Modular Ion Generator Assembly for Fast HVAC Length Customization
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Solution Overview
Problem
Historically, ionization bars have been custom manufactured for specific applications, leading to long lead times in manufacturing and inefficiencies in treating and delivering air in HVAC systems.
Innovation Solution
A modular ion generator device with standard sizes that can be connected in various lengths, featuring a housing with a cavity, electrodes, and engagement devices for securing multiple units together, including magnets for mounting on cooling coil frames, and printed circuit boards for ion emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ionization bars are custom manufactured for specific application lengths, then the device can be precisely tailored to the application requirements, but the manufacturing lead time increases
Solution Approach 1:
The ionization bar is divided into multiple modular segments that can be connected in series to achieve the required length. Each segment contains its own housing, electrodes, and engagement features, allowing standardization of individual units while providing flexibility through combination. This segmentation enables off-the-shelf manufacturing of standard segments, eliminating custom manufacturing lead times.
Solution Approach 2:
The modular segments are designed with universal engagement devices and standardized interfaces that allow any segment to be connected with any other segment. The engagement devices include complementary features (protrusions and receptacles) that create a universal connection system, enabling the same standard components to serve multiple application lengths and configurations.
2Loss of time
If modular ion generator devices are connected in series to achieve required length, then manufacturing lead time is reduced, but the device complexity increases
Solution Approach 1:
Multiple functional elements are merged into each modular segment, including the housing, electrodes, engagement devices, and mounting features. This integration ensures that each standalone segment is a complete functional unit, reducing the need for additional connection components and simplifying the overall assembly process despite the modular architecture.
3Ease of operation
If engagement devices are added to connect modular devices, then the ease of assembly is improved, but the device complexity increases
Solution Approach 1:
The engagement devices use an inverted design where the connection features protrude from each segment rather than requiring separate fastening components. Each segment has engagement devices that actively seek to mate with complementary features on adjacent segments, making the assembly process intuitive and self-aligning, thereby improving ease of assembly while keeping the structural addition minimal.
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
This solution provides a flexible and efficient air treatment system by allowing modular ion generator devices to be easily secured and mounted, reducing manufacturing lead times and enhancing air treatment capabilities in HVAC systems.
Implementation Method 1
a magnet positioned on the device for selectively securing the device to a cooling coil frame
Implementation Method 2
At least one electrode is positioned within the cavity... an ion generator device
Data Source
AI summary
A modular ion generator device that includes a bottom portion, two opposed side portions, a front end, a back end, and a top portion. A cavity is formed within the two opposed side portions, front end, back end, and top portion. At least one electrode is positioned within the cavity, and an engagement device is engaged to the front end and/or an engagement device engaged to the back end for allowing one or more modular ion generator devices to be selectively secured to one another.