Machine for generating cleaning compositions

Abstract

The present disclosure relates to a machine for generating cleaning compositions and a method of generating cleaning compositions. The machine comprises a single-chamber electrolyzer and a saltwater container. The saltwater container comprises a salt inlet. Salt may be supplied from a salt source (4), preferably saltwater, to the saltwater container. The electrolyzer is configured for generating electrolyzed saltwater.

Description

[0001] Machine for Generating Cleaning Compositions

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a machine for generating cleaning compositions and a method for generating cleaning compositions.

[0004] BACKGROUND OF THE INVENTION

[0005] Cleaning compositions are used in countless different settings and applications for cleaning countless different objects. As an example, cleaning compositions may be used to clean floors, sanitary facilities, kitchens, hospitals, etc. Depending on the use, different cleaning compositions are required. It is therefore necessary to resort to large stocks on-site and / or frequent transport of many different chemical cleaning compositions for different applications.

[0006] For many cleaning applications, it is also desirable to provide cleaning compositions that also acts as a disinfectant. For this purpose, many cleaning compositions contain chlorinated water as the main disinfecting agent. Chlorinated water is generally prepared by either adding chlorine gas to water or by mixing bleach to water. However, it is difficult to control the amount of concentration of chlorine being diffused in the water when done manually on site. Further, the conventional methods are unsafe for a person handling the procedure.

[0007] To overcome the above disadvantages, machines exist where brine is electrolyzed with the help of a conventional dual-chambered electrolyzer. Along with chlorinated water these dual-chamber electrolyzers generate highly reactive caustic soda as a byproduct of the reaction. When this byproduct is discarded as waste it is harmful to the environment and extremely unsafe for manual handling.

[0008] There is therefore a need for a machine and a method of producing a large variety of cleaning compositions on site or decentralized, which overcome the above- mentioned deficiencies.

[0009] SUMMARY OF THE INVENTION

[0010] It is therefore an object of the disclosure to advance the state of the art in the area of machines for generating cleaning compositions and methods for generating cleaning compositions, and preferably to overcome the disadvantages of the prior art fully or partially. In advantageous embodiments, a machine for generating cleaning compositions and a method for generating cleaning compositions are provided which allows a user to generate a plurality of different cleaning compositions, preferably using only a single machine as well as using only salt or saltwater, tapwater and a limited number of optional additives as the only necessary ingredients.

[0011] According to a first aspect, the present invention relates to a machine for generating cleaning compositions. The machine comprises a single-chamber electrolyzer for generating electrolyzed saltwater, wherein the electrolyzer comprises a chamber, a pair of electrodes, an electrolyzer inlet and an electrolyzer outlet. The machine further comprises a saltwater container. The saltwater container comprises a salt inlet for supplying salt from a salt source to the saltwater container, wherein the salt source is preferably solid salt. The machine typically further comprises a salinity sensor for measuring the salinity of the saltwater supplied to the electrolyzer inlet. The machine further comprises a control unit configured for maintaining the salinity of the saltwater supplied to the electrolyzer inlet in a range equal to or higher than 0.1 g / L, preferably in a range from 0.1 g / L to 30 g / L, wherein the control unit is further configured for maintaining the temperature of the electrolyzed saltwater generated by the electrolyzer below 60 °C, preferably in a range from 4 °C to 50 °C, more preferably in a range from 20 °C to 45 °C. The machine further comprises at least one additive container for containing at least one additive. The machine further comprises a dispensing unit for dispensing a cleaning composition comprising electrolyzed saltwater and optionally at least one additive.

[0012] The saltwater container is suitable for containing saltwater. The saltwater container may be configured for supplying saltwater to the electrolyzer inlet. In an embodiment, the saltwater container is fluidically connected to a mixing chamber and the mixing chamber is fluidically connected to the electrolyzer. In this embodiment, preferably, saltwater flows from the saltwater container to the mixing chamber and then from the mixing chamber to the electrolyzer. In an embodiment, the mixing chamber is also in fluidic connection with a freshwater source. In this embodiment, the saltwater flowing from the saltwater source into the mixing chamber is mixed with the freshwater flowing into the mixing chamber from the freshwater source and the resulting mixed saltwater then flows from the mixing chamber to the electrolyzer. The saltwater container comprises a salt inlet for supplying salt from the salt source to the saltwater container. Preferably, the salt source is solid salt, such as in cases where saltwater is no locally available. The salt source may also be saltwater, particularly in cases where saltwater is locally available.

[0013] In an embodiment, the saltwater container further comprises a freshwater inlet for supplying freshwater from a freshwater source to the saltwater container. This embodiment is in particular preferably in cases where solid salt is used as salt source.

[0014] Saltwater as used herein is typically a solution of a salt in water. Besides water and salt, the saltwater may additionally comprise further components, such as at least one additive. Depending on the application and depending on the specific component of the machine, the saltwater may have a specific concentration, i.e. salinity. As an example, typically, the saltwater in the saltwater container has a higher salinity than the saltwater that is supplied to the electrolyzer because typically, the saltwater from the saltwater container is mixed with freshwater (and optionally also with at least one additive) in a mixing chamber and the resulting mixture, which may be labelled as ‘mixed saltwater’ or simply ‘saltwater’, is then supplied to the electrolyzer. In other words, typically, a mixing chamber inlet is in fluidic connection, preferably in separate fluidic connection, with the saltwater container, with the freshwater source and optionally with a pre-electrolyzer additive container.

[0015] The salinity sensor is configured for measuring the salinity of the saltwater supplied to the electrolyzer inlet. The saltwater supplied to the electrolyzer inlet typically includes saltwater originally derived from the saltwater source, freshwater originally derived from the freshwater source, and at least one additive from a pre-electrolyzer additive container. In other words, typically, saltwater, freshwater and optionally at least one additive are mixed inside the mixing chamber and the resulting mixture is then supplied to the electrolyzer. It is typically the salinity of this resulting mixture that is being measured by the salinity sensor. In an embodiment, the salinity sensor is configured for measuring the salinity of the saltwater flowing into the electrolyzer. In an embodiment, the salinity sensor is configured for measuring the salinity of the saltwater supplied to the electrolyzer inlet from a mixing chamber outlet. As an example, the salinity sensor may be arranged in a conduit connecting a mixing chamber and the electrolyzer.

[0016] In an embodiment, the control unit is configured for maintaining the salinity of the saltwater supplied to the electrolyzer inlet at a level that is higher than the highest salinity needed in any of the cleaning compositions to be generated. In an embodiment, the control unit is configured for maintaining the salinity of the saltwater supplied to the electrolyzer inlet in a range from 0.1 g / L to 30 g / L, such as from 2 g / L to 30 g / L.

[0017] In a preferred embodiment, the machine is suitable for generating a plurality of cleaning compositions, preferably at least two different cleaning compositions, more preferably at least five different cleaning compositions, more preferably between 8 and 100 different cleaning compositions. A cleaning composition may, for example, differ from another cleaning composition by addition of one or more additives with varying ratios of the amounts of all ingredients and varying process parameters, such as flow rates, electrolization-voltage, -current, -duration and - temperature. Single-chamber electrolyzer as used herein is an electrolyzer that is free of a membrane separating the cathode from the anode. In a typical embodiment, therefore, a liquid electrolyte may move freely between the two electrodes, without having to pass through a membrane.

[0018] The electrolyzer typically has a volume from 30 ml to 500ml, depending on the production capacity of the machine. Typically it has a volume from 100 ml to 200 ml. The electrolyzer may, for example, have a volume of 120 ml to 140 ml, such as 120 ml or 140 ml.

[0019] The saltwater container is typically connected with the electrolyzer inlet by a conduit. The freshwater inlet is typically connected with the freshwater source by a conduit. The salt inlet is typically connected with the salt source by a conduit. The salt source may, for example, be solid salt or a solution of salt, such as brine. As an example, the salt source may be seawater.

[0020] In a typical embodiment, the electrolyzed saltwater generated by the electrolyzer has a residual chlorine level of at least 1000 ppm of free chlorine. As an example, to produce 1000 ppm residual chlorine through electrolysis, a salt solution having a salinity of 15 g / L may be used together with Boron doped diamond electrodes at 12 V, 16 A and at flow rate 200 ml / min.

[0021] In an embodiment, the electrolyzer comprises at least one boron doped diamond electrode. In an embodiment, the electrolyzer comprises at least one titanium- based electrode, preferably an iron-titanium-oxide electrode. In a preferred embodiment the electrolyzer comprises two boron doped diamond electrodes. In an embodiment, the machine comprises an electrolyzed saltwater container for containing and storing electrolyzed saltwater generated by the electrolyzer, wherein the electrolyzed saltwater container comprises an electrolyzed saltwater container inlet in fluidic connection with the electrolyzer outlet and an electrolyzed saltwater container outlet in fluidic connection with the dispensing unit. The electrolyzed saltwater generated by the electrolyzer is typically a preconfigured mixture of saltwater, freshwater and optional additives. Typically, the electrolyzed saltwater container is connected to the electrolyzer by a conduit. In an embodiment, the salinity sensor is arranged in a conduit connecting a mixing chamber and the electrolyzer. In an embodiment, the electrolyzed saltwater container has a housing that is configured for substantially preventing the inside of the electrolyzed saltwater container from being exposed to incumbent light from outside the electrolyzed saltwater container, in particularly from incumbent light from outside the machine. In an embodiment, the housing of the electrolyzed saltwater container is made of plastic, preferably polyvinylchloride or polyamide. In an embodiment, the electrolyzed saltwater container further comprises a ventilation unit for at least temporarily venting excess gas from the electrolyzed saltwater container. In an embodiment, the ventilation unit comprises a tube having a length of at least 1 m, preferably between 2 m and 4 m, and an internal diameter of less than 20 mm, preferably from 3 mm to 6 mm.

[0022] The electrolyzer comprises an electrolyzer inlet configured for being supplied with saltwater. In an embodiment, the electrolyzer further comprises a freshwater inlet configured for being supplied with freshwater, typically in a controlled manner.

[0023] The dispensing unit is arranged downstream of the electrolyzer. One advantage of these embodiments is that they allow storage of the electrolyzed saltwater generated in the electrolyzer. In particular, it is possible to store the electrolyzed saltwater without loss of its cleaning and disinfecting cleaning properties.

[0024] In an embodiment, the machine further comprises a temperature sensor for measuring the temperature of the electrolyzed saltwater generated by the electrolyzer, wherein the temperature sensor is arranged downstream of the electrolyzer and preferably upstream of the electrolyzed saltwater container. In an embodiment, the control unit is configured for initiating a temporary cooling measure when the temperature detected by the temperature sensor exceeds 50 °C, preferably when it exceeds 40 °C. The temporary cooling measure includes one or more of the following: temporary suspension of the voltage applied to the electrodes, temporary suspension of the inflow of saltwater into the electrolyzer or temporary reduction of the conductivity of the medium inside the electrolyzer. The medium may, for example, be the saltwater being electrolyzed inside the electrolyzer. Typically, during temporary suspension of the inflow of saltwater into the electrolyzer, the flow of freshwater is unchanged.

[0025] One advantage of these embodiments is that they allow a high activity of the cleaning compositions to be achieved and also maintained even after longer periods of storage.

[0026] In an embodiment, the machine further comprises a mixing chamber arranged upstream of the electrolyzer and downstream of the saltwater container, wherein the mixing chamber comprises a mixing chamber inlet in fluidic connection with the saltwater container and a mixing chamber outlet in fluidic connection with the electrolyzer. In an embodiment, the mixing chamber inlet is also in fluidic connection with a freshwater source. In an embodiment, the at least one additive container comprises a pre-electrolyzer additive container configured for supplying at least one additive to the mixing chamber, wherein the pre-electrolyzer additive container is in fluidic connection with the mixing chamber inlet.

[0027] In an embodiment, the mixing chamber comprises means for generating a turbulent flow inside the mixing chamber. In an embodiment, the mixing chamber inlet comprises a first mixing chamber inlet pipe that is in fluidic connection with the saltwater container and extends along a first axis, wherein the mixing chamber inlet further comprises a second mixing chamber inlet pipe that is in fluidic connection with the pre-electrolyzer additive container and extends along a second axis, wherein the first axis and the second axis are at an angle of at least 30°, preferably from 90° to 180°. In an embodiment, the first mixing chamber inlet pipe and the second mixing chamber inlet pipe each have an internal diameter of less than 10 mm, preferably from 2 mm to 6 mm, more preferably from 2 mm to 4 mm.

[0028] In an embodiment, the mixing chamber further comprises a fluid obstruction element that is arranged at the intersection point of the first axis and the second axis.

[0029] In an embodiment, the mixing chamber inlet is in fluidic connection with a freshwater source for supplying the mixing chamber with freshwater.

[0030] In an embodiment, the control unit is configured for adjusting the rate of the flow of saltwater from the saltwater container to the mixing chamber,

[0031] - the rate of the flow of freshwater from the freshwater source to the mixing chamber and

[0032] - optionally the rate of the flow of the at least one additive from the preelectrolyzer additive container to the mixing chamber, such that the salinity measured by the salinity sensor ranges from 2g / L to 30g / L. The salinity range may be chosen in accordance with the type of cleaning solution to be produced. As an example, for a cleaning solution for general floor cleaning, the salinity range may be from 2 g / L to 8 g / L, preferably 5 g / L. As a further example, for a cleaning solution for disinfecting medical supplies, the salinity range may be from 25 g / L to 30 g / L, preferably 30 g / L.

[0033] In an embodiment, the control unit may maintain the salinity in the indicated range by measuring the conductivity of the saltwater supplied to the electrolyzer inlet. As an example, the salinity sensor may be configured for measuring the conductivity of the saltwater flowing through a conduit connecting the mixing chamber and the electrolyzer. In another embodiment, the control unit is configured for measuring the conductivity as a function of a voltage drop in the power supplied to the electrodes. The machine may further comprise a power supply that is configured to supply power to the electrodes, wherein the power supply is further configured such that the maximum current it can supply does not exceed the maximum allowed current though the electrolyzer. As an example, the power supply has limited power and a known voltage versus current curve. The power supply may be designed so that the maximum current it can supply does not exceed the maximum allowed current through the electrolyzer. The maximum current through the electrolyzer mainly depends on the size of the smallest electrode and typically has a value of is 1 to 2 A / cm2.

[0034] In an embodiment, the machine further comprises a metal sensor for detecting one or more of the following metals or their respective salts: arsenic and magnesium.

[0035] In an embodiment, the electrolyzer is configured to be operable on reversal of the polarity of the electrical current applied to the electrodes, particularly on periodic reversal of the polarity. In other words, in this embodiment, the electrodes are configured to be operable in a periodic polarity reversal mode. To allow for this periodic polarity reversal, both electrodes are preferably able to withstand chemical degradation when functioning as an anode and as a cathode. In an embodiment this is realized by using a boron doped diamond electrode both as the cathode and as the anode in the electrolyzer.

[0036] In an embodiment, the electrolyzer comprises a recirculation outlet, a recirculation inlet and a recirculation conduit for recirculating electrolyzed saltwater into the electrolyzer, wherein the recirculation conduit fluidically connects the recirculation outlet and the recirculation inlet. This allows particularly high cleaning activities and disinfecting properties to be achieved. In an embodiment, the at least one additive container comprises a post-electro- lyzer additive container arranged downstream of the electrolyzer, preferably downstream of the electrolyzed saltwater container, wherein the post-electrolyzer additive container is configured for supplying at least one additive to the dis- penser.

[0037] According to a second aspect, the present invention relates to a method of generating a cleaning composition using the machine according to the first aspect of the invention. The method comprises the steps of:

[0038] • providing saltwater inside a saltwater container; • inflow of the provided saltwater from the saltwater container into a mixing chamber at a saltwater flow rate;

[0039] • inflow of freshwater from a freshwater source into the mixing chamber at a freshwater flow rate;

[0040] • mixing of the saltwater and the freshwater flown into the mixing chamber to provide mixed saltwater inside the mixing chamber;

[0041] • measuring the salinity of the provided mixed saltwater;

[0042] • adjusting the saltwater flow rate and the freshwater flow rate such that the salinity measured by the salinity sensor ranges from 5 g / L to 30 g / L; • supplying the mixed saltwater from the mixing chamber to a single-chamber electrolyzer comprising a pair of electrodes;

[0043] • electrolyzing the mixed saltwater in the electrolyzer to provide electrolyzed saltwater;

[0044] • maintaining the temperature of the electrolyzed saltwater generated by the electrolyzer below 60 °C, preferably in a range from 4 °C to 50 °C;

[0045] • supplying the electrolyzed saltwater to a dispensing unit and optionally supplying at least one additive from at least one additive container to provide a cleaning composition comprising electrolyzed saltwater and optionally at least one additive.

[0046] In an embodiment, the step of providing saltwater inside a saltwater container includes supplying freshwater from a freshwater source to the saltwater container and supplying salt from a salt source to the saltwater container to provide saltwater inside the saltwater container.

[0047] In an embodiment, in the step of mixing of the saltwater and the freshwater flown into the mixing chamber, the mixed saltwater has a salinity between that of the freshwater flown into the mixing chamber and the salinity of the saltwater flown into the mixing chamber.

[0048] In an embodiment, the method further comprises supplying at least one additive from a pre-electrolyzer additive container to the mixing chamber, wherein the at least one additive supplied from the pre-electrolyzer additive container is selected from one or more of the following: hydrochloric acid, vinegar, acetic acid, potassium hydroxide and sodium hydroxide.

[0049] In an embodiment, the method further comprises supplying at least one additive from a post-electrolyzer additive container to the dispensing unit, wherein the at least one additive supplied from the post-electrolyzer additive container is selected from one or more of the following: sodium laureth sulfate (SLES), jasmine, sodium hydroxide, a dispersion coloring agent, a protease, an amylase and brine.

[0050] In an embodiment, during the step of electrolyzing the mixed saltwater, the polarity of the current supplied to the electrodes is regularly reversed, preferably reversed at least once every 15 minutes.

[0051] In an embodiment, during the step of electrolyzing the mixed saltwater, the voltage applied to the electrodes is below 70 VDC. Additionally, the current may be controlled such that it is less than 1 A per cm2 of the surface of the smallest electrode projected onto the other electrode, preferably higher than 0.9 A / cm2, such as higher than 0.95 A / cm2. As an example, the voltage applied to the electrodes may be below 70 VDC and combined with the conductivity of the medium between the electrodes and distance between the electrodes resulting in a current close to but below 1 A per cm2of the surface of the smallest electrode projected onto the other electrode. Preferably, the voltage is between 5 V and 15V.

[0052] In an embodiment, during the step of electrolyzing the mixed saltwater, the current applied to the electrodes is pulsed. Pulsed, in this context, means that periodically the current is switched off to allow the medium, such as the saltwater being electrolyzed, in the electrolyzer to remain below a certain desired temperature. In an embodiment the flow through the electrolyzer is also stopped while the current is switched off to avoid unelectrolyzed water to exit the electrolyzer. This could, for example, diminish the residual chlorine level of the generated electrolyzed water.

[0053] In an embodiment, the method further comprises the step of temporarily storing the electrolyzed saltwater generated by the electrolyzer in an electrolyzed saltwater container before supplying it to the dispensing unit, wherein the electrolyzed saltwater is preferably stored in the electrolyzed saltwater container for up to 30 days, preferably from 1 day to 7 days, more preferably from 1 to 3 days.

[0054] In an embodiment, the method comprises measuring the temperature of the electrolyzed saltwater generated by the electrolyzer, wherein the temperature sensor is arranged downstream of the electrolyzer and preferably upstream of an electrolyzed saltwater container. In an embodiment, the method further comprises initiating a temporary cooling measure when the temperature detected by the temperature sensor exceeds 50 °C, preferably when it exceeds 40 °C, wherein the temporary cooling measure includes one or more of the following: temporary suspension of the voltage applied to the electrodes or temporary suspension of the inflow of saltwater into the electrolyzer. In an embodiment, the temporary cooling measure consists of temporary suspension of the voltage applied to the electrodes.

[0055] In an embodiment, in the step of supplying salt to the saltwater container, the salt is supplied as saltwater, preferably as seawater or as saline groundwater, such as saline groundwater having a salinity of at least 2 g / L, preferably at least 5 g / L. In an embodiment, in the step of supplying freshwater to the saltwater container, the freshwater is supplied as tapwater. In an embodiment, the only liquids used in the method are tap water, saltwater and optionally additives. In an embodiment, the saltwater inside the saltwater container is saturated.

[0056] In an embodiment, the electrolyzer comprises a recirculation outlet, a recirculation inlet and a recirculation conduit fluidically connecting the recirculation outlet and the recirculation inlet, wherein the step of electrolyzing the mixed saltwater in the electrolyzer includes recirculating at least some of the electrolyzed saltwater generated inside the electrolyzer from the recirculation outlet through the recirculation conduit to the recirculation inlet.

[0057] In an embodiment, the salt comprises at least 80 wt.-% NaCI, preferably at least 90 wt.-% NaCI, more preferably at least 95 wt.-% NaCI, more preferably at least 99 wt.-%, NaCI, more preferably at least 99.5 wt.-% NaCI. Typically, the salt is NaCI.

[0058] The embodiments previously disclosed in the context of the machine of the first aspect of the invention, in particular all embodiments relating to the freshwater source, the salt source, the saltwater container, the mixing chamber, the preelectrolyzer additive container, the electrolyzer, the electrolyzed saltwater container, the post-electrolyzer additive container and the dispenser, among others, also apply to the method according to the second aspect of the invention, and vice versa. It is to be understood that both the foregoing general description and the following detailed description present embodiments, and are intended to provide an overview or framework for understanding the nature and character of the disclosure. The accompanying drawings are included to provide a further understanding, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments, and together with the description serve to explain the principles and operation of the concepts disclosed.

[0059] BRIEF DESCRIPTION OF THE DRAWINGS

[0060] The invention described herein will be more fully understood from the detailed description given herein below and the accompanying drawings, which should not be considered limiting to the invention described in the appended claims. The drawings are showing:

[0061] Fig. 1 shows an embodiment of the machine for generating cleaning compositions.

[0062] DESCRIPTION OF THE EMBODIMENTS

[0063] Reference will now be made in detail to certain embodiments, examples of which are illustrated in the accompanying drawings, in which some, but not all features are shown. Indeed, embodiments disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Whenever possible, like reference numbers will be used to refer to like components or parts.

[0064] The machine and the process of the present invention have a range of advantages. They allow on-site, flexible generation of a multitude of disinfecting and cleaning solutions, with an unmatched combination of highly powerful effectiveness coupled with extremely eco-friendly properties while needing a very limited amount of ingredients.

[0065] Further improvements include:

[0066] • Compared to pre-packaged specific disinfecting and cleaning solutions: o Greatly improved eco-friendliness by generating a cleaning composition that is very powerful when produced, but in some embodiments having a limited shelf life. This makes sure that shortly after producing and using the cleaning composition it becomes harmless to the environment. o Greatly improves logistics and handling. For most embodiments up to 99.5% of the cleaning composition will be produced from tap water, limiting transport significantly while still producing all kinds of cleaning compositions automatically without manual dilution. As a possible embodiment even 100% of the ingredients could be the combination of local tap water and seawater or slightly saline groundwater, eliminating logistics completely. Note that the reduced logistics and elimination of packaging further improve the eco-friendliness significantly. o Improves flexibility, allowing the end-user to select the best possible composition for the job, just by selecting a recipe using different machine parameters, like using a different voltage, flow rate, etc., so even without adding the optional additives. o Cost reduction is particularly significant in situations where logistics are an important factor, such as high-volume end-users and more remote locations.

[0067] • Compared to existing electrolyzer machines, the disclosed machine: o Generates highly powerful cleaning compositions suitable for cleaning and disinfecting external objects. This separates the machine from all machines that just disinfect the fluid that passes through the machine itself, such as machines for disinfecting pool-water and drinking-water. o Improves eco-friendliness by using a highly innovative single-chamber electrolyzer that generates a single electrolyzed liquid. This differs from all electrolyzers that need a separation, typically a membrane, between the positive and negative electrode in the electrolyzer. The membrane is needed there to avoid the liquids generated in the positive and negative side of the electrolyzer to cancel each other out immediately after leaving the electrolyzer. This results there in producing two liquids, from which only one is useful as a desired cleaning composition, generating significant waste and also making it harder for the remaining liquid to revert back to its original harmless components after application by the user. In some embodiments, the electrolyzer used in the machine according to the present disclosure uses a cathode material to generate a single liquid that is stable enough to not cancel itself out immediately after electrolysis. Therefore no immediate waste is generated and the cleaning composition can revert back to its original harmless components after being used (typically as a result of being subjected to light and outside air). Greatly improved flexibility. All known electrolyzer machines generate a single output, possibly with varying strength, providing at most a partial solution for the cleaning / disinfecting needs of a typical enduser location such as hotels, hospitals or other public buildings. The invented machine makes it possible to generate the entire spectrum of cleaning compositions needed in said typical use-cases. It does this by allowing optional additives to be mixed into the flow before and / or after the electrolyzer, providing the necessary control end feedback electronics and integrated user interface to access built in and user-configurable recipes defining a virtually endless array of possible cleaning compositions the machine can produce. Summarizing, the machine and the process disclosed herein are based on a synergetic combination of attributes, working together to provide ground breaking new possibilities in the flexible, eco-friendly and cost effective production of disinfecting and cleaning solutions, allowing eco-friendly products to become more main-stream.

[0068] In a typical embodiment, the machine comprises means to generate flow, such as means to generate flow from all the liquid sources and containers.

[0069] Figure 1 shows an embodiment of the machine of the present disclosure. The illustrated machine can generate a highly powerful cleaning composition, reaching a residual chlorine level equivalent of at least 1000 ppm of free chlorine, while still using a very low salinity. This is achieved by using an electrolyzer with highly catalytic electrodes, combined with a control unit that optimizes the flow rate and ratio of water, salt and pre-electrolyzer additives for each desired cleaning composition.

[0070] The problem with generating a highly powerful cleaning composition is that the electrode surface quickly degenerates due to agglomeration of elements present in normal tap water such as magnesium, calcium, etc.. This leads to a short life span or to a low limit in reachable residual chlorine levels in the order of less than 10 ppm free chlorine level. To solve this problem, in one of the embodiments the machine automatically reverses the voltage on the electrolyzer, causing the elements to release from the electrode surfaces that had agglomerated before the voltage was reversed. One of the embodiments of the machine uses electrodes coated with the highly catalytic boron doped diamond. This can generate oxidizing agents such as HOCI, NaOCI, H2O2, O3 that are stable enough to not fall back to their original components even when produced by an electrolyzer without a membrane-like separation between the electrodes. The cleaning composition produced in this way will keep at least 80% of its strength for 3 days when kept in a dark, airtight, plastic container.

[0071] Saltwater container 6 holds the saltwater. One of the embodiments uses a relatively large container for this where solid salt can be filled. In this case the control unit automatically adds tapwater to this container, keeping it nearly full at all times. The amount of salt is typically enough for about 1 to 6 months of production. This allows enough time for the added tapwater to become fully saturated with salt, resulting in a relatively stable salinity when salt is added before it is fully consumed.

[0072] Another embodiment is a connection to a seawater sources. Here typically a pump is used to pump seawater with a relatively stable salinity into saltwater container 6, keeping it close to full during normal operation.

[0073] The machine may comprise a means to control saltwater flow 10, which may comprise a pump. The machine may further comprise a flow sensor 1 1 , which may be realized by pump timing. The machine may comprise a first, second and third means to control freshwater flow 3, 9, 13, which preferably may each comprise a pump. Another embodiment is a connection to a saline groundwater sources. Here typically a pump is used to pump groundwater with a salinity of at least 2g / L (typically at least 5g / L) into saltwater container 6, keeping it close to full during normal operation.

[0074] To optionally add 0 or more pre-electrolyzer additives to the produced electrolyzed water, in some embodiments, the machine includes a flow sensor 14, a means to control pre-electrolyzer additive flow 15, a pre-electrolyzer additive container 16 and a level sensor of the pre-electrolyzer additive container 17. The second means to control freshwater flow 9 may be a valve. The flow sensor 14 may be realized by pump-timing. The means to control pre-electrolyzer additive flow may be a pump. The level sensor of the pre-electrolyzer additive container may be configured for measuring a minimum fill level. Pre-electrolyzer additive container 16, a pre-electrolyzer additive can be stored. This typically can be filled by hand. In the preferred embodiment a level sensor is used to check if sufficient additive is present. In another embodiment the level is controlled by user input when new additive is added and by calculation of the used additive for production.

[0075] In an embodiment, pump 15 is used to pump the additive towards the electrolyzer while the pumped amount is registered with a flow sensor. In another embodiment the amount pumped is registered by using pump timing.

[0076] In an embodiment, the pre-electrolyzer additives may be selected from one or more of the following:

[0077] In a typical embodiment, all fluids that flow through the electrolyzer are automatically mixed in the mixing chamber 12 before entering the electrolyzer. The mixing facilitates for sensor 18 to measure the salinity at the entrance of the electrolyzer, providing a feedback loop to the control unit. Together with the flow speed and additives, this allows to vary the properties of the electrolyzed saltwater generated, depending on the settings of the machine. In an embodiment, salinity sensor 18 is integrated in the electrolyzer. In an embodiment the sensor is integrated in the control unit, using the voltage between the electrolyzer electrodes to meas- ure the salinity. In an embodiment, the saltwater container salinity sensor 8 may be near an outlet of the saltwater container. In an embodiment, the machine comprises a flow sensor 25, which may be realized by pump timing. The flow sensor 25 typically measured the flow through a conduit connecting the electrolyzed saltwater container and the dispensing unit. In an embodiment, the machine further comprises a means to control flow to the dispensing unit 26, which may, for example, be realized by pump timing. In an embodiment, the machine further comprises a flow sensor 29, which may, for example be arranged between the postelectrolyzer additive container and the dispensing unit. The flow sensor 29 may, for example, be realized by pump timing. The machine may further comprise a means to control post-electrolyzer additive flow 30, which may, for example, comprise a pump.

[0078] Pump timing, as used herein, is defined as using positive displacement pumps with a known and constant flow rate and controlling the pumping time. The pumped volume can then be calculated from the known flow rate multiplied by the pumping time. In another embodiment the number of revolutions or part s of revolutions can be counted. This in combination with the known volume pumped per revolution can be used to calculate the pumped volume. In another embodiment a flow meter is used to measure the volume passing the flow meter at any time, typically by counting the pulses while the amount per pulse is known for the flow meter. The flow meter embodiment is typically used when the flow generating means is not a positive displacement pump, but typically a valve in combination with a pressure source, such as is common in the tapwater inlet.

[0079] In an embodiment the mixing chamber 12 includes of a labyrinth optimized to bring the different fluids in close contact while generating turbulence in the flow. In the preferred embodiment this is done by using relatively small diameter tubes, placed close together at different angles where the different fluids enter the mixing chamber, followed by small obstructions in the mixing chamber that break laminar flow and generate turbulent flow.

[0080] The electrolysis typically supports varying the flow rate and ratio of all liquids, where the flow can also be 0 to allow prolonged electrolysis, where the current through the electrolyzer can be pulsed with varying duty cycles and in different directions (polarity reversal). The flow rate depends proportionally on the volume of the electrolyzer, so doubling the volume of the electrolyzer typically requires doubling the flow rate. Usable average flow rates though a 100 ml electrolyzer would be between 10 ml / minute and 300 ml / minute, preferably 50 to 200 ml / mi- nute. In an embodiment temperature sensor 20 is used to measure the temperature of the electrolyzed saltwater at the output side of the electrolyzer, allowing optimization of the process. Since a high temperature (above 40°C) is typically detrimental to the stability of the produced high-strength electrolyzed saltwater, in an embodiment the control unit optimizes the process by adding cool-down periods during the process where current and flow through the electrolyzer are both close to 0. Together with the embodiment where the polarity of the electrolyzer is periodically reversed to avoid buildup of harmful elements on the electrodes, this significantly prolongs the lifetime of the electrolyzer.

[0081] The electrolyzed saltwater generated may be stored in electrolyzed saltwater container 24. This container and the machine housing make sure that the electrolyzed saltwater is not exposed to sunlight during normal operation. As an example, the housing may be made of plastic (preferably PVC or PA). To avoid contact between outside air and the generated electrolyzed saltwater, but still allow the electrolyzed saltwater to enter and exit this container without significant pressure changes, a long thin tube 23 may be used that connects the top of this container to an outside area. Typical dimensions of this tube are 3 m long with an internal diameter of 4 mm. A significant benefit of this tube is that it vents potentially harmful gasses out of range of people and confined spaces, allowing it to disperse without any negative influences. In the preferred embodiment maximum level sensor 22 is used to avoid overfilling container 24. In an embodiment, 0 or more post-electrolyzer additives are supplied to the dispenser. As an example, a level sensor of the post-electrolyzer additive container 27 may be used. Further, a post-electrolyzer additive container 28 may be used, as well as a flow sensor 29 and a means to control post-electrolyzer additive flow 30. The flow sensor 29 may, for example, be realized by pump timing. The means to control post-electrolyzer additive flow may, for example, comprise a pump. In post-electrolyzer additive container 28, a post-electrolyzer additive can be stored. This typically can be filled by hand. In the preferred embodiment a level sensor 33 is used to check if sufficient additive is present for electrolyzed saltwater generation. The level sensor 33 may, for example, comprise a weight sensor. In a further embodiment the level is controlled by user input when new additive is added and by calculation of the used additive for production. In an embodiment pump 30 is used to pump the additive towards the dispense head while the pumped amount is registered with a flow sensor. In another embodiment the amount pumped is registered by using pump timing.

[0082] In a specific embodiment, brine is used as a post-electrolyzer additive. As an example, where brine (salt-water) is used as a post-additive, the brine can be pumped directly from the saltwater container 6, using the group of items 27, 29, 30 connected to container 6 to implement this. It has been found that adding brine can significantly increase the viscosity of the formulation. This allows for much better adhesion to the surfaces to disinfect and therefore a much longer con- tact / disinfection time, significantly improving disinfection efficiency and reduction of the amount needed of the formula. In an embodiment, the pre-electrolyzer additives may be selected from one or more of the following:

[0083] To generate a wide range of different cleaning compositions for all kinds of appli- cations, the control unit may have a user interface where the operator can select pre-defined recipes. In an embodiment the operator can add and / or change these recipes himself, typically only when given the user level and password to do so. A recipe typically specifies the ratio of freshwater, electrolyzed saltwater and post-electrolyzer additives, where some of these components can have a ratio of 0%. In the embodiment where the machine has multiple dispense heads, the operator can also select which one to use, typically choosing between a connected external bulk tank or a small container used for direct application such as a spray flask. In an embodiment the machine implements sensor 33 as a weighing sensor of a direct application container. This can then be used to first determine the current contents and / or the type of flask placed, automatically determining the amount of the recipe to be dispensed. In another embodiment sensor 33 is a level sensor in an external tank, used to determine if additional dispensing is needed. In a typical embodiment, all sensor, pumps and valves disclosed herein are connected to the control unit. In a typical embodiment, components and / or objects that are described to be in fluidic communication or fluidic connection with one another may, in an embodiment, be connected to each other by a conduit. With reference to figure 1 , as an example in an embodiment, the solid lines shown in figure 1 illustrate conduits for fluidic connection.

[0084] LIST OF DESIGNATIONS

[0085] 1 freshwater source

[0086] 2 sensor for measuring waterflow

[0087] 3 first means to control freshwater flow

[0088] 4 salt source

[0089] 5 means to control saltwater flow

[0090] 6 saltwater container

[0091] 7 maximum level sensor

[0092] 8 saltwater container salinity sensor

[0093] 9 second means to control freshwater flow

[0094] 10 means to control saltwater flow

[0095] 11 flow sensor

[0096] 12 mixing chamber

[0097] 13 third means to control freshwater flow

[0098] 14 flow sensor

[0099] 15 means to control pre-electrolyzer additive flow

[0100] 16 pre-electrolyzer additive container

[0101] 17 level sensor of the pre-electrolyzer additive container

[0102] 18 salinity sensor

[0103] 19 single-chamber electrolyzer

[0104] 20 temperature sensor

[0105] 21 minimum level sensor

[0106] 22 maximum level sensor

[0107] 23 ventilation unit

[0108] 24 electrolyzed saltwater container 25 flow-sensor

[0109] 26 means to control flow to dispensing unit

[0110] 27 level sensor of post-electrolyzer additive container

[0111] 28 post-electrolyzer additive container 29 flow sensor

[0112] 30 means to control post-electrolyzer additive flow

[0113] 31 dispensing unit

[0114] 32 external container to be filled with cleaning composition

[0115] 33 level sensor

Claims

PATENT CLAIMS1. Machine for generating cleaning compositions, wherein the machine comprises:• a single-chamber electrolyzer (19) for generating electrolyzed saltwater, wherein the electrolyzer (19) comprises a chamber, a pair of electrodes, an electrolyzer inlet and an electrolyzer outlet;• a saltwater container (6) comprising a salt inlet for supplying salt from a salt source (4) to the saltwater container, wherein the salt source (4) is preferably solid salt;• a salinity sensor (18) for measuring the salinity of saltwater supplied to the electrolyzer inlet;• a control unit configured for maintaining the salinity of the saltwater supplied to the electrolyzer inlet in a range from 2 g / L to 30 g / L, wherein the control unit is further configured for maintaining the temperature of the electrolyzed saltwater generated by the electrolyzer below 60 °C, preferably in a range from 4 °C to 50 °C;• at least one additive container (16, 28) for containing at least one additive; and a dispensing unit (31 ) for dispensing a cleaning composition comprising electrolyzed saltwater and optionally at least one additive.

2. Machine according to claim 1 , wherein the electrolyzer comprises a boron doped diamond electrode and / or an iron-titanium-oxide electrode, wherein preferably the electrolyzer comprises two boron doped diamond electrodes.

3. Machine according to claim 1 or 2, further comprising an electrolyzed saltwater container (24) for containing and storing electrolyzed saltwater generated by the electrolyzer (19), wherein the electrolyzed saltwater container (24) comprises an electrolyzed saltwater container inlet in fluidic connection with the electrolyzer outlet and an electrolyzed saltwater container outlet in fluidic connection with the dispensing unit (31 ).

4. Machine according to one of the previous claims, further comprising a temperature sensor (20) for measuring the temperature of the electrolyzed saltwater generated by the electrolyzer (19), wherein the temperature sensor (20) is arranged downstream of the electrolyzer (19) and preferably upstream of the electrolyzed saltwater container (24).

5. Machine according to the previous claim, wherein the control unit is configured for initiating a temporary cooling measure when the temperature detected by the temperature sensor (20) exceeds 50 °C, preferably when it exceeds 40 °C, wherein the temporary cooling measure includes one or more of the following: temporary suspension of the voltage applied to the electrodes or temporary reduction of the conductivity of the medium inside the electrolyzer.Machine according to one of the previous claims, further comprising a mixing chamber (12) arranged upstream of the electrolyzer and downstream of the saltwater container (6), wherein the mixing chamber (12) comprises a mixing chamber inlet in fluidic connection with the saltwater container (6) and a mixing chamber outlet in fluidic connection with the electrolyzer (19). Machine according to the previous claim, wherein the at least one additive container (16, 28) comprises a pre-electrolyzer additive container (16) configured for supplying at least one additive to the mixing chamber (12), wherein the pre-electrolyzer additive container (16) is in fluidic connection with the mixing chamber inlet. Machine according to claim 6 or 7, wherein the salinity sensor is arranged in a conduit connecting the mixing chamber (12) and the electrolyzer (19). Machine according to one of claims 6-8, wherein the mixing chamber (12) comprises means for generating a turbulent flow inside the mixing chamber (12). Machine according to the previous claim, wherein the mixing chamber inlet comprises a first mixing chamber inlet pipe that is in fluidic connection with the saltwater container (6) and extends along a first axis, wherein the mixing chamber inlet further comprises a second mixing chamber inlet pipe that is in fluidic connection with the pre-electrolyzer additive container (16) and extends along a second axis, wherein the first axis and the second axis are at an angle of at least 30°, preferably from 90° to 180°.11 . Machine according to the previous claim, wherein the first mixing chamber inlet pipe and the second mixing chamber inlet pipe each have an internal diameter of less than 10 mm, preferably from 2 mm to 6 mm, more preferably from 2 mm to 4 mm.

12. Machine according to claim 10 or 1 1 , wherein the mixing chamber further comprises a fluid obstruction element that is arranged at the intersection point of the first axis and the second axis.

13. Machine according to one of claims 6-12, wherein the mixing chamber inlet is in fluidic connection with a freshwater source (1 ) for supplying the mixing chamber with freshwater.

14. Machine according to claim 13, wherein the control unit is configured for adjusting• the rate of the flow of saltwater from the saltwater container (6) to the mixing chamber (12),• the rate of the flow of freshwater from the freshwater source (1 ) to the mixing chamber (12) and• optionally the rate of the flow of the at least one additive from the pre-electrolyzer additive container (16) to the mixing chamber (12), such that the salinity measured by the salinity sensor (18) ranges from 2 g / L to 30 g / L.Machine according to one of the previous claims, wherein the electrolyzer (19) comprises a recirculation outlet, a recirculation inlet and a recirculation conduit for recirculating electrolyzed saltwater into the electrolyzer, wherein the recirculation conduit fluidically connects the recirculation outlet and the recirculation inlet. Method of generating a cleaning composition using the machine according to one of the previous steps, the method comprising the steps of:• providing saltwater inside a saltwater container;• inflow of the provided saltwater from the saltwater container into a mixing chamber (12) at a saltwater flow rate;• inflow of freshwater from a freshwater source into the mixing chamber (12) at a freshwater flow rate;• mixing of the saltwater and the freshwater flown into the mixing chamber (12) to provide mixed saltwater inside the mixing chamber (12);• measuring the salinity of the provided mixed saltwater;• adjusting the saltwater flow rate and the freshwater flow rate such that the salinity measured by the salinity sensor (18) ranges from 2 g / L to 30 g / L;• supplying the mixed saltwater from the mixing chamber (12) to a single-chamber electrolyzer (19) comprising a pair of electrodes;• electrolyzing the mixed saltwater in the electrolyzer (19) to provide electrolyzed saltwater;• maintaining the temperature of the electrolyzed saltwater generated by the electrolyzer below 60 °C, preferably in a range from 4 °C to 50 °C; and• supplying the electrolyzed saltwater to a dispensing unit (31 ) and optionally supplying at least one additive from at least one additive container (16, 28) to provide a cleaning composition comprising electrolyzed saltwater and optionally at least one additive. Method according to claim 16, further comprising supplying at least one additive from a pre-electrolyzer additive container (16) to the mixing chamber (12), wherein the at least one additive supplied from the pre-electrolyzer additive container (16) is selected from one or more of the following: hydrochloric acid, vinegar, acetic acid, potassium hydroxide and sodium hydroxide. Method according to claim 16 or 17, further comprising supplying at least one additive from a post-electrolyzer additive container (28) to the dispensing unit (31 ), wherein the at least one additive supplied from the post-elec- trolyzer additive container (28) is selected from one or more of the following:sodium laureth sulfate (SLES), jasmine, sodium hydroxide, a dispersion coloring agent, a protease, an amylase and brine. Method according to one of claims 16-18, wherein during the step of electrolyzing the mixed saltwater, the polarity of the current supplied to the electrodes is regularly reversed, preferably reversed at least once every 15 minutes. Method according to one of claims 16-19, further comprising measuring the temperature of the electrolyzed saltwater generated by the electrolyzer (19), wherein the temperature sensor (20) is arranged downstream of the electrolyzer (19) and preferably upstream of an electrolyzed saltwater container (24). Method according to the previous claim, further comprising initiating a temporary cooling measure when the temperature detected by the temperature sensor (20) exceeds 50 °C, preferably when it exceeds 40 °C, wherein the temporary cooling measure includes one or more of the following: temporary suspension of the voltage applied to the electrodes or temporary reduction of the conductivity of the electrolyzed saltwater being electrolyzed inside the electrolyzer (19). Method according to one of claims 16-21 , wherein in the step of supplying salt to the saltwater container, the salt is supplied as saltwater, preferably as seawater or as saline groundwater, such as saline groundwater having a salinity of at least 2 g / L, preferably at least 5 g / L.Method according to one of claims 16-22, wherein the electrolyzer (19) comprises a recirculation outlet, a recirculation inlet and a recirculation conduit fluidically connecting the recirculation outlet and the recirculation inlet, wherein the step of electrolyzing the mixed saltwater in the electrolyzer (19) includes recirculating at least some of the electrolyzed saltwater generated inside the electrolyzer from the recirculation outlet through the recirculation conduit to the recirculation inlet.

Images