Electrolysis apparatus, system, and method for producing chlorine bleach

An electrolysis apparatus for producing chlorine bleach includes an anode plate, a cathode plate spaced apart from the anode plate, one or more inner conductive plates positioned between and spaced apart from the anode plate and the cathode plate, and a sleeve surrounding the anode plate, the cathode plate, and the one or more inner conductive plates. A system for producing chlorine bleach includes, in addition to the electrolysis apparatus, a container having an opening and which is configured to hold a solution of water and salt. The system further includes a power source having a first terminal connected to the anode plate and a second terminal connected to the cathode plate. Upon connecting the anode plate and the cathode plate to the power source and inserting the electrolysis apparatus into the solution, electrolysis of the solution produces chlorine bleach.

BACKGROUND OF THE INVENTION

The present invention pertains to an electrolysis apparatus, system, and method for producing chlorine bleach.

In many parts of the world, particularly in developing countries that lack basic resources, such as clean drinking water and reliable electricity, sanitation is often difficult. Chlorine bleach (aqueous sodium hypochlorite), which can be used to kill pathogens in water and to clean clothes and other goods, is often expensive to transport to remote locations because of its weight, which is primarily water weight. Even concentrated bleach is largely water but poses additional dangers due to its high concentration of chemicals. For example, one gallon of bleach of any concentration can weigh eight pounds or more, including packaging. Because it is utilized for so many purposes, a remote location may need hundreds of gallons on hand, which can be costly to transport.

SUMMARY OF THE INVENTION

The present invention is an electrolysis apparatus, system, and method for producing chlorine bleach.

An electrolysis apparatus made in accordance with the present invention includes an anode plate, a cathode plate spaced apart from the anode plate, one or more inner conductive plates positioned between and spaced apart from the anode plate and the cathode plate, and a sleeve surrounding the anode plate, the cathode plate, and the one or more inner conductive plates. The anode plate and the cathode plate are connected to the terminals of a power source, such as a 12-V car battery, by respective wires.

In some embodiments, the anode plate, the cathode plate, and the one or more inner conductive plates are substantially parallel to one another and are substantially the same size.

In some embodiments, there are two inner conductive plates which are equally spaced between the anode plate and the cathode plate. In one exemplary embodiment, the two inner conductive plates are equally spaced about 0.3125 inches between the anode plate and the cathode plate, such that anode plate and the cathode plate are spaced about 0.9375 inches apart. The inner conductive plates are not connected to power source, nor connected directly to the anode plate or the cathode plate. Rather, one or more combs are attached to at least one of the anode plate, the cathode plate, and the one or more inner conductive plates, and the one or more combs maintain spacing between the anode plate, the cathode plate, and the one or more inner conductive plates.

In some embodiments, the inner conductive plates include notches on each side, and the combs are positioned in the aligned notches on either side of the inner conductive plates, such that, when assembled, the top of each of the combs is positioned below the lower surface of anode plate, and the bottom of each of the combs is positioned above the upper surface of the cathode.

In some embodiments, each of the combs defines two slots, which allow the combs to engage the edges of the respective inner conductive plates. Specifically, when assembled, a portion of the first inner conductive plate is inserted into a slot of each comb, and a portion of the second inner conductive plate is inserted into another slot of each comb. The combs thus prevent the anode plate, the cathode plate, and the inner conductive plates from coming into contact with one another.

In some embodiments, the electrolysis apparatus further includes one or more posts extending through holes defined in the anode plate, the cathode plate, and the one or more inner conductive plates. Such posts improve structural stability and hold the components together.

As mentioned above, the anode plate, the cathode plate, and the inner conductive plates are surrounded by a sleeve. The sleeve is comprised of a non-reactive material that is both non-conductive and corrosion-resistant, such as high-density polyethylene (HDPE) or a similar thermoplastic. In operation, the sleeve is subjected to both an electric current, as well as corrosive liquid, i.e., water that includes both bleach and salt. Thus, the sleeve is constructed of a material that is durable in harsh conditions. Furthermore, the sleeve includes a plurality of openings that allow liquid to enter and circulate through the sleeve.

An exemplary system for producing chlorine bleach made in accordance with the present invention further includes a jerry can or similar container having an opening and configured to hold a solution of water and salt (i.e., a saline solution). The system further includes a power source, such as a 12-V car battery.

The sleeve of the exemplary electrolysis apparatus is sized to fit into the opening of the jerry can or similar container. To this end, in some embodiments of the present invention, a collar is assembled around the electrolysis apparatus and is screwed onto the jerry can to secure the electrolysis apparatus in position.

In an exemplary method for producing chlorine bleach in accordance with the present invention, in a first step, a jerry can or other similar container is filled with a solution of water and salt (i.e., a saline solution). In particular, the jerry can is filled with a predetermined volume of water and a predetermined amount of salt, which are then mixed within the jerry can to produce a saline solution. In one particular implementation, about five liters of water are mixed with about 350 milliliters of salt.

After filling the jerry can with the saline solution, in a second step, the electrolysis apparatus is inserted into opening of the jerry can until the sleeve is at least partially submerged in the solution.

Next, the electrolysis apparatus is connected to the power source (such as a 12-V car battery). In particular, a first wire is used to connect the anode plate to the first (positive) terminal of the power source, and a second wire is used to connect the cathode plate to the second (negative) terminal of the power source. Once the electrolysis apparatus is connected to the battery, over time, the saline solution is converted into chlorine bleach.

DETAILED DESCRIPTION OF THE INVENTION

An electrolysis apparatus for producing chlorine bleach made in accordance with the present invention produces a chlorine bleach (aqueous sodium hypochlorite) concentrate that meets the World Health Organization's (WHO) standard for disinfection in a medical setting. Chlorine bleach is the WHO's recommended disinfectant to stop the spread of many infectious diseases, including Ebola. Furthermore, chlorine bleach is the most commonly used disinfectant in the world, making it ideal because it is both effective and versatile. The chlorine bleach that is produced with the electrolysis apparatus of the present invention may be utilized to disinfect household items, such as clothing and cooking utensils, as well as surfaces for food preparation, medical purposes, and other surfaces. Potable (or drinking) water can also be dosed with small amounts of the chlorine bleach to kill parasites and bacteria in the water, allowing for clean potable (or drinking) water in remote locations.

Furthermore, the electrolysis apparatus of the present invention is easily portable, safe, and effective for use in remote locations and relies on the use of only a few commonly available resources. Specifically, in at least one exemplary implementation, and as further described below, the electrolysis apparatus of the present invention allows for production of approximately one gallon of chlorine bleach in a short period of time (e.g., approximately an hour), utilizing available water, common table salt (sodium chloride), and a power source (e.g., a 12-V car battery). The water can be sourced locally, and thus does not need to be shipped long distances (as would be the case with shipping bleach). Salt may also be readily available, but if not, shipping salt is much cheaper than shipping a liquid due to its lower weight. Finally, 12-V car batteries are often used in remote locations as power sources and can be used with the electrolysis apparatus of the present invention. Indeed, such 12-V car batteries can be used while installed or temporarily removed from vehicles. Thus, the entire electrolysis apparatus is small enough to fit into a backpack and weighs less than five pounds (i.e., less than a gallon of bleach).

The electrolysis apparatus of the present invention utilizes electrolysis to make chlorine bleach, preferably at about 0.5 percent concentration, which is the recommended concentrate suggested by the WHO for medical applications. By producing bleach at a known concentration, the electrolysis apparatus allows producers to know exactly how much to dilute the product. This lessens the possibility of over-dilution or under-dilution of the bleach. A test kit is preferably used to verify the proper concentration.

Referring now toFIGS. 1, 2, and 6, an exemplary electrolysis apparatus10for producing chlorine bleach made in accordance with the present invention includes an anode plate15, a cathode plate20, and a sleeve60. In use, and as shown inFIG. 6, the anode plate15and the cathode plate20are connected to the terminals of a power source70(such as a 12-V car battery) by respective wires40,45. Specifically, as shown inFIG. 6, the anode plate15is connected to a first (positive) terminal72of the power source70by the first wire40, and the cathode plate20is connected to a second, or negative, terminal74of the power source70by the second wire45.

FIG. 3is a plan view of the anode plate15in this exemplary embodiment. As shown, the anode plate15is substantially rectangular with a narrower tongue15aat one end of the anode plate15. In this exemplary embodiment, the anode plate15is about 0.94 inches wide, and the tongue15ais about 0.58 inches wide. Furthermore, the anode plate15is about 9.5 inches long, with the tongue15abeing about 1.5 inches long, and the remainder of the anode plate15being about 8.0 inches long. As shown inFIGS. 1 and 2, the anode plate15is substantially flat, with a thickness of about 0.04 inches in this exemplary embodiment. Finally, in this exemplary embodiment, the anode plate15defines several holes16,17, the importance of which will be described below.

FIG. 4is a plan view of the cathode plate20in this exemplary embodiment. As shown, the cathode plate20is substantially rectangular with a narrower tongue20aat one end of the cathode plate20. In this exemplary embodiment, the cathode plate20is about 0.94 inches wide, and the tongue20ais about 0.58 inches wide. Furthermore, the cathode plate20is about 9.5 inches long, with the tongue20abeing about 1.5 inches long, and the remainder of the cathode plate20being about 8.0 inches long. As shown inFIGS. 1 and 2, the cathode plate20is substantially flat, with a thickness of about 0.04 inches in this exemplary embodiment. The cathode plate20further defines several holes21,22, the importance of which will be described below. In short, in this exemplary embodiment, the cathode plate20is identical to the anode plate15with respect to its shape and dimensions.

The anode plate15and cathode plate20are both comprised primarily of titanium. In some embodiments, the anode plate15further includes a mixed metal oxide (MMO) coating comprised of one or more of ruthenium, iridium, and titanium to promote bleach formation. In some embodiments, the cathode plate20is sand-blasted and acid washed, rather than including a mixed metal oxide (MMO) coating.

Referring again toFIGS. 1 and 2, the exemplary electrolysis apparatus10also includes first and second inner conductive plates25,30positioned between the anode plate15and the cathode plate20.

FIG. 5is a plan view of the first inner conductive plate25(which is identical to the second inner conductive plate30) in this exemplary embodiment. As shown, the first inner conductive plate25is substantially rectangular with a narrower tongue25aat one end of the first inner conductive plate25. In this exemplary embodiment, the first inner conductive plate25is about 1.0 inches wide, and the tongue25ais about 0.58 inches wide. Furthermore, the first inner conductive plate25is about 8.52 inches long, with the tongue25abeing about 0.52 inches long, and the remainder of the first inner conductive plate25being about 8.0 inches long. As shown inFIGS. 1 and 2, the first inner conductive plate25is substantially flat, with a thickness of about 0.04 inches in this exemplary embodiment. Finally, in this exemplary embodiment, the first inner conductive plate25defines several notches25balong the edges of the first inner conductive plate25, as well as several holes26, the importance of which will be described below.

As mentioned above, in this exemplary embodiment, the first and second inner conductive plates25,30are identical. In other words, the second inner conductive plate30is substantially rectangular with a narrower tongue30aat one end of the second inner conductive plate30. In this exemplary embodiment, the second inner conductive plate30is about 1.0 inches wide, and the tongue30ais about 0.58 inches wide. Furthermore, the second inner conductive plate30is about 8.52 inches long, with the tongue30abeing about 0.52 inches long, and the remainder of the second inner conductive plate30being about 8.0 inches long. As shown inFIGS. 1 and 2, the second inner conductive plate30is substantially flat, with a thickness of about 0.04 inches in this exemplary embodiment. Finally, in this exemplary embodiment, the second inner conductive plate30further defines several notches30balong the edges of the second inner conductive plate30, as well as several holes31, in the same manner as the first inner conductive plate25shown inFIG. 5, the importance of which will be described below.

The inner conductive plates25,30are comprised primarily of titanium. In some embodiments, one or both of the inner conductive plates25,30further includes a mixed metal oxide (MMO) coating comprised of one or more of ruthenium, iridium, and titanium to promote bleach formation.

Referring once again toFIGS. 1 and 2, the inner conductive plates25,30are not connected to the power source70, nor connected directly to the anode plate15or the cathode plate20. As best shown inFIG. 2, in this exemplary embodiment, the inner conductive plates25,30include notches25b,30bon each side, although only one side is visible inFIG. 2. Combs220are positioned in the aligned notches25b,30bon either side of the inner conductive plates25,30, such that, when assembled, the top of each of the combs220is positioned below the lower surface of anode plate15, and the bottom of each of the combs220is positioned above the upper surface of the cathode plate20. In other words, the combs220are positioned between the anode plate15and the cathode plate20.

Referring still toFIGS. 1 and 2, the combs220, however, are attached to the inner conductive plates25,30. In particular, in this exemplary embodiment, each of the combs220defines two slots221,222, which allow each comb220to engage the edges of the respective inner conductive plates25,30. Specifically, when assembled, a portion of the first inner conductive plate25on the inner edge of the notch25bis inserted into the slot221of each comb220, and a portion of the second inner conductive plate30on the inner edge of the notch30bis inserted into the slot222of each comb220. The combs220therefore prevent the anode plate15, the cathode plate20, and the inner conductive plates25,30from coming into contact with one another. In this exemplary embodiment, the combs220maintain the anode plate15, the cathode plate20, and the inner conductive plates25,30at substantially equal intervals of 0.3125 inches from one another. The combs220are comprised of a non-reactive and non-conducting material, such as high-density polyethylene (HDPE) or a similar thermoplastic. Of course, other configurations and compositions of the combs220are possible so long as the combs220maintain the spacing between the anode plate15, the cathode plate20, and the inner conductive plates25,30and prevent them from coming into contact with one another.

With respect to the use of the inner conductive plates25,30, is it believed that the chemical reaction that produces bleach is most effective at 3-4 V. By using the inner conductive plates25,30, the voltage supplied by the power source70(i.e., 12-V car battery) is effectively reduced from 12V to about 4V. Specifically, adding the first inner conductive plate25and the second inner conductive plate30between the anode plate15and the cathode plate20results in three spaces between the anode plate15and the cathode plate20. The configuration effectively divides the 12V from the power source70to about 4V, so that the electrolysis apparatus10is operating in the optimal range.

Furthermore, it should be recognized that each of the inner conductive plates25,30can be characterized as an anode on one side and a cathode on the other side. Specifically, the first inner conductive plate25that is closest to the anode plate15is a cathode on the side that faces the anode plate15, and is an anode on the side that faces the second inner conductive plate30. Similarly, the second inner conductive plate30that is closest to the cathode plate20is an anode on the side that faces the cathode plate20, and is a cathode on the side that faces the first inner conductive plate25.

Referring again toFIG. 2, in addition to the combs220, in this exemplary embodiment, the electrolysis apparatus10includes posts50,55, with each post passing through one of the holes17defined through the anode plate15, one of the holes26defined through the first inner conductive plate25, one of the holes31defined through the second inner conductive plates30, and one of the holes22defined through the cathode plate20. The posts50,55thus improve structural stability. The posts50,55are also comprised of a non-reactive and non-conducting material to prevent flow of current directly between the anode plate15and the cathode plate20, such as low-density polyethylene (LDPE) or a similar thermoplastic. Furthermore, the posts50,55preferably are mushroomed (or have an enlarged head) at each end in order to effectively hold the components together.

Referring again toFIGS. 1 and 2, the anode plate15, the cathode plate20, and the inner conductive plates25,30are surrounded by a sleeve60. The sleeve60is comprised of a non-reactive material that is both non-conductive and corrosion-resistant, such as high-density polyethylene (HDPE) or a similar thermoplastic. In operation, the sleeve60is subjected to both an electric current, as well as corrosive liquid, i.e., water that includes both bleach and salt. Thus, the sleeve60is constructed of a material that is durable in harsh conditions. Furthermore, the sleeve60includes a plurality of openings65that allow liquid to enter and circulate through the sleeve60. In this exemplary embodiment, the distal end60aof the sleeve60is also open to facilitate liquid flow to and around the anode plate15, the cathode plate20, and the inner conductive plates25,30when the electrolysis apparatus10is submerged, as further described below.

As shown inFIGS. 1 and 2, the sleeve60further defines upper and lower holes61,63to accommodate the post55. In particular, as shown inFIG. 1, the post55passes not only through the anode plate15, the cathode plate20, and the inner conductive plates25,30, but further passes through the upper and lower holes61,63defined through the sleeve60, effectively securing the anode plate15, the cathode plate20, and the inner conductive plates25,30within the sleeve60, while also providing additional support for the anode plate15, the cathode plate20, and the inner conductive plates25,30within the sleeve60.

Referring still toFIGS. 1 and 2, in this exemplary embodiment, an end plate35is provided near the proximal end60bof the sleeve60. The end plate35includes four slots35a-dthat allow for the tongue15aof the anode plate15, the tongue20aof the cathode plate20, and the respective tongues25a,30aof the inner conductive plates25,30to penetrate the end plate35. Upon insertion of the tongues15a,20a,25a,30a, through the end plate35, the remainder of the plates15,20,25,30extend into the sleeve60at substantially the same length of about 8.0 inches. Furthermore, and as best shown inFIG. 1, the tongue15aof the anode plate15and the tongue20aof the cathode plate20each extend further through the end plate35than the tongues25a,30aof the inner conductive plates25,30, thus facilitating connection to the power source70, as further described below.

In this exemplary embodiment, and referring still toFIG. 2, a screw200passes through the hole16defined through the anode plate15and is secured by a nut210. The first wire40is secured between the nut210and the lower surface of the anode plate15, and the nut210is tightened to secure the first wire40in place. Similarly, a screw205passes through the hole21defined through the cathode plate20and is secured by a nut215. The second wire45is secured between the nut215and the upper surface of the cathode plate20, and the nut215is tightened to secure the second wire45in place. Of course, this is just one example of how the wires40,45could be electrically connected to the anode plate15and the cathode plate20, and other configurations of components could be used to complete this electrical connection without departing from the spirit and scope of the present invention.

Referring now toFIG. 6, in some embodiments, the electrolysis apparatus10is part of a system that also includes (i) a jerry can80or similar container configured to store a predetermined volume of water and a predetermined amount of salt; and (ii) a power source70, such as a 12-V car battery.

As shown inFIG. 6, the jerry can80has an opening82, and the sleeve60of the electrolysis apparatus10is sized to fit into the opening82. Furthermore, in this exemplary embodiment, the electrolysis apparatus10is secured in the opening82through the use of a collar36. The collar36is assembled around the electrolysis apparatus10, engaging the end plate35along its periphery. The collar36also has internal threads (not shown) for mating with external threads84on the jerry can80, much in the same manner that a spout or lid is secured to a jerry can80. Thus, the collar36can be screwed onto the jerry can80to secure the electrolysis apparatus10in position.

Referring now toFIG. 7, in an exemplary method for producing chlorine bleach in accordance with the present invention, in a first step S101, a jerry can80or similar container is filled with a solution of water and salt. In particular, the jerry can80is filled with a predetermined volume of water and a predetermined amount of salt, which are then mixed within the jerry can80to produce a saline solution. In one particular implementation, about five liters of water are mixed with about 350 milliliters of salt.

After filling the jerry can80with the saline solution, in a second step S102, the electrolysis apparatus10is inserted into opening82of the jerry can80until the sleeve60is at least partially submerged in the solution. As described above, the collar36, which is assembled around the electrolysis apparatus10, engaging the end plate35along its periphery, can then be screwed onto the jerry can80to secure the electrolysis apparatus10in position.

Next, in a step S103, the electrolysis apparatus10is connected to the power source70. In particular, the first wire40is used to connect the anode plate15to the first (positive) terminal72of the power source70, and the second wire45is used to connect the cathode plate20to the second (negative) terminal74of the power source70. Once the electrolysis apparatus10is connected to the power source70, over time, the saline solution is converted into chlorine bleach. In particular, it is contemplated that, in the method of the present invention, after an extended period of time, the chlorine bleach stabilizes at about 0.5 percent concentration. In other words, chemical equilibrium is reached at this concentration, and additional time where the electrolysis apparatus10is connected to the power source70does not result in a higher concentration.

One of ordinary skill in the art will recognize that additional embodiments and implementations are possible without departing from the teachings of the present invention. This detailed description, and particularly the specific details of the exemplary embodiments and implementations disclosed therein, is given primarily for clarity of understanding, and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit or scope of the present invention.