Electrolytic cell assembly

An electrolytic cell assembly for connection to a liquid flow line includes an electrode set, a cell housing supporting the electrode set, a cell retainer attached to the flow line and in fluid communication with the flow line, and a connection for detachably connecting the housing to the cell retainer in an operating position.

BACKGROUND OF THE DISCLOSURE

Electrolytic cells can be used to generate a halogen, such as bromine or chlorine, for providing sanitizing water treatment in a body of water. For example, electrolytic cells may be used to sanitize swimming pools, spas, or hot tubs. The electrolytic cell may include plates mounted in a recirculating flow path for the body of water. It may be desirable to periodically remove the cell for inspection, cleaning, repair or replacement.

DETAILED DESCRIPTION OF THE DISCLOSURE

In the following detailed description and in the several figures of the drawing, like elements are identified with like reference numerals.

FIG. 1illustrates an exemplary embodiment of a spa or pool system1. In an exemplary embodiment, a spa or pool system1may include a vessel2holding a body of water2A such as, for example, a pool, spa or hot tub. The spa or pool system1may also include a pump3for recirculating the water. In an exemplary embodiment, the pump3may draw water from the body of water2A through a filter4A and a secondary suction port4B into a recirculating water flow line4, and pump the water back into the body of water2A through a discharge side of the recirculating water flow line4. The filter may be located at various locations in the vessel2, and is diagrammatically shown inFIG. 1. In an exemplary embodiment, the recirculating water flow line may be piping, for example PVC piping. A heat exchanger or heater3A may be in the water flow line4.

In an exemplary embodiment, the spa system1may include an electrolytic cell assembly5. The electrolytic cell assembly5may include an electrolytic cell housing or electrode plate support6supporting electrode plate set21, and a connection port or cell retainer7for detachably connecting the housing6to an opening in the flow line4. The cell retainer7may include an opening fluidically connected to the flow path8through the flow line4. In an exemplary embodiment, the cell retainer7may be attached to a tee44which is connected in the flow line4. The electrode plate set21may extend through the cell retainer7and into the flow path8within the flow line4. Operation of the electrolytic cell assembly5, in an appropriate aqueous solution, may cause the generation of halogens, for example chlorine or bromine, thereby provide sanitizing water treatment for water moving along the flow path8through the flow line4. In an exemplary embodiment, the electrolytic cell assembly may be located on the flow line4on the discharge side of the pump3. In another embodiment, the electrolytic cell assembly may be located on the flow line4on the intake side of the pump.

In an exemplary embodiment, the housing6holds the electrode plate set21in a fixed, desired orientation with respect to the flow path8in an operating position. In an exemplary embodiment, the electrode plate set21may be arranged in parallel planes which may be parallel with the direction of the flow path8to mitigate resistance to water flow through the electrolytic cell assembly5.

In an exemplary embodiment, the housing6and electrode plate set21may be detachably connected to the cell retainer7by an indexed connection13arranged to hold the housing6and electrode plate set21in place in the operating position, with the housing6in a desired, fixed orientation to hold the electrode plate set21parallel to the flow path and at a desired fixed insertion distance within the flow line4. The indexed connection13may include latching pin entrance slot22, latching pin landing23and latching pin25(FIGS. 2 and 3) arranged on one or the other of the cell retainer7and/or the housing6. In an exemplary embodiment, the entrance slot22, landing slot23and latching pin25(FIGS. 2 and 3) operate together to hold the housing6in place on the cell retainer7with the electrode plate set21in the desired, fixed orientation with respect to the flow path8.

In an exemplary embodiment, detachably connecting an electrolytic cell housing6on a cell retainer7may provide for convenient maintenance and/or replacement of the electrolytic cell by avoiding the necessity of removing an entire segment of flow line4. In an exemplary embodiment, using an indexed connection13may provide a convenient method of fixing the electrode plate set21in an operating position with a desired orientation in the flow path8.

Referring again toFIG. 1, in an exemplary embodiment, the spa or pool system1includes a control system10, which receives electrical power from an external voltage source9, typically a line voltage at 120 VAC or 240 VAC. The control system10provides auxiliary power lines11to supply power at the appropriate voltage and current levels to operate and control various components of the spa or pool system1, including for example the pump3. Other typical components may include a water heater3A and a light system. In an exemplary embodiment, the control system10includes an electrolytic cell drive circuit19which provides electrical power to drive the electrolytic cell5through lines18. The control system10may include a microprocessor-based controller12which provides control signals and power to the electrolytic cell drive circuit19. Alternatively, the drive circuit19may be a stand alone circuit which may interact with control system10.

FIG. 1Aillustrates an alternate exemplary embodiment of a spa or pool system100. In an exemplary embodiment, the electrolytic cell assembly5is connected in a separate recirculating water path or circuit400. A pump300may be controlled by the control system10to recirculate water through the water path400and the cell5to provide a desired halogen content in the spa or pool. This permits independent control over a function provided by the cell5, e.g. a sanitizing function, without requiring the heating and/or water recirculation functions provided by pump3be activated. The control system10may include a microprocessor-based controller12which provides control signals and power to the electrolytic cell drive circuit19. Alternatively, the drive circuit may be a stand alone circuit which may interact with control system10.

FIG. 2illustrates an exploded view of an exemplary embodiment of an electrolytic cell assembly5. In an exemplary embodiment, an electrolytic cell assembly5may include a cell housing6, electrode plate set21and a cell retainer7connected to the recirculating water flow line4by attachment to a tee44connected in the flow line4. In an exemplary embodiment, the housing6may be detachably connectable to the cell retainer7by an indexed connection13.

In an exemplary embodiment, the cell retainer7may be formed as a separate unit such as a collar or fitting to be attached to tee44. The tee44receives the cell retainer7, which may be an adapter unit having an inner diameter sized to be received over the transverse portion44A of the tee44in a close-fit sliding relationship. For example, the tee44may be fabricated of PVC, ABS, plastic, a high temperature plastic, or other suitable material. In an exemplary embodiment, the tee44may be a standard 2″ schedule 40 PVC tee. In an exemplary embodiment, the cell retainer7may be fabricated of PVC, ABS, plastic, a high temperature plastic, or other suitable material. In an exemplary embodiment, the cell retainer7is attached to the tee44by an adhesive or solvent which acts to weld adjacent surfaces together. Such adhesives are known in the art to connect elements of PVC piping systems. In the exemplary embodiment ofFIG. 2, the cell retainer adaptor unit7has a contour-shaped shoulder16formed to meet the outside of the tee44. In this embodiment, the shoulder16is curved to fit against the curved outer periphery of the tee44, so that the rotational position of the cell retainer7is fixed in relation to the line4and tee44.

In an exemplary embodiment, the housing6may comprise of PVC, ABS, plastic, for example a high temperature plastic, or other suitable material. In an exemplary embodiment, the housing6may include a longitudinally-extending latching pin entrance slot22and an indexed laterally-extending latching pin landing slot23(FIG. 2). A latching pin retaining lip24may be formed in housing6at the inner corner between the latching pin entrance slot22and the latching pin landing slot23. In an exemplary embodiment, there may be two entrance slot/landing slot structures located on radially opposite sides of the housing and cell retainers as shown inFIG. 3, for example. In exemplary embodiment, the entrance slots22, landing slots23and latching pin retaining lips24may interact with a latching pin25on the cell retainer7to form an indexed connection13. In an exemplary embodiment, the latching pin entrance slot22has a longitudinal length and width that is suitable to allow the latching pin to enter. The latching pin landing slot likewise has a suitable lateral length and width to allow the latching pin to enter. In an exemplary embodiment, for a pin25diameter of 0.315 inch, the latching pin entrance slot22has a longitudinal length of 0.870 inch, and a width of 0.320 inch, and the latching pin landing slot23has a lateral length of 0.630 inch and a width of 0.375 inch.

In an exemplary embodiment, the entrance slot22, landing slot23and latching pin retaining lip24may be arranged to mate with the raised latching pin25on the cell retainer7. In an exemplary embodiment, the housing may be slid along its longitudinal axis onto the cell retainer7with the slot22aligned with the latching pin25, which guides the housing into the desired position. The housing6may slide over the cell retainer7until the latching pin25stops further travel at the end of the slot22. The housing6may then be rotated, less than 360 degrees in an exemplary embodiment, providing relative motion between the latching pin25and the latching pin retaining lip24until the housing6and cell retainer7are fully engaged with the latching pin25in the landing slot23In an exemplary embodiment, the housing6may be rotated an angular distance of about 10 degrees relative to the cell retainer7to move the latching pin retaining lip24over the pin25to position the pin in the landing slot23. In an exemplary embodiment, the landing slot23and latching pin retaining lip24may tend to hold the latching pin25in place when installed. The housing6is removable by pressing and rotating the housing6to move the latching pin retaining lip over the pin25to align the pin with the slot22and then pulling the housing6back from the cell retainer7.

In an exemplary embodiment, the latching pins25and latching pin landings23are indexed with the desired orientation of the plates of the electrolytic cell such that the plane of the plate set21of the electrolytic cell5may be in a desired orientation with respect to a fluid flow path8when the housing6is attached to the cell retainer7and the latching pins25are fully engaged within the landing slots23.

FIG. 3illustrates a cross-sectional view of an exemplary embodiment of an electrolytic cell assembly5including an electrolytic cell housing6, electrode plates21, cell retainer7and flow line tee44. The housing6is positioned in the attached, operational position relative to the cell retainer7and tee44. When attached, the electrode plate set21extends through the transverse portion44A of the tee44and into the flow path8. In an exemplary embodiment, the plates26A-26D may extend about 3.23 inches beyond the support structure31into the tee44. In an exemplary embodiment, the ends of the plates26A-26D may extend to about 0.023 inches or about 0.026 inches from the inside wall of the distal end of the tee44installed in the flow line4.

In an exemplary embodiment, the latching pin entrance slots22in the housing6may be aligned to fit over the latching pins25on the cell retainer7. In an exemplary embodiment, the latching pins25are arranged on the cell retainer7at positions aligned perpendicular to a flow path8(FIGS. 1 and 2) through the flow line4. The electrode plates26will be rotated at an angle slightly away from being parallel with the flow path when being inserted over the cell retainer7while the latching pins are in the slots22. When the housing6is fully engaged with the cell retainer7, the housing6may be rotated so that the latching pins25fit within latching pin landings23. In an exemplary embodiment, the relative orientation of the plates, the latching pins and the latching pin landing slot are arranged so that the plates are parallel with the flow path when installed to reduce or mitigate flow restriction through the flow line.

In an exemplary embodiment, a mass of sealant40, which may be a dielectric potting material, covers the ends of the plates26A-26D on the dry side32of the housing6. In an exemplary embodiment, the sealant40fixes the plates26A-26D in their desired position and seals the plate slots28against leakage. Terminals14for plates26A and26D may extend above a surface of the sealant40for connecting to a drive circuit.

The electrolytic cell assembly may include a seal30, for example a rubber or synthetic elastomer O-ring, for sealing the housing6when in the installed position. Thus, in an exemplary embodiment, an O-ring30is installed at the end41A of an inner portion41of the mating end42of the housing6. In an exemplary embodiment, the inner portion41has a notch43around its circumference in which the O-ring30may be placed. In an exemplary embodiment, the external radius of the inner portion41fits snuggly with the internal radius of the transverse tube extension44A of the tee44. The O-ring and the snug fit of the inner portion41of the mating portion42of the housing6provide a seal against water leakage between the flow line4and the housing6. The inner surface of the transverse portion44A of the tee44has a slight taper, ending at a shoulder44A-1, which is standard on schedule 40 PVC tee fittings. The O-ring acts in compression with the tapered inside wall of the portion44A, the shoulder44A-1and the groove43to provide a radial seal.

In an exemplary embodiment, the entrance slot22, landing slot23and latching pin retaining lip24may be in a radially outer portion of the mating end42of the housing6. The mating end of the cell retainer7and the transverse tube portion44A of the tee44of the flow line4may fit in a recess34between an outer portion45of the mating end42of the housing6and an inner portion41of the mating end42of the housing6(FIG. 3).

FIG. 4illustrates a top view of an exemplary embodiment of the housing6, which may include a plurality of plate slots28corresponding to plates of an electrolytic cell to be housed in the housing. In an exemplary embodiment, guide notches46in the housing correspond to the stops or extensions29(FIG. 2) on the dry-side ends of the electrolytic plates to be installed. In an exemplary embodiment, the notches46may provide a guide for installing and arranging the plates in the proper aspect and orientation. In an exemplary embodiment, the notches46are on an inner wall recessed within the housing. In an exemplary embodiment, the recess may be filled with a sealant40(FIG. 3) to secure the plates in their desired position and seal against water leakage.

In an exemplary embodiment, the electrode plate set21may include a plurality of plates, for example four plates26A-26D, which are supported in the housing6in slots28(FIGS. 3-4) formed in the housing. In an exemplary embodiment, the plates may comprise titanium plates. In an exemplary embodiment, the plates may be coated with an anodically active material. Exemplary anodically active materials are discussed in U.S. Pat. Nos. 3,632,498 and 3,711,385, the entire contents of which are incorporated herein by this reference. By way of example, one material suitable for the coating is ruthenium.

In an exemplary embodiment, the electrode plate set21produces a halogen, for example bromine or chlorine, when the plate set21is in an appropriate aqueous solution and operatively connected to an electrical drive circuit, e.g. circuit19. In an exemplary embodiment, at least two of the plates have electrical connection portions or terminals14(FIGS. 2-3) for connecting the electrolytic cell to wiring18connected to the drive circuit. In an exemplary embodiment, the outer plates or primary plates26A and26D are connected to opposite polarities of an operating voltage waveform.

The housing6and cell retainer7may each be injection molded of a molded material, e.g. a plastic material.

In an exemplary embodiment, the electrical connection portions or terminals14may extend above an encapsulant sealant40(FIG. 3) covering the ends of the plates26A-26D in the housing6on the dry side32of the housing6. In an exemplary embodiment, the encapsulant sealant40may comprise a chemically resistant material, for example an epoxy. The plates26A-26D may have holes15(FIG. 2) through the plates which will be above the plate slots28, on the dry side32(FIG. 3) of the housing6when the plates are installed. In an exemplary embodiment, the holes15may allow liquid sealant to be dispensed from a single point and allow the sealant to flow between the plates evenly, and may fill with sealant40(FIG. 3) which may help hold the plates in place when installed. The plates each have end side tabs29(FIG. 2) which fit into guide notches46(FIGS. 2 and 4) in the housing6adjacent the slots28, and which serve to register the position of the plates along the longitudinal extent of the housing6.

In an exemplary embodiment, the plates26A-26D are electrically isolated from each other. The two inner plates or secondary plates26B-26C are not connected to the drive circuit19in an exemplary embodiment.

In an exemplary embodiment, the plates26A-26D of the cell assembly5are held in place by the web portion or plate support structure31(FIGS. 3-4) within the housing6. In an exemplary embodiment, the cell support structure31may be a solid barrier between a dry side32and a wet side33of the housing. In an exemplary embodiment, the support structure31may include plate support slots28through the support structure31. The “wet side” refers to the side of the support structure which may be exposed to water when the housing is installed in a spa or pool system and the “dry side” refers to the non-wet side of the support structure.

In an exemplary embodiment, the plate support structure31may have a number of slots28equal to the number of plates21, each one for holding one of the plates26A-26D in place within the housing6and at a desired orientation such that the plates26A-26D may be substantially parallel with the flow path8when the housing is installed. In an exemplary embodiment, the slots are arranged to hold the plates in planes substantially parallel with each other. In an exemplary embodiment, the plates26A-26D may have end side tabs29(FIG. 2) which enter guide notches46on the dry side of the support structure31when the plates26A-26D are installed into the slots28. In an exemplary embodiment, the housing6is a unitary structure fabricated by an injection molding process.

In an exemplary embodiment, the plates may be about 1.85 inches wide and 4.13 exclusive of the terminals. In an exemplary embodiment, the terminals on plates26A and26D may extend about 0.58 inches above the end of the plate. In an exemplary embodiment, the plates may be about 0.035 inches thick after plating and may be spaced about 0.24 inches apart from one another.

FIGS. 5-13diagrammatically depict alternate embodiments of an electrolytic cell assembly.FIG. 5depicts an assembly5A which employs a one-piece cell retainer structure7/44which performs the functions of the cell retainer7and the tee44of the assembly depicted inFIGS. 1-4. The structure7/44may be a unitary structure fabricated by injection molding. In other respects, the assembly5A is similar to assembly5.

FIG. 6illustrates a cell assembly embodiment in which the cell retainer is fitted about the body of the tee44, from its underside and extending upwardly to present a shoulder7-1A with pins7-1B. The housing structure6-1is a modified version of the housing6ofFIGS. 1-4, with a corresponding shoulder6-1A and pin slots6-1B. The indexed connection in this embodiment is achieved by inserting the electrode set into the tee opening to the depth illustrated, positioning the shoulders7-1A and6-1A in contact with each other, and rotating the housing6-1to seat the pins7-1B against the distal ends of the slots6-1B. The depth of the slots is selected so that the electrodes will be parallel to the flow path within the tee44. The retainer7-1may be fabricated of a metal or a plastic such as PVC, and secured to the tee44, e.g. by an adhesive or other attachment technique.

FIG. 7illustrates an electrolytic cell assembly5C which is analogous to cell assembly5B ofFIG. 6, except that the cell retainer7-2positions inwardly facing pins7-2A to engage the slots of the housing6. The housing6is identical to that depicted inFIGS. 1-4. An indexed connection of the housing6and electrode set21is provided by the pins7-2A and the slots22and23(FIG. 2) of the housing6. The retainer7-2may be fabricated of a metal or a plastic such as PVC, and secured to the tee44, e.g. by an adhesive or other attachment technique.

FIG. 8shows an electrolytic cell assembly5D with a cell retainer7-3which may be assembled to a tee44in the same manner as retainer7-1or7-2. The cell retainer7-3is formed with barbed fingers7-3A, which capture corresponding barb features6-2A of the housing6-2. An indexed connection of the housing6-2and cell retainer7-3is provided in this example by features of the fingers7-3A and/or features6-2A. To connect the housing6-2in the operating position illustrated inFIG. 8, the housing6-2and electrode set21may be inserted into the tee, until the features6-2A ride under the barb fingers7-3A and seat into recesses under the barb fingers. Alternatively, the connection may be made by inserting the housing6-2and electrode set21into the tee in a position rotated to avoid contact with the fingers7-3A, and then rotate the housing6-2to slide the barb features6-2A into contacting position with the barb fingers7-3A.

FIG. 9illustrates an alternate embodiment of an electrolytic cell assembly5E which employs a clamp retainer structure as a cell retainer7-4. In this embodiment, the housing structure6-3is similar to that of housing structure6ofFIGS. 1-4, but includes a set of protruding ear features6-3A on opposed sides of the housing, at locations which will index the position of the housing to the tee44. The retainer7-4is a clamp retainer structure, comprising a band portion which terminates at each end in hooks7-4B. A clamp7-4A is attached to the band portion, and includes a thumbscrew which may be turned to bear against the bottom of the tee, thereby exerting a force on the hooks7-4B. With the hooks engaging the ear features, the force is exerted on the housing structure to hold it in the operating position shown inFIG. 9. To remove the housing6-3, e.g. for cleaning, the thumbscrew may be loosened, allowing the hooks to be disengaged from the ear features.

FIG. 10depicts an embodiment of electrolytic cell assembly5F, which employs as a cell retainer7-5a cam lock retainer structure. In this embodiment, the housing structure6-4is similar to housing6ofFIGS. 1-4, except that the structure includes a pair of leg portions6-4A which extend on opposite sides of the housing structure to a length sufficient to extend past the bottom of the tee44with the housing and electrode plate set21positioned in the operating position. Slots6-4B are formed in the distal ends of the leg position to receive a cam lock pin7-5. The pin includes a cam surface7-5B and a transverse lock element7-5A at an end distal from a handle7-5C. The housing64and electrode set21may be positioned in the tee44in the operating position depicted inFIG. 10, and the retainer7-5inserted through the slots in the leg portions, and turned so that the cam surface bears against the bottom of the tee to lock the housing in position. The rotational position of the housing is indexed by the leg portions6-4A.

FIG. 11depicts an embodiment of an electrolytic cell assembly5G, which employs as a cell retainer7-6a clamp retainer structure. In this embodiment, the housing structure6-5is similar to housing6ofFIGS. 1-4, except that the structure includes a pair of tab features6-5A protruding from the housing at opposite sides thereof, each with a slot opening6-5B formed therein. The cell retainer7-6in this embodiment includes a pair of retainer bolts7-6A, a saddle member7-6B and threaded fasteners7-6D which thread onto a threaded end of the bolts. The distal end of the bolts have knobs formed therein which are larger than the size of slots6-5B. The saddle fits against the underside of the tee44. By tightening the fasteners7-6D, force is applied on the bolts7-6A, which is transferred to the housing6-5by action of the knob ends on the tab features. The bolts and saddle together with the tab feature location tends to register or index the rotational position of the housing relative to the tee, so that the plate set21is aligned with the flow through the tee. To remove the housing and electrode plate set from the tee, the fasteners may be loosened and the bolts slid out of the slots6-5B.

FIGS. 12 and 13depict embodiments of an electrolytic cell assembly which employ as a cell retainer respective hose clamp retainer structures. The assembly5H ofFIG. 12employs a housing structure6-6which is similar to housing6ofFIGS. 1-4, except that the structure includes a pair of flanges6-6A which are used to fasten the housing6-6and electrode plate set21in the operating position relative to the tee44by hose clamps7-7.FIG. 13depicts a cell assembly5I in which the housing structure6-7is similar to housing6ofFIGS. 1-4, except that legs6-7A are sized to abut the top surface of the tee44when in the installed position. The legs have a contour surface which matches contours of the tee44, and registers the radial position of the housing and electrode set21. A single hose clamp7-8is passed around the tee44and through the dry portion of the housing to secure the housing6-7in the operating position. The housing can be removed for servicing by loosening the hose clamp.

It is understood that the above-described embodiments are merely illustrative of the possible specific embodiments which may represent principles of the present invention. Other arrangements may readily be devised in accordance with these principles by those skilled in the art without departing from the scope and spirit of the claimed subject matter.