Modular Ion Generator Assembly for Custom-Length HVAC Bars
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Solution Overview
Problem
Historically, ionization bars have been custom manufactured for specific applications, leading to long manufacturing lead times, which is addressed by providing a standard size off-the-shelf modular ion generator device that can be connected in any quantity to meet the required length for a given application.
Innovation Solution
A modular ion generator device with a standardized design featuring a bottom, side, front, and back portion with cavities, electrodes, and engagement devices that allow multiple units to be securely connected, including a magnet for mounting on a cooling coil frame, and electrodes made of carbon fiber or stainless steel for efficient ion generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If custom manufactured ionization bars are used for specific applications, then the ion generator can be precisely tailored to application requirements, but manufacturing lead time increases significantly
Solution Approach 1:
The ion generator is divided into modular segments that can be connected in series to achieve the required total length. Each module contains standardized components (electrodes, housing, engagement devices) that can be mass-produced independently, then assembled to create custom-length generators without custom manufacturing, thus reducing lead time while maintaining application adaptability.
Solution Approach 2:
The patent creates universal mounting interfaces and engagement devices that work across all module variants. Standardized receptacles, magnets, and connection mechanisms allow any module to be integrated with any other, enabling a single platform to serve multiple application-specific configurations without requiring custom manufacturing for each application.
2Loss of time
If standard size off-the-shelf modular bars are used, then manufacturing lead time is reduced, but flexibility in configuring specific applications may be limited
Solution Approach 1:
By segmenting the ion generator into standardized modules with uniform engagement interfaces, the system allows flexible configuration through simple assembly of pre-manufactured components. This enables rapid deployment (reducing lead time) while maintaining the ability to adapt to different applications by varying the number and arrangement of modules.
Solution Approach 2:
The modular design with engagement devices creates a dynamic system where the generator configuration can be easily adjusted by adding or removing modules. The standardized interfaces enable reconfigurability without custom manufacturing, allowing the same standard modules to adapt to different application requirements through dynamic assembly changes.
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 modular design reduces manufacturing lead times and allows for flexible configuration of ion generator devices, enabling efficient ionization of air in HVAC systems, effectively treating air for improved quality and reducing the need for custom manufacturing.
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
The present invention provides methods and systems for 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.