Ozone generator reservoir

Abstract

An ozone generator for use with a faucet. The ozone generator in a storage mode includes a fluid reservoir for hydration of an electrolytic cell assembly.

Description

OZONE GENERATOR RESERVOIRCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to U.S. Provisional Patent Application Serial No. 63 / 532,989, filed August 16, 2023, the disclosure of which is expressly incorporated herein by reference.BACKGROUND AND SUMMARY OF THE DISCLOSURE

[0002] The present disclosure relates generally to an ozone generator for use with a fluid delivery device. More particularly, the present disclosure relates to a hydration reservoir for an electrolytic ozone generator for use with a faucet.

[0003] It is known to provide electrolytic ozone generators for providing ozone in water for discharge by a faucet. The ozone may perform a beneficial disinfecting function by destroying bacteria and pathogens in the water or surfaces it contacts. However, existing ozone generators may experience performance issues and / or reduced life expectancies if not properly hydrated, particularly during initial operation.

[0004] According to an illustrative embodiment of the present disclosure, an ozone generator for use with a faucet includes a first current spreader, a first electrode supported by the first current spreader, a second current spreader, and a second electrode supported by the second current spreader. A separator is positioned between the first electrode and the second electrode. A reservoir for receiving water is in fluid communication with the separator.

[0005] According to another illustrative embodiment of the present disclosure, an ozone generator for use with a faucet includes an electrolytic cell assembly, and an outer cylindrical cartridge receiving the electrolytic cell assembly. A reservoir is configured to receive a fluid and at least partially receives the outer cylindrical cartridge.

[0006] According to a further illustrative embodiment of the present disclosure, a method of storing an ozone generator includes the steps of providing an electrolytic cell assembly having a first electrode, a second electrode, and a separator positioned between the first electrode and the second electrode, and a reservoir defining a chamber. The method further includes the steps of placing hydration fluid within the chamber of the reservoir,inserting the electrolytic cell assembly within the chamber of the reservoir wherein the separator is in contact with the hydration fluid, and securing an end cap to the reservoir.

[0007] Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed subscription of illustrated embodiments. Exemplifying the best mode of carrying out the invention as presently perceived.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The detailed description of the drawings particularly refers to the accompanying figures in which:

[0009] FIG. 1 is a right perspective view of an illustrative system including an ozone generator of the present disclosure in an operating mode;

[0010] FIG. 2 is a left perspective view of the illustrative system of FIG. 1;

[0011] FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1;

[0012] FIG. 4 is a perspective view of the illustrative ozone generator of FIG. 1 in a storage mode;

[0013] FIG. 5 is an exploded perspective view of the illustrative ozone generator of FIG. 3;

[0014] FIG. 6 is a first cross-sectional view taken along line 6-6 of FIG. 4;

[0015] FIG. 7 is a second cross-sectional view taken along line 7-7 of FIG. 4;

[0016] FIG. 8 is a perspective view of an electrolytic cell assembly of the ozone generator of FIG. 4; and

[0017] FIG. 9 is an exploded perspective view of the illustrative electrolytic cell assembly of FIG. 8.

[0018] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.DETAILED DESCRIPTION OF THE DRAWINGS

[0019] For the purposes of promoting and understanding the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described herein. The embodiments disclosed herein are not intended to be exhaustive or to limit the invention to the precise form disclosed. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. Therefore, no limitation of the scope of the claimed invention is thereby intended. The present invention includes any alterations and fiirther modifications of the illustrated devices and described methods and further applications of principles in the invention which would normally occur to one skilled in the art to which the invention relates.

[0020] Referring initially to FIG. 1 of the drawings, an illustrative water treatment system 10 is configured for use with a faucet (not shown) and includes an ozone generator 12. In the following description, FIGS. 1-3 illustrate the ozone generator 12 in an operating mode, while FIGS. 4-7 illustrate the ozone generator 12 in a storage mode. The illustrative ozone generator 12 includes an electrolytic cell assembly 14 (FIG. 4). FIGS. 3 and 6-9 illustrate additional details of the electrolytic cell assembly 14. A solenoid valve body 16 includes an ozone generator receiving chamber 18 at least partially receiving the ozone generator 12.

[0021] In the illustrative system 10, a first, or mixed water, pilot operated diaphragm solenoid valve 20a is received within a first valve receiving chamber 22a of the valve body 16. A second, or ozone, pilot operated diaphragm solenoid valve 20b is received within a second valve receiving chamber 22b of the valve body 16. The valve receiving chamber 22a is in fluid communication with the ozone generator receiving chamber 18 through the valve body 16.

[0022] Inlet housings or retainers 24a and 24b secure the solenoid valves 20a and 20b within the valve receiving chambers 22a and 22b. More particularly, the inlet retainers 24a, 24b each include a retainer body 25 a, 25b supporting external threads that mate with internal threads of the valve body 16 to secure the inlet retainers 24a, 24b within the valve receiving chambers 22a, 22b. The retainer bodies 25a, 25b include connector tubes 29a, 29b extending outwardly from valve body 16 (FIG. 2). Fluid passageways extend through the inlet retainers 24a, 24b. Sealing rings promote sealed connections between the retainers 24a, 24b and the solenoid valve body 16.

[0023] With respect to the illustrative embodiment of FIGS. 1 and 2, a power supply (not shown) is electrically coupled to a printed circuit board (PCB) 28 through an electrical cable 30 including a wall plug 32 at a first end and a connector 34 at a second end. The wall plug 32 illustratively includes an AC to DC 24 volt switching power supply. The connector 34 is received within a socket 35 supported by the printed circuit board 28. Electrical cable 36 of the ozone generator 12 includes a connector 38 coupled to a socket 37 supported by the printed circuit board 28. A controller 39 is illustratively supported by the printed circuit board, and may include a constant current light emitting diode (LED) power integrated circuit (1C) chip. The IC chip is illustratively configured to maintain the current constant as the resistance of the ozone generator 12 changes over its life (e.g., due to accumulation on and / or degradation of the electrodes).

[0024] With further reference to FIG. 2, a conventional mixing valve 40 is illustratively in fluid communication with the first and second solenoid valves 20a and 20b. More particularly, an outlet 42 of the mixing valve 40 is fluidly coupled to the first solenoid valve 20a through conventional fluid line 44. More particularly, the fluid line 44 is fluidly coupled to the connector tube 29a of the inlet retainer 24a. A wye fitting 46 is fluidly coupled to the second retainer 24b. The wye fitting 46 includes an inlet tube 48 including an inlet port 50, and an outlet tube 52 including a first outlet port 54 and a second outlet port 56. The inlet port 50 of the inlet tube 48 is illustratively fluidly coupled to a cold water source 58 through a conventional fluid line 60, the first outlet port 54 of the outlet tube 52 is illustratively fluidly coupled to the first solenoid valve 20a through connector tube 29b of the inlet retainer 24b, and the second outlet port 56 of the outlet tube 52 is illustratively fluidly coupled to a cold water inlet 62 of the mixing valve 40 through a conventional fluid line 64. A hot water source 66 is fluidly coupled to a hot water inlet 68 of the mixing valve 40 through a conventional fluid line 70.

[0025] An outlet fitting 72 is fluidly coupled to the outlet passageway in the solenoid valve body 16. A fluid delivery device, illustratively a conventional pullout wand or sprayer 74 of the faucet, is fluidly coupled to the outlet fitting 72.

[0026] Additional details of the solenoid valves 20a, 20b, the solenoid valve body 16 and associated components of the illustrative system 10 are provided in U.S. Patent No.11,634,828 to Jonte et al., the disclosure of which is expressly incorporated herein by reference.

[0027] An exemplary ozone generator 12 of the present disclosure is further shown in FIGS. 3-9. The illustrative ozone generator 12 has an inlet end 82, an outlet end 84, and a longitudinal axis L extending therebetween.

[0028] With reference to FIG. 3, the illustrative ozone generator 12 includes an outer pipe fitting or end cap 86, an outer cylindrical cartridge 88, and one or more outer sealing rings 90 surrounding the cartridge 88. The pipe fitting 86 and the cartridge 88 may define a space therebetween for receiving a fluid pipe 89. More particularly, the pipe fitting 86 is internally threaded to mate with the externally threaded fluid pipe 89. The sealing rings 90, illustratively elastomeric o-rings, promote a sealed connection between the pipe fitting 86, the cartridge 88, and the fluid pipe 89.

[0029] As shown in FIGS. 4-9, the ozone generator 12 further includes an electrolytic cell assembly 14 located inside the cartridge 88. The illustrative electrolytic cell assembly 14 includes a first housing or carrier 92a and a second housing or carrier 92b, a first current spreader 94a and a second current spreader 94b, a first frame 99a and a second frame 96a, a first electrode 98a and a second electrode 98b, and an electrolytic separator 100.

[0030] The first and second housings 92a, 92b of the electrolytic cell assembly 14 are compressed together with the other components of the electrolytic cell assembly 14 being mechanically and electrically sandwiched therebetween. One or more sealing rings 102, illustratively elastomeric o-rings, are positioned around the housings 92a, 92b to hold the housings 92a, 92b together. According to an exemplary embodiment of the present disclosure, the housings 92a, 92b are held together by the sealing rings 102 independently of the outer cartridge 88 to facilitate storage and assembly of the electrolytic cell assembly 14, with or without cartridge 88 in place. It is also within the scope of the present disclosure that the first and second housings 92a, 92b may be clamped, fastened, or otherwise held together. The illustrative housings 92a, 92b are constructed of an electrically insulating material, such as a polymer. An exemplary polymer is the Udel® P-1700 polysulfone material available from Solvay Plastics.

[0031] The first and second current spreaders 94a, 94b of the electrolytic cell assembly 14 mate with the first and second housings 92a, 92b, respectively. According to an exemplary embodiment of the present disclosure, the first and second housings 92a, 92b are overmolded onto the first and second current spreaders 94a, 94b, respectively, to form integral, pre-assembled, water-tight, hermetically-sealed components without the need foradditional seals (e.g., epoxy). The current spreaders 94a, 94b are constructed of an electrically conductive material, such as titanium or another suitable material.

[0032] With further reference to FIGS. 8 and 9, the first current spreader 94a includes a first terminal 104a that extends out of the first housing 92a in a sealed manner for electrical communication with a first wire lead 106a. The first terminal 104a illustratively supports a contact 108a configured to be crimped onto the first wire lead 106a. Likewise, the second current spreader 94b includes a second terminal 104b that extends out of the second housing 92a in a sealed manner for electrical communication with a second wire lead 106b. The second terminal 104b illustratively supports a contact 108b which is configured to be crimped onto the second wire lead 106b. Sealing o-rings 110a, 110b may be supported by the terminals 104a, 104b, respectively.

[0033] The first and second frames 96a, 96b of the electrolytic cell assembly 14 mate with the first and second housings 92a, 92b, respectively. The frames 96a, 96b are constructed of an electrically insulating material, such as a polymer. An exemplary polymer is the Udel® P-1700 polysulfone material available from Solvay Plastics. As shown in FIG. 8, the first frame 96a includes a first scalloped opening 112a that is sized and shaped to receive the first electrode 98a in electrical communication with the first current spreader 94a. Likewise, the second frame 96b includes a second scalloped opening 112b that is sized and shaped to receive the second electrode 98b in electrical communication with the second current spreader 94b. The first and second frames 96a, 96b may cooperate with the first and second overmolded housings 92a, 92b to otherwise shield or insulate the first and second current spreaders 94a, 94b, respectively, to prevent electrical contact between the first and second current spreaders 94a, 94b.

[0034] The first and second electrodes 98a, 98b of the electrolytic cell assembly 14 are received within the first and second frames 94a, 94b, respectively. Each electrode 98a, 98b may have a back side that interacts with the adjacent current spreader 96a, 96b, respectively, and a front side that interacts with the separator 100. An exemplary electrode 98a, 98b is constructed of boron-doped silicon or another suitable material. The boron doped silicon material serves as a conductor to pass current between the current spreader and boron doped, The depoed silicon material may be about 200-800 microns thick, such as about 500 microns thick. The front side of each electrode 98a, 98b may have a boron-doped diamond coating or another suitable coating. The coating may be about 2-10 microns thick. The coating may be applied to the underlying silicon material by chemical vapor deposition(CVD) or another suitable deposition technique. The illustrative electrodes 98a, 98b are generally rectangular in shape, having a width of about 8 millimeters and a length of about 10 millimeters, although the size and shape of the electrodes 98a, 98b may vary.

[0035] The electrodes 98a, 98b communicate with the water flowing through the electrolytic cell assembly 14. Each electrode 98a, 98b may include a plurality of water passageways 114 (e.g., slots) to increase the exposed surface area of each electrode 98a, 98b for communication with water and to allow water flow through each electrode 98a, 98b. To allow for precise control of their size and shape, the water passageways 114 may be formed using deep reactive ion etching (DR1E) or another suitable technique.

[0036] Additional details of illustrative electrodes 98a, 98b are provided in U.S. Patent No. 10,767,270 to Jonte et al., the disclosure of which is expressly incorporated herein by reference.

[0037] Illustratively, the separator 100 of the electrolytic cell assembly 120 is positioned between the first and second electrodes 98a, 98b. The illustrative separator 100 is an ion or proton exchange membrane (PEM) designed to conduct protons between the electrodes 98a, 98b. The separator 100 may be constructed of a solid polymer electrolyte (SPE) membrane. An exemplary SPE membrane is a polytetrafluoroethylene (PTFE) / perfluorosulfonic acid (PFSA) copolymer membrane, which is commercially available from DuPont™ as a Nafion® membrane. Because pressures on the separator 100 are balanced, the separator 100 may be a thin, cast film. The thin separator 100 may allow for some cross-diffusion of water, hydrogen, and / or oxygen without negatively impacting the performance of the electrolytic cell assembly 14. In fact, such diffusion may promote efficiency and output by reducing polarization voltage associated with dehydration and reducing bulk ion resistance. An exemplary separator 100 may be about 20-30 microns thick, such as about 25 microns thick.

[0038] In the operating mode of the ozone generator 12, external threads 116 of the fluid pipe 89 of the solenoid valve body 16 cooperate with the internally threaded pipe fitting 86 of the ozone generator 12 (FIG. 3). Sealing rings 90 promote a sealed connection between the pipe fitting or end cap 86, the cartridge 88, and the solenoid valve body 16.

[0039] In the illustrative embodiment, a hydration reservoir 120 at least partially receives the electrolytic cell assembly 14 for holding a hydration fluid 121 (such as distilled water) to hydrate the separator 100 when the ozone generator 12 is in a storage mode. More particularly, the reservoir 120 illustratively includes a cup 122 having a distal end wall 124and a cylindrical side wall 126 defining a chamber 127 receiving the hydration fluid 121. The side wall 126 illustratively includes external threads 128 cooperating with the internal threads 130 of the end cap 86 for operably coupling the cup 122 to the electrolytic cell assembly 14. A tool engagement section, such as a plurality of flats 132, may be formed on the distal end of the cup 122 to facilitate insertion and removal of the cup 122 to the electrolytic cell assembly 14. The cup 122 may be formed as a single component (e.g., a molded polymer).

[0040] In preparing for storage and / or transport of the ozone generator 12, the cup 122 of the reservoir 120 may be filled with a liquid (such as distilled water) and then threaded onto the end cap 86. Water stored in the cup 122 keeps the perfluorosulfonic acid (PFSA) membrane or layer of the separator 100 hydrated.

[0041] When ready for use, the cup 122 of the reservoir 120 is unthreaded from the end cap 86. The electrolytic cell assembly 14 is then inserted into the receiving chamber 18 and secured to the fluid pipe 89 via the end cap 86. The ozone generator 12 is now in the operating mode with a hydrated separator 100.

[0042] There is a known “run-in” period for the ozone generator 12. If the separator 100 is dry when the ozone generator 12 is initially operated, the perfluorosulfonic acid (PFSA) membrane can be damaged. If the ozone generator 12 is hydrated by water upon start-up, then the “run-in” period is more predictable. The hydration reservoir 120 of the present disclosure facilitates such hydration of the electrolytic cell assembly 14 and, more particularly, the separator 100.

[0043] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims.

Claims

WHAT IS CLAIMED IS:

1. An ozone generator comprising: an electrolytic cell assembly including: a first current spreader; a first electrode; a second current spreader; a second electrode; and a separator positioned between the first electrode and the second electrode; and a reservoir for receiving hydration fluid in fluid communication with the separator.

2. The ozone generator of claim 1, wherein the separator includes a proton exchange membrane (PEM).

3. The ozone generator of claim 2, wherein the separator includes a perfluorosulfonic acid (PFSA) membrane.

4. The ozone generator of claim 1, further comprising: a first housing operably coupled to the first current spreader; and a second housing operably coupled to the second current spreader.

5. The ozone generator of claim 4, wherein: the first current spreader includes a body and a terminal having electrical connection to a first wire lead; and the second current spreader includes a body and a terminal having an electrical connection to a second wire lead.

6. The ozone generator of claim 5, wherein: the body of the first current spreader including and opening; and the body of the second current spreader includes an opening.

7. The ozone generator of claim 1, where the reservoir includes a cup having a cylindrical sidewall and an end wall.

8. The ozone generator of claim 7, wherein the sidewall includes external threads.

9. The ozone generator of claim 8, further comprising an end cap including internal threads cooperating with the external threads of the sidewall of the cup.

10. The ozone generator of claim 7, further comprising an outer cylindrical cartridge receiving the electrolytic cell assembly, the outer cylindrical cartridge at least partially received within the cup.

11. An ozone generator comprising: an electrolytic cell assembly; an outer cylindrical cartridge receiving the electrolytic cell assembly; and a reservoir cup at least partially receiving the outer cylindrical cartridge.

12. The ozone generator of claim 11 , wherein: the electrolytic cell assembly includes a first electrode, a second electrode, and a separator positioned between the first electrode and the second electrode; and the reservoir cup receives a hydration fluid to hydrate the separator.

13. The ozone generator of claim 12, wherein the electrolytic cell assembly further includes a first current spreader operably coupled to the first electrode, and a second current spreader operably coupled to the second electrode.

14. The ozone generator of claim 13, further comprising: a first housing operably coupled to the first current spreader; and a second housing operably coupled to the second current spreader.

15. The ozone generator of claim 14, wherein: the first current spreader includes a body and a terminal having electrical connection to a first wire lead; and the second current spreader includes a body and a terminal having an electrical connection to a second wire lead.

16. The ozone generator of claim 12, wherein the separator includes a proton exchange membrane (PEM).

17. The ozone generator of claim 16, wherein the separator includes a perfluorosulfonic acid (PFSA) membrane.

18. The ozone generator of claim 11 , where the reservoir includes a cup having a cylindrical sidewall and an end wall.

19. The ozone generator of claim 18, wherein the sidewall includes external threads.

20. The ozone generator of claim 19, further comprising an end cap including internal threads cooperating with the external threads of the sidewall of the cup.

21. A method of storing an ozone generator, the method including the steps of: providing an electrolytic cell assembly including a first electrode, a second electrode, and a separator positioned between the first electrode and the second electrode: providing a reservoir defining a chamber; placing hydration fluid within the chamber of the reservoir; inserting the electrolytic cell assembly within the chamber of the reservoir wherein the separator is in contact with the hydration fluid; and securing an end cap to the reservoir.

22. The method of claim 21 , wherein the reservoir includes a cup having a cylindrical sidewall and an end wall.

23. The method of claim 22, wherein the sidewall of the cup includes external threads, and the end cap includes internal threads cooperating with the external threads of the sidewall of the cup.

24. The method of claim 21, further comprising the steps of removing the end cap from the reservoir; removing the electrolytic cell assembly from the chamber of the reservoir; and inserting the electrolytic cell assembly within a fluid pipe fluidly coupled to a faucet.

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