APPARATUS FOR GENERATING DRY MIST

A dry mist generating apparatus has a plastic housing, an ultrasonic transducer, a fan inducing airflow within the plastic housing, a diffuser plate for directing airflow, increasing velocity, and decreasing pressure, at least one opening for releasing the resulting dry mist, and a reservoir for capturing droplets that exceed 4 microns.

TECHNICAL FIELD

The present disclosure relates to airborne mists. More particularly, the present disclosure relates to an apparatus for generating a dry mist.

BACKGROUND

Pathogens, such as bacteria, viruses, mold, and mildew may be easily spread by remaining on surfaces or by passing through the air. Disinfectants have been used to reduce the spread of these pathogens, but their effectiveness is limited. For example, most disinfectants are of a liquid solution and must be either wiped or sprayed onto a surface. Spraying disinfectant into the air, via an applicator, is not effective as the droplets fall to the ground and surface much too fast due to the droplet size and weight. As a result, current disinfectants are inadequate for neutralizing airborne pathogens. Additionally, disinfectant sprays and solutions leave surfaces wet, which is not ideal and may not be safe for many surfaces, such as those with electronics. Disinfectant sprays and sprayers on the market typically do not achieve a micron size smaller than 10. As a result, the droplets are subject to gravity and will burst when landing on a surface, creating a wet spot. As a result, users must typically wipe the surfaces after using these sprayers.

Liquid droplets for cleaning may be separated into 3 major groups:

First, there are the 50 micron and larger droplets that are produced from hand-pump sprayers. Due to their size and mass, gravity pulls them down to the surface. This liquid must then be wiped, spread, or dried after the application. Typical spray glass and bathroom cleaners are examples.

Second, there are 10-50 micron droplets that come from high pressure sprayers with ultra-small orifices in the nozzle. Utilizing hundreds of pounds per square inch pressure, the liquid is forced through these small orifices to break the liquid into small droplets. While these are much smaller than the above-mentioned droplets, they also are subject to gravity and will be pulled down to surfaces and the droplet will “burst” on impact and become a wet spot. As with the above, drying, wiping, and spreading the liquid will be required.

Third, there are 1-9 micron droplets (referred to as dry mist) that are produced by ultrasonic transducers vibrating thousands of times per second. The ultrasonic transducer produces water droplets in all sizes from 1-200 microns. However, 1-9 micron size droplets are not influenced by gravity and remain suspended for hours and/or days based on heat and humidity.

Accordingly, there is a need for a dry mist (e.g., 1-9 micron droplets) disinfectant. In other words, there is a need for a disinfectant that can remain airborne for a significant amount of time, that may penetrate small spaces, and that does not leave surfaces wet. Additionally, there is a need for an apparatus that may produce this dry mist that is not susceptible to corrosion and other component failures. Current dry mist chambers and foggers are designed using metal components, which will not withstand prolonged exposure to hypochlorous acid (HOCL) and water. Delivering HOCL as a dry-mist disinfectant fog with traditional methods results in rapid failure of the metal parts in sprayers, nozzles, chambers, and pumps. Further, the mist expelled needs to be 9 microns and smaller, and ideally less than 4 microns, which has not been consistently achieved using the prior art. While examples are used above that demonstrate the need for dry mist disinfectants, it will be appreciated that the invention is not limited to disinfectant applications. For example, non-disinfectant dry mist (e.g., water) is also needed in plant growth, humidification, and other industries. Accordingly, the present disclosure seeks to solve these and other problems.

SUMMARY OF EXAMPLE EMBODIMENTS

In some embodiments, a dry mist generating apparatus comprises a plastic housing, an ultrasonic transducer, a fan inducing air within the plastic housing, a diffuser plate for controlling direction, velocity, and pressure of the induced air, at least one discharge opening for releasing the resulting dry mist, and a reservoir for capturing droplets that exceed 4 microns. In some embodiments, the ultrasonic transducer is an ultrasonic disc.

In some embodiments, a dry mist generating apparatus further comprises one or more discharge tubes for releasing the dry mist. The length of the tubes may be varied, along with their diameter and angle, to achieve varying micron droplet sizes at discharge.

In some embodiments, a dry mist generating apparatus comprises one or more wheels for easy transportation. In one embodiment, a dry mist generating apparatus may be placed in a cart or carriage.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The following descriptions depict only example embodiments and are not to be considered limiting in scope. Any reference herein to “the invention” is not intended to restrict or limit the invention to exact features or steps of any one or more of the exemplary embodiments disclosed in the present specification. References to “one embodiment,” “an embodiment,” “various embodiments,” and the like, may indicate that the embodiment(s) so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an embodiment,” do not necessarily refer to the same embodiment, although they may.

Reference to the drawings is done throughout the disclosure using various numbers. The numbers used are for the convenience of the drafter only and the absence of numbers in an apparent sequence should not be considered limiting and does not imply that additional parts of that particular embodiment exist. Numbering patterns from one embodiment to the other need not imply that each embodiment has similar parts, although it may.

It should be understood that the steps of any such processes or methods are not limited to being carried out in any particular sequence, arrangement, or with any particular graphics or interface. Indeed, the steps of the disclosed processes or methods generally may be carried out in various sequences and arrangements while still falling within the scope of the present invention.

The term “coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous, and are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including, but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes, but is not limited to,” etc.).

As previously discussed, there is a need for a mist that can remain airborne for a significant amount of time, that may penetrate small spaces, and that does not leave surfaces wet, which may be useful in a variety of industries, including, but not limited to, disinfecting, humidifying, plant growth, etc. Additionally, there is a need for an apparatus that may produce this dry mist that is not susceptible to corrosion and other component failures. The apparatus for generating dry mist disclosed herein solves these and other problems.

In some embodiments, as shown inFIGS.1-10, a dry mist generating apparatus100comprises a plastic housing102having a first chamber104and a second chamber106separated by a diffuser plate108. As shown, the diffuser plate108is non-perpendicular (e.g., angled 45 degrees) to a top110and a base112of housing102. The base112comprises an ultrasonic transducer (e.g., ultrasonic disc) aperture114configured to receive an ultrasonic transducer115(best seen inFIGS.8&10). The diffuser plate108comprises an air aperture116near the base112and straddling the ultrasonic transducer aperture114that allows for the passage of air and mist from the first chamber104to the second chamber106. A fan118forces air into the top of the first chamber104where the diffuser plate108directs the air to the lower, front of the first chamber104(i.e., a narrow neck126,FIG.3). The narrow neck126increases the velocity of the air and reduces pressure. The air then passes above the ultrasonic transducer via the air aperture116of the diffuser plate108and into the second chamber106. Because of the reduced air pressure when entering the second chamber106, the air lifts the dry mist (ideally about 3 microns or less, but range from 1-9 microns), which is created by an ultrasonic transducer within aperture114, to force it out through one or more discharge tubes120,122.

Droplets that exceed 4 microns remain in the reservoir (bottom of chambers104,106) by condensing and falling back to the chambers104,106. For example, liquid is added to the housing102where it is then converted to a dry mist via an ultrasonic transducer located at the base of the housing102. The fan118then causes air to flow from the first chamber104, under the diffuser plate108, and into the second chamber106where it then rises upwardly to exit through the discharge tubes120,122at the top of the housing102. As the air travels upward to the discharge tubes120,122, the dry mist is carried in the air upward and outward through the discharge tubes120,122as well. If any droplets larger than 4 microns happen to enter the discharge tubes120,122, the droplets condense on the sides of the tubes and fall back into the second chamber106. To ensure this occurs, the discharge tubes120,122are, ideally, non-linear. In other words, the discharge tubes120,122have bends that aid in collecting droplets excess in size, as best shown inFIGS.12-13. This non-linear configuration is most readily achieved using flexible tubing. However, it will be appreciated that non-flexible tubing that is shaped to be non-linear may also be used.

The dry mist generating apparatus100further comprises a controller124(e.g., microcontroller) which may be coupled to the housing102via a mounting plate103. The controller124is configured to control the power status of the dry mist generating apparatus100, as well as monitor various components of the dry mist generating apparatus100, as will be discussed in greater detail later herein.

As shown inFIGS.8-9, circular rotation air flow, which is turbulent and vortex, is induced into the first chamber104of the housing102using the fan118. The air pathway is shown using arrows. Due to the angle of the diffuser plate108, a narrow neck126is formed at the bottom of the first chamber104. In other words, a top portion125of the first chamber104has a first distance from the diffuser plate108to a front wall105of the housing102. The diffuser plate108is angled so that the lower end is closer to the front wall105, forming the narrow neck126. Because the turbulent and vortex air is compressed into the narrow neck126using the diffuser plate108, the velocity of the air is increased, thereby increasing the pressure. The air then passes through the air aperture116of the diffuser plate108and above the ultrasonic transducer115. As the air enters the second chamber106, the larger volume space allows the air pressure to drop (e.g., Venturi effect) and the turbulent and vortex air flow from the first chamber104is flattened into straight laminar airflow over the ultrasonic transducer115. The ultrasonic transducer115creates droplets, with some less than 10 microns in size. As the air passes into a bottom portion128of the second chamber106, airflow is slowed, decreasing (e.g., Venturi effect). pressure and allowing accumulation. The heavier droplets fall while the smaller, sub-10 micron sized droplets proceed to the discharge tubes120,122. In some embodiments, it is preferable to produce droplets smaller than 5 microns so that they may pass through an HVAC unit, continuing to disinfect.

The length of the discharge tubes120,122, along with their diameter and bend, may be varied to achieve varying micron-sized droplets at discharge to the atmosphere. For example, the longer the discharge tubes120,122, the smaller the micron-sized droplets that exit. Conversely, shorter tubes120,122allow for larger droplets to be expelled. Additionally, the size of the ultrasonic transducer may also be used to control the size of the droplets. Accordingly, a user may adjust the discharge tubes120,122and their bends in order to achieve the maximum desired micron size of the droplets at an exit130,132of each discharge tube120,122. In order to achieve micron sizes less than 4 microns, the discharge tubes120,122are ideally non-linear, comprising bends as shown inFIGS.12-13. By achieving droplets that have a size of less than 4 microns, the droplets remain suspended in the air and may freely flow therewith (defined herein as a “dry mist”). This dry mist is then able to penetrate all areas of a space or building as it flows through the air, thereby disinfecting the space or building as it penetrates.

In some embodiments, as shown inFIGS.11-23, the dry mist generating apparatus100may be contained within a wheeled cart134, the wheeled cart134comprising one or more handles136A-B, a hinged lid138, and a plurality of wheels140A-D. As shown inFIGS.12-13, the hinged lid138can secured in an open position, such as by using a rod142, with the discharge tubes120,122coupled to the hinged lid138such that they are raised with the hinged lid138. As shown, the discharge tubes120,122are non-linear (comprise bends), which thereby aids in collecting droplets greater than 4 microns in size. Referring toFIGS.14-20, portions of the wheeled cart134have been removed for ease of viewing internal components. As understood, the wheeled cart134may comprise the dry mist generating apparatus100, a first liquid holding tank144, a second liquid holding tank146, and a waste tank148. As best seen inFIG.15, the liquid holding tanks144,146are elevated in relation to the housing102. In other words, the bases of the liquid holding tanks144,146are higher than the base112of the housing102. As a result, liquid may be gravity-fed from the one or more liquid holding tanks144,146to the housing102(which may be positioned on a riser101to achieve a desired height), such as through one or more pipes150. One or more electric valves may be used to control the flow of liquid, as discussed later herein.

FIG.16illustrates a longitudinal cross-section of the wheeled cart134and the components therein. When closed, the exit130,132of each discharge tube120,122rests in a basin152that collects excess moisture, where it is directed to the waste tank148via a conduit154.FIGS.17-19illustrate various angles of the wheeled cart134and its components.

FIG.20illustrates a top, detailed view of the wheeled cart134with the hinged lid138removed therefrom. The discharge tubes120,122have also been removed from the ports156,158in this view. Turning toFIGS.21-22, liquid (e.g., Hypochlorous Acid (HOCL)) is able to flow from a first liquid holding tank144and liquid (e.g., water) is able to flow from a second holding tank146via at least one pipe150. The HOCL may be controlled via an electric valve160and the water may be controlled via an electric valve162. It will be appreciated that a coupler may be used to combine the liquid from both tanks144,146once released from their respective electric valves160,162and into a single pipe150for conveying to the housing102. Further, the housing may comprise an outlet pipe164for releasing liquid from within the housing102when the dry mist generating apparatus100is not in operation. The outlet pipe164may be controlled via an electronic valve166. The outlet pipe164exits at a position higher than where it enters the waste tank148so that it may be gravity fed as well.

In addition, the level of liquid within each tank144,146, and waste tank148may be monitored using sensors and the controller124. For example, the HOCL tank may comprise a “full” liquid sensor168and a “low” liquid sensor170. Likewise, the water tank may comprise a “full” liquid sensor172and a “low” liquid sensor174. The waste tank148may comprise a “full” liquid sensor176. Each liquid sensor is capable of detecting when liquid is in contact therewith, which is read by the controller124, which is configured to control the on/off status of the apparatus as well as provide alerts to a user. For example, referring toFIG.23, a user control panel178may comprise an on/off switch180and a plurality of indicators and/or switches182A-I. The indicators/switches182A-I may alert a user to high levels of liquid, low levels of liquid, a fault or error, or may reset the controller124. The indicators may be lights (e.g., LEDs) or audible.

In one method of use, a user would maneuver the wheeled cart134to the desired location for disinfecting (or humidifying, or other use), would ensure that the first liquid holding tank144and second liquid holding tank146are full of the desired liquid. This may be determined by a user by reviewing the control panel178and the various indicators/switches182A-I. The controller124is configured to control the indicators/switches182A-I and may thereby indicate full or low status. With both tanks144,146full, a user may open the hinged lid138and secure it in position. With the hinged lid138raised, the discharge tubes120,122are angled upwardly (best seen inFIGS.12-13).

A user may then start the dry mist generating apparatus100using the on/off switch180. The controller124then actuates the electric valves160,162, allowing liquid from both tanks144,146to be gravity fed to the housing102. For sanitization, the liquid may be HOCL in the first tank144and water in the second tank146. The ultrasonic transducer115converts the liquid into droplets sized 4 microns or less (the dry mist). As the transducer115creates the dry mist, the fan118induces air into the first chamber104where it passes to the second chamber106via the aperture116, then upwardly to the discharge tubes120,122. As the air travels upward, the dry mist is likewise pulled with the air and up through the discharge tubes120,122. Due to the bends, angle, and length and diameter of the discharge tubes120,122, only dry mist (e.g., droplets of 4 microns or less) exit the discharge tubes at the exits130,132. Accordingly, it will be appreciated that a user may vary the angle, length, and diameter of the tubes to control the micron size of the droplets at the exits130,132.

The dry mist generating apparatus100will continue to operate until switched off by a user or until the controller124determines that a condition is met, such as that the run timer has reached the entered set point (10-240 minutes), or that the first tank144is low, the second tank146is low, or that the waste tank148is full, among other conditions. Because the HOCL exits as a dry mist, it is able to penetrate all areas of a room or building, thereby disinfecting both the air and surfaces. Because the HOCL is a dry mist, no residue remains and surfaces do not become wet—there is no need for any cleanup, which overcomes issues in the prior art.

It will be appreciated that the housing102may vary in size. In some embodiments, the housing102is sized so as to allow a user to easily carry the dry mist generating apparatus100for use and may comprises handles for easier carrying. In other embodiments, the housing102is too large to carry and must be pushed or otherwise transported using wheels either directly coupled to the housing102or on a cart as shown and described earlier.

As shown inFIG.24, a dry mist generating apparatus200may comprise a plurality of discharge tubes202A-D, a plurality of intake fans204A-B, a plurality of ultrasonic transducers206A-B, and a diffuser plate208. Referring toFIG.25, a dry mist generating apparatus300may comprise a plurality of discharge tubes302A-D, a plurality of intake fans304A-B, an ultrasonic transducer306, and a diffuser plate308. Accordingly, it is appreciated that the present invention is not limited to the number of fans, transducers, or discharge tubes.

Further, while liquid holding tanks144,146were discussed above as feeding liquid to the housing102, other configurations may be used without departing herefrom. For example, the housing102may comprise one or more threaded inlets (or other couplers) allowing for a bottle or other container to be threaded thereto. One or more bottles may then feed water and/or HOCL into the housing102, either by manual flow valves or electronic flow valves. This allows the overall size to be reduced, allowing the system to carried by a user in some embodiments. For example, the housing102may comprise a handle allowing a user to carry it by hand. A user may then feed the desired liquid into the housing102via the coupled bottles where it can be turned into dry mist. The riser101may also function as a waste container in such a scenario. In the alternative, a waste container may be coupled to the housing102. While embodiments discussed herein have generally discussed a portable dry mist generating apparatus, the present disclosure is not so limited. For example, the dry mist generating apparatus100may be coupled to an HVAC unit or may otherwise be secured to a building. Accordingly, it will be appreciated that the dry mist generating apparatus100may vary in size and may be portable or a fixture. Additionally, while plastic is used as an example herein, it will be appreciated that other corrosion resistant materials may be used, such as fiberglass, aluminum, carbon fiber, and others.

Because the droplets expelled from the discharge tubes120,122have a micron size of 3 or less, the droplets are easily suspended in the air for extended times (i.e., a dry mist). This dry mist may be distributed in office spaces, schools, buildings, or any other enclosed area in need of disinfecting. Additionally, the dry mist may be distributed directly onto surfaces without creating wet surfaces. As a result, surface pathogens are neutralized. This is a significant improvement over the prior art, which does not remain airborne and causes wet surfaces.

Accordingly, the dry mist generating apparatus100solves the problems in the art, namely, the need for a disinfectant that can remain airborne for a significant amount of time, that may penetrate small spaces, that does not leave surfaces wet and that may produce this dry mist in an apparatus that is not susceptible to corrosion and other component failures.

It will be appreciated that systems and methods according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties or features (e.g., components, members, elements, parts, and/or portions) described in other embodiments. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment unless so stated. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and/or portions without necessarily departing from the scope of the present disclosure.

Exemplary embodiments are described above. No element, act, or instruction used in this description should be construed as important, necessary, critical, or essential unless explicitly described as such. Although only a few of the exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in these exemplary embodiments without materially departing from the novel teachings and advantages herein. Accordingly, all such modifications are intended to be included within the scope of this invention.