Modular ion generator device
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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 not efficient for meeting the needs of HVAC systems that require flexible and adaptable air treatment solutions.
Innovation Solution
A modular ion generator device with a standard size and design that can be easily connected in various lengths, featuring a housing with a cavity for electrodes, engagement devices for securing multiple units together, and a magnet for mounting to a cooling coil frame, along with electrodes made of carbon fiber brushes, allowing for flexible and efficient air ionization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If ionization bars are custom manufactured for specific applications, then the system can be tailored to exact specifications, but manufacturing lead time increases significantly
Solution Approach 1:
The ionization bar is divided into multiple modular segments of standard lengths (e.g., 12 inches each). These segments can be connected end-to-end using engagement devices to create custom-length ionization bars for different applications. This segmentation allows standardization of production while maintaining customization capability, resolving the contradiction between adaptability and manufacturing lead time.
Solution Approach 2:
The modular segments are designed with universal engagement devices that allow them to be connected in various configurations for different applications. The same standard segment can serve multiple purposes by simply changing the number and arrangement of segments, eliminating the need for custom manufacturing while maintaining application-specific adaptability.
2Loss of time
If standard size modular bars are used, then manufacturing lead time is reduced, but flexibility in length customization is needed
Solution Approach 1:
The ionization system uses discrete modular segments that can be assembled in different quantities to achieve various total lengths. Standard segments are manufactured in advance, reducing lead time, while the segmentation enables flexible length customization through simple assembly of the required number of segments.
Solution Approach 2:
The system allows dynamic configuration of ionization bar length by adding or removing modular segments based on application requirements. The engagement devices enable quick assembly and disassembly, providing dynamic adaptability without requiring custom manufacturing for each length specification.
3Ease of operation
If modular design with engagement devices is implemented, then assembly flexibility is improved, but device complexity increases
Solution Approach 1:
The modular design divides the ionization bar into standardized segments with simplified engagement devices. While this creates multiple components, each component is simpler in design, and the overall assembly process becomes more flexible. The engagement devices use straightforward mechanical connections that reduce operational complexity despite increasing structural elements.
Solution Approach 2:
The engagement device integrates multiple functions into a single component: mechanical connection, electrical continuity, and alignment guidance. By merging these functions, the design reduces the number of separate parts needed, offsetting the complexity increase from modular segmentation while maintaining assembly flexibility.
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 customizable ion generator systems that can efficiently treat air by producing a high concentration of ions, improving indoor air quality and reducing the need for outside air recirculation, thereby lowering heating and cooling costs.
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... efficiently treat air by producing a high concentration of ions
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.