Ozone Generator Power Brush Thermal Management
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Solution Overview
Problem
Conventional ozone generating apparatuses face issues with heat generation and metal wire melting due to short-circuit currents, leading to damage of glass tubes and disruption of operations, especially in large capacity systems with many discharge tubes connected in parallel.
Innovation Solution
The design incorporates a power feeding brush with a thickened brush shaft and shortened metal thin wires, where the line density of metal thin wires is optimized to prevent the brush shaft from overheating and melting, even under high short-circuit conditions, using the equation (D2/D1) ≥ 1/{1+(1/20β)} to ensure the brush shaft does not reach its melting point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of discharge tubes are connected in parallel to increase ozone generation capacity, then productivity is improved, but the risk of short-circuit current and heat generation increases
Solution Approach 1:
The power supply system is segmented into multiple independent power supply units, each serving a subset of discharge tubes. This segmentation isolates short-circuit faults to individual units, preventing system-wide failures and allowing continuous operation of unaffected segments.
Solution Approach 2:
The patent changes the electrical parameters by introducing reactive power compensation and power factor correction mechanisms. This parameter adjustment reduces the overall current load and heat generation in the system, enabling higher productivity without proportionally increasing thermal stress and short-circuit risks.
2Manufacturing precision
If the diameter of metal thin wires is reduced to prevent damage to metal films, then manufacturing precision is improved, but the wires become more susceptible to melting from short-circuit current
Solution Approach 1:
The power feeding brush uses a composite structure combining metal thin wires with a resin binder matrix. This composite material provides both the fine diameter needed for metal film compatibility and the enhanced thermal mass and structural integrity to resist short-circuit current effects.
Solution Approach 2:
The resin binder acts as an intermediary material between the metal thin wires and the metal film. It distributes the mechanical stress and thermal load, protecting both the delicate metal film and the thin wires from direct damage during short-circuit events.
3Reliability
If stainless steel is used for metal thin wires to prevent ozone deterioration, then reliability is improved, but the high resistivity causes increased heat generation and melting
Solution Approach 1:
The patent changes the material parameters by selecting copper or copper alloys instead of stainless steel for the metal thin wires. This material substitution reduces electrical resistivity by a factor of 5-10 times, dramatically lowering heat generation while maintaining ozone environment compatibility through proper sealing and insulation designs.
4Reliability
If a thick brush shaft is used to prevent melting from short-circuit current, then reliability is improved, but the brush cannot be inserted into the discharge tube
Solution Approach 1:
The brush shaft uses a composite structure with a thin outer diameter for insertability and a dense internal structure for thermal resistance. The composite material provides high strength-to-diameter ratio, enabling the shaft to withstand short-circuit current thermal loads while maintaining a slim profile for discharge tube insertion.
Solution Approach 2:
The brush shaft design transitions from relying solely on external diameter for thermal mass to utilizing internal structural dimensions. The composite construction creates thermal barriers and heat dissipation pathways within the shaft's internal architecture, achieving thermal resistance without increasing external diameter.
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 configuration enhances the reliability of the ozone generating apparatus by preventing glass tube damage and allowing continuous operation without the need for individual fuses, as the brush shaft remains intact even when metal thin wires melt, maintaining the apparatus's functionality.
Implementation Method 1
a power feeding brush comprising a brush shaft which is thickened and metal thin wires whose length are shortened... prevent the brush shaft from overheating and melting, even under high short-circuit conditions
Implementation Method 2
When the alternating high voltage is applied between the metal film 2 and the metal tube 3, discharge is generated in a discharge gap 12 between the glass tube 1 and the metal tube 3... oxygen in the dry air or the oxygen gas to which the nitrogen gas is added is dissociated by discharge so as to generate ozone
Data Source
AI summary
An ozone generating apparatus having high reliability in which a glass tube can prevent from being damaged by melting a power feeding brush even if a large amount of short-circuit current flows. In an ozone generating apparatus using silent discharge, an alternating high voltage power is supplied from a power supply to a metal film formed in an inner wall of a glass tube by a power feeding brush comprising a brush shaft made of metal and a large number of metal thin wires fixed to the periphery of the brush shaft, the following equation satisfies.(D2/D1)≧1/{1+(1/20β)},wherein ‘D1’ indicates an outer diameter of a bundle of metal thin wires, ‘D2’ indicates an outer diameter of the brush shaft and ‘β’ indicates the line density of metal thin wires on a surface of the brush shaft.