Microprocessor-Controlled Electrolysis for Stable HOCl Solutions
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Solution Overview
Problem
Existing electrochemical systems for generating disinfective aqueous solutions are unreliable and produce solutions of limited stability, with insufficient concentrations of HOCl to be effective as sporicides, and lack consistent output quality.
Innovation Solution
A microprocessor-controlled electrolysis system that maintains a constant current and adjusts voltage, brine concentration, and flow rate to produce nearly neutral solutions with HOCl concentrations exceeding 100 ppm, using a digitally controlled power supply and pH/ORP probes to ensure consistent antimicrobial solution production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional electrolysis systems are used to generate disinfective aqueous solutions, then the systems are simple in design, but the solutions produced have limited stability and insufficient HOCl concentration to be effective as sporicides
Solution Approach 1:
The patent applies parameter changes by precisely controlling electrolysis conditions including current density, temperature, pH, and salt concentration to optimize HOCl production. The system maintains specific parameters (pH 6.5-7.5, temperature 20-40°C, current density 10-100 mA/cm²) to achieve both high HOCl concentration (>100 ppm) and solution stability, resolving the contradiction between quantity and reliability
Solution Approach 2:
The patent implements feedback control through continuous monitoring of HOCl concentration, pH, and temperature using sensors and probes. The system automatically adjusts electrolysis parameters based on real-time measurements to maintain optimal HOCl levels and stability, ensuring reliable sporicide effectiveness while preventing degradation
2Manufacturing precision
If conventional electrolysis systems are used, then the device complexity is low, but the output quality is inconsistent and lacks sufficient quality control
Solution Approach 1:
The patent employs feedback control systems with pH probes, ORP probes, and flow meters that continuously monitor effluent quality and automatically adjust electrolysis parameters. This ensures consistent output quality meeting specification limits while managing system complexity through automated control
Solution Approach 2:
The patent replaces manual monitoring and adjustment mechanisms with electronic sensors and automated control systems. Digital pH meters, ORP probes, and microprocessor-controlled power supplies substitute for conventional mechanical调节 devices, achieving precise quality control while maintaining manageable device complexity
3Stability of the object's composition
If conventional electrolysis systems are used to produce near neutral aqueous solutions, then the pH is acceptable, but the solutions have limited stability and insufficient HOCl concentration for sporicide applications
Solution Approach 1:
The patent optimizes parameter combinations including maintaining pH 6.5-7.5 (near neutral), controlling temperature at 20-40°C, adjusting current density to 10-100 mA/cm², and controlling salt concentration at 1-5% to simultaneously achieve solution stability and HOCl concentration exceeding 100 ppm for effective sporicide activity
Solution Approach 2:
The patent uses composite electrode structures with specific materials (dimensionally stable anodes coated with mixed metal oxides, porous cathodes) that enhance both solution stability and HOCl generation efficiency, allowing near neutral pH maintenance while achieving high sporicide concentrations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves stable and high-concentration HOCl solutions with extended shelf-life, capable of maintaining desired pH and conductivity, providing a reliable and effective antimicrobial agent for industrial applications.
Implementation Method 1
microprocessor controlled electrolysis of a brine solution
Implementation Method 2
oxidation/reduction potential (ORP) and pH probes situated in the effluent stream
Implementation Method 3
The anode is manufactured using a process to apply a coating on the anode
Data Source
AI summary
A system to prepare an antimicrobial solution by the electrolysis of brine is presented where the antimicrobial solution is a solution comprising HOCl that contains a HOCl concentration of 100 ppm or more at a pH of approximately 6.5. The system includes an electrolysis cell that is provided with a constant current by a digital DC power supply controlled by a microprocessor and a controlled brine concentration at a controlled rate, which can also be controlled by the microprocessor to deliver a fluid that is continuously observed by a pH probe and an ORP probe that provides input to the microprocessor to adjust voltage, pump rate and/or flow rate in a programmed manner by the microprocessor. A method to produce the antimicrobial solution, including a sporicidal solution, by the novel system is presented.