A1 also
discloses other structures on which the various structural elements
and processes disclosed herein can be utilized either separately or
together. For example, Field et al. disclose a wall mount platform
for generating anolyte and catholyte EA liquid.
[0180] Any of these apparatus can be configured to provide a visual
indication of a functional operating state or operating
characteristic of the electrolysis cell, wherein illumination of
the indicator is visible through the liquid from a viewpoint that
is external to the apparatus. The indicator light is not required
to be in a direct line of sight of the observer, but may be out of
sight. For example, the illumination might be visible due to
diffusion and/or diffraction of the light, such as through the
liquid.
[0181] In one example, a wall-mounted platform supports an
electrolysis cell and a liquid flow path from an inlet of the
platform, through the electrolysis cell, to an outlet of the
platform. At least a portion of the flow path is at least
translucent and visible from an exterior of the platform. The
platform further includes an indicator light, such as that shown in
FIG. 7, that illuminates the liquid along at least a portion of the
flow path, such as along a tube and/or a reservoir of the
platform.
13. Mobile Surface Cleaner
[0182] The features and methods described herein, such as those of
the electrolysis cell, can be used in a variety of different
applications, such on a spray bottle, a mobile surface cleaner,
and/or a free-standing or wall-mount electrolysis platform. For
example, they can be implemented onboard (or off-board) a mobile
surface cleaner, such as a mobile hard floor surface cleaner, a
mobile soft floor surface cleaner or a mobile surface cleaner that
is adapted to clean both hard and soft floors or other surfaces,
for example.
[0183] Field et al. U.S. Publication No. 2007/0186368 A1 various
apparatus in which the features and methods described herein can be
used, such as a mobile surface cleaner having a mobile body
configured to travel over a surface. The mobile body has a tank for
containing a cleaning liquid, such as tap water, a liquid dispenser
and a flowpath from the tank to the liquid dispenser. An
electrolysis cell is coupled in the flowpath. The electrolysis cell
has an anode chamber and a cathode chamber separated by an ion
exchange membrane and electrochemically activates tap water that
has passed through the functional generator.
[0184] The functional generator converts the tap water into an
anolyte EA liquid and a catholyte EA liquid. The anolyte EA liquid
and the catholyte EA liquid can be separately applied to the
surface being cleaned and/or sanitized, or can be combined on-board
the apparatus to form a combination anolyte and catholyte EA liquid
and dispensed together through a cleaning head, for example.
[0185] FIG. 17 illustrates an example of a mobile hard and/or soft
floor surface cleaner 700 disclosed in Field et al. U.S.
Publication No. 2007/0186368 A1 in which one or more of the
above-described features and/or methods can be implemented. FIG. 17
is a perspective view of cleaner 700 having its lid in an open
position.
[0186] In this example, cleaner 700 is a walk-behind cleaner used
to clean hard floor surfaces, such as concrete, tile, vinyl,
terrazzo, etc. in other examples, cleaner 700 can be configured as
a ride-on, attachable, or towed-behind cleaner for performing a
cleaning and/or sanitizing operation as described herein. In a
further example, cleaner 700 can be adapted to clean soft floors,
such as carpet, or both hard and soft floors in further
embodiments. Cleaner 700 may include electrical motors powered
through an on-board power source, such as batteries, or through an
electrical cord. Alternatively, for example, an internal combustion
engine system could be used either alone, or in combination with,
the electric motors.
[0187] Cleaner 700 generally includes a base 702 and a lid 704,
which is attached along one side of the base 702 by hinges (not
shown) so that lid 704 can be pivoted up to provide access to the
interior of base 702. Base 702 includes a tank 706 for containing a
liquid or a primary cleaning and/or sanitizing liquid component
(such as regular tap water) to be treated and applied to the floor
surface during cleaning/sanitizing operations. Alternatively, for
example, the liquid can be treated onboard or offboard cleaner 700
prior to containment in tank 706. In addition, cleaner 700 includes
an electrolysis cell 708, which treats the liquid prior to the
liquid being applied to the floor being cleaned. The treated liquid
can be applied to the floor directly and/or through a cleaning head
710, for example. The treated liquid that is applied to the floor
can include an anolyte EA liquid stream, a catholyte EA liquid
stream, both and anolyte and catholyte EA liquid streams and/or a
combined anolyte and catholyte EA liquid stream. The cell 408 can
include an ion selective membrane or be configured without an ion
selective membrane.
[0188] Field et al. U.S. Publication No. 2007/0186368 A1 also
discloses other structures on which the various structural elements
and processes disclosed herein can be utilized either separately or
together. For example, Field et al. disclose a wall mount platform
for generating anolyte and catholyte EA liquid. This platform can
be controlled with a control voltage pattern as disclosed herein,
for example.
14. Wall-Mount Platform
[0189] For example, FIG. 18 illustrates a simplified block diagram
of a cleaning liquid generator 800 that is mounted to a platform
802 according to an exemplary embodiment. Platform 802 can be
configured to be mounted or placed in a facility on a floor, a
wall, a bench or other surface, held by hand, carried by an
operator or vehicle, attached on to another device (such as carried
by a cleaning or maintenance trolley or mop bucket), or carried on
a person. In one specific embodiment, platform 802 is mounted to
the wall of a facility for loading cleaning devices, such as mop
buckets, mobile cleaning machines, etc., with cleaning and/or
sanitizing liquid.
[0190] Platform 802 includes an inlet 803 for receiving a liquid,
such as tap water, from a source. Alternatively, for example,
platform 802 can include a tank for holding a supply of liquid to
be treated. Platform 802 further includes one or more electrolysis
cells 804 and a control circuit 806 (such as those disclosed
above). Electrolysis cell(s) 804 can have any of the structures
described herein or any other suitable structure. Platform 802 can
also include any other devices or components such as but not
limited to those disclosed herein.
[0191] The flow path or paths from the output of electrolysis cell
804 can be configured to dispense anolyte EA liquid and catholyte
EA liquid separately and/or blended anolyte and catholyte EA liquid
through outlet 808. Unused anolyte or catholyte can be directed to
a waste tank on platform 802 or to a drain outlet, for example. In
embodiments in which both anolyte and catholyte EA are dispensed
through outlet 808, the outlet can have separate anolyte and
catholyte ports and/or a combined port, which delivers a blended
mixture of catholyte and anolyte, for example, as discussed above.
Further, any of the embodiments herein can include one or more
storage tanks for containing the anolyte and/or catholyte produced
liquid by the electrolysis cell.
[0192] In one specific embodiment, electrolysis cell 804 includes
at least one anode and at least one cathode that are separated by
at least one ion-selective membrane, forming one or more anode
chambers and cathode chambers. Outlet 808 has separate anolyte and
catholyte ports, which are fluidically coupled to the anode
chambers and cathode chambers, respectively, without any fluid
valving, for example. The control circuit 806 energizes the anodes
and cathodes with a voltage pattern discussed above with reference
to FIG. 6 such that each anolyte port supplies a substantially
constant anolyte EA liquid output, and each catholyte port supplies
a substantially constant catholyte EA liquid output. A
substantially constant, relatively positive voltage is applied to
the anodes, while a substantially constant, relatively negative
voltage is applied to the cathodes. Periodically each voltage is
briefly pulsed to a relatively opposite polarity to repel scale
deposits.
[0193] If the number of anode electrodes is different than the
number of cathode electrodes, e.g., a ratio of 3:2, or if the
surface area of the anode electrode is different than the surface
area of the cathode electrode, then the applied voltage pattern can
be used in the above-manner to produce a greater amount of either
anolyte or catholyte to emphasize cleaning or sanitizing properties
of the produced liquid. Other ratios can also be used. Platform 802
further can include a switch or other user input device 810, if
desired, for operating the control circuit to selectively invert
the voltage patterns applied to each electrode to produce a greater
amount of anolyte or catholyte depending upon the state of the
switch.
15. All Surface Cleaner
[0194] FIG. 19 is a perspective view of an all surface cleaning
assembly 980, which is described in more detail in U.S. Pat. No.
6,425,958, which is incorporated herein by reference in its
entirety. The cleaning assembly 980 is modified to include a liquid
distribution path with one or more electrolysis cells with
electrodes and a control circuit as described herein such as but
not limited to those shown or described with reference to FIG. 1,
for example, or any of the other embodiments disclosed herein.
[0195] Cleaning assembly 980 can be constructed to deliver and
optionally recover one or more of the following liquids, for
example, to and from the floor being cleaned: anolyte EA water,
catholyte EA water, blended anolyte and catholyte EA water, or
other electrically-charged liquids. For example, liquid other than
or in addition to water can be used.
[0196] Cleaning assembly 980 can be used to clean hard surfaces in
restrooms or any other room having at least one hard surface, for
example. Cleaning assembly 980 includes the cleaning device and the
accessories used with the cleaning device for cleaning the
surfaces, as described in U.S. Pat. No. 6,425,958. Cleaning
assembly 980 includes a housing 981, a handle 982, wheels 983, a
drain hose 984 and various accessories. The accessories can include
a floor brush 985 having a telescoping and extending handle 986, a
first piece 987 and a second piece 988 of a two piece double bend
wand, and various additional accessories not shown in FIG. 19,
including a vacuum hose, a blower hose, a sprayer hose, a blower
hose nozzle, a spray gun, a squeegee floor tool attachment, a
gulper tool, and a tank fill hose (which can be coupled to ports on
assembly 980). The assembly has a housing that carries a tank or
removable liquid container and a recovery tank or removable
recovery liquid container. The cleaning assembly 980 is used to
clean surfaces by spraying the cleaning liquid through a sprayer
hose and onto the surfaces. The blower hose is then used to blow
dry the surfaces and to blow the fluid on the surfaces in a
predetermined direction. The vacuum hose is used to suction the
fluid off of the surfaces and into the recovery tank within
cleaning device 980, thereby cleaning the surfaces. The vacuum
hose, blower hose, sprayer hose and other accessories used with
cleaning assembly 980 can be carried with the cleaning device 980
for easy transportation.
[0197] In addition, similar to the embodiment shown in FIGS. 8-16,
any of the apparatus shown in or described with FIGS. 17-19 can
include one or more indicator lights 414 and/or 416 (shown in the
block diagram of FIG. 7) positioned on the apparatus to illuminate
the liquid itself, either prior to treatment by electrolysis cell
404 and/or after treatment. For example, the indicator light, when
illuminated, generates luminous flux in the visible wavelength
range that is visually perceptible through the liquid from a
viewpoint that is exterior to the apparatus. For example, the
liquid may diffuse at least a portion of the light, giving a visual
impression that the liquid, itself, is illuminated. In one
embodiment, the apparatus comprises a container, lumen or other
element that contains the liquid and comprises a material and/or
portion that is at least translucent and positioned to transmit at
least some of the light produced by indicator 414 and/or 416 when
illuminated. This container, lumen or other element is at least
partially visible from an exterior of the apparatus.
16. Control Circuit for Spray Bottle Shown in FIGS. 8-16
[0198] FIG. 20 is a block diagram illustrating a control circuit
for controlling the various components within the hand-held spray
bottles 500, 500' shown in FIGS. 8-16 according to an illustrative
example of the disclosure. The main components of the control
circuit include a microcontroller 1000, a DC-to-DC converter 1004,
and an output driver circuit 1006.
[0199] Power to the various components is supplied by a battery
pack 542 carried by the bottle, as shown in FIG. 16B, for example.
In a specific example, battery pack 542 includes 10 nickel-metal
hydride batteries, each having a nominal output voltage of about
1.2 Volts. The batteries are connected in series, so the nominal
output voltage is about 10V to 12.5V with a capacity of about 1800
milliampere-hours. Hand trigger 570,572 (shown in FIGS. 8A and 8B,
for example) selectively applies the 12-volt output voltage from
battery pack 542 to voltage regulator 1003 and to DC-to-DC
converter 1004. Any suitable voltage regulator can be used, such as
an LM7805 regulator from Fairchild Semiconductor Corporation. In a
particular example, voltage regulator 1003 provides a 5 Volt output
voltage for powering the various electrical components within the
control circuit.
[0200] DC-to-DC converter 1004 generates an output voltage to be
applied across the electrodes of electrolysis cell 552. The
converter is controlled by microcontroller to step the drive
voltage up or down in order to achieve a desired current draw
through the electrolysis cell. In a particular example, converter
1004 steps the voltage up or down between a range of 8 Volts to 28
Volts (or greater) to achieve a current draw through electrolysis
cell 552 of about 400 milliamps, as pump 550 pumps water from
container 510, through cell 552 and out nozzle 508 (FIGS. 8A and
8B). The required voltage depends in part on the conductivity of
the water between the cell's electrodes.
[0201] In a particular example, DC-to-DC converter 1004 includes a
Series A/SM surface mount converter from PICO Electronics, Inc. of
Pelham, N.Y., U.S.A. In another example, converter 1004 includes an
NCP3064 1.5A Step-Up/Down/Inverting Switching regulator from ON
Semiconductor of Phoenix, Ariz., U.S.A, connected in a boost
application. Other circuits can be used in alternative
embodiments.
[0202] Output driver circuit 1006 selectively reverses the polarity
of the driving voltage applied to electrolysis cell 552 as a
function of a control signal generated by microcontroller 1000. For
example, microcontroller 1000 can be configured to alternate
polarity in a predetermined pattern, such that shown and/or
described with reference to FIG. 6. Output driver 1006 can also
provide an output voltage to pump 550. Alternatively, for example,
pump 550 can receive its output voltage directly from the output of
trigger switch 570, 572.
[0203] In a particular example, output driver circuit 1006 includes
a DRV 8800 full bridge motor driver circuit available from Texas
Instruments Corporation of Dallas, Tex., U.S.A. Other circuits can
be used in alternative embodiments. The driver circuit 1006 has an
H-switch that drives the output voltage to electrolysis cell 552
according to the voltage pattern controlled by the microcontroller.
The H-switch also has a current sense output that can be used by
the microcontroller to sense the current drawn by cell 552. Sense
resistor R.sub.SENSE develops a voltage that is representative of
the sensed current and is applied as a feedback voltage to
microcontroller 1000. Microcontroller 1000 monitors the feedback
voltage and controls converter 1004 to output a suitable drive
voltage to maintain a desired current draw.
[0204] Microcontroller 1000 also monitors the feedback voltage to
verify that electrolysis cell 552 and/or pump 550 is operating
properly. As discussed above, microcontroller 1000 can operate LEDs
594 and 596 as a function of the current levels sensed by output
driver circuit 1006. For example, microcontroller 1000 can turn off
(or alternatively, turn on) one or both of the sets of LEDs 594 and
596 as a function of whether the current level sensed is above or
below a threshold level or within a range.
[0205] In a particular embodiment, microcontroller 1000 can include
any suitable controller, such as an MC9S08SH4CTG-ND Microcontroller
available from Digi-Key Corporation of Thief River Falls, Minn.,
U.S.A.
[0206] In the example shown in FIG. 20, the illumination control
portion of the circuit includes output resistors R1 and R2 and a
first, "red" LED control leg formed by pull-up resistor R3, red LED
diodes D1-D4, and pull-down transistor Q1. Microcontroller 1000 has
a first control output, which selectively turns on and off red LEDs
D1-D4 by turning on and off transistor Q1. The illumination control
portion of the circuit further a second, "green" LED control leg
formed by pull-up resistor R4, green LED diodes D5-D8, and
pull-down transistor Q2. Microcontroller 1000 has a second control
output, which selectively turns on and off green LEDs D5-D8 by
turning on and off transistor Q2.
[0207] The control circuit further includes a control header 1002,
which provides an input for reprogramming microcontroller 1000.
[0208] In one particular example, the elements 1000, 1002, 1003,
1004, 1006, R1-R4, D1-D8 and Q1-Q2 reside on circuit board 540,
shown in FIG. 16B.
[0209] In addition, the control circuit shown in FIG. 20 can
include a charging circuit (not shown) for charging the batteries
within battery pack 542 with energy received through the power jack
523 shown in FIG. 8C.
[0210] One or more of the control functions described herein can be
implemented in hardware, software, firmware, etc., or a combination
thereof. Such software, firmware, etc. is stored on a
computer-readable medium, such as a memory device. Any
computer-readable memory device can be used, such as a disc drive,
a solid state drive, flash memory, RAM, ROM, a set of registers on
an integrated circuit, etc.
[0211] Although the present disclosure has been described with
reference to one or more embodiments, workers skilled in the art
will recognize that changes may be made in form and detail without
departing from the spirit and scope of the disclosure and/or the
appended claims.
* * * * *