Abstract:
The ion chip operating module allows for the inevitable ionising electrode erosion by high voltage ionisation of the prior art ion chip, by extending its life, improving its performance and maintenance. A ionising module is provided which lengthens the life of its ionising structure by providing more ionising electrodes, which usually operate sequentially, and also allows replacement of an exhausted module by a fresh one. The ionising electrodes are provided by ionising needles, conductive carbon coated fibres and mixtures thereof. The carbon coated fibres when in brush form present a very large number of potential ionising electrodes. The module is a metal plate with the ionising structure on one side and a pin adapted to engage a socket on the other. The advantage of injecting negative ions into air conditioning systems to enhance air quality by increasing negative ions and by precipitating particulate contaminants is known.

Description:
[0001]    This application is directed to an improved ion chip and operating module for generating atmospheric ions, preferably negative ions. 
         [0002]    The ion chip operating module was developed to overcome the inevitable ionising electrode erosion by high voltage ionisation of the prior art ion chip of U.S. Pat. No. 7,161,789 hereby incorporated by reference. The module extends operating life, improves operating performance, and eases maintenance, of systemic application of negative ionising emitters to improve indoor air quality. The ion chip operating module is an insert to connect to the metallic surface of the ion chip, it has more ionising electrodes than the original ion chip, which lengthens the life of the ionising structure, because the ionising electrodes usually operate sequentially until exhausted. It also allows replacement of an exhausted module by a fresh one. The ionising electrodes are provided by ionising needles, conductive carbon fibres, preferably in brush form, and mixtures thereof. The carbon fibre brush thread ends present a very large number of potential ionising electrodes. There are two forms of emitter: one to inject negative ions into ventilation airflow of (sick) buildings to correct known deficiencies in electrical air quality; the other to cause precipitation of airborne contaminants, including harmful bacteria, spores and viruses to reduce cross infection in hospitals, which is a current major problem, in view of prospective pandemics such as SARS. In both types of emitter the output profile of strongly focused air ion streams can be determined by the number, spacing and arrangement of modules within an emitter, typically linearly spaced, and the arrangement of emitters in an array, to achieve the desired result of cleaner fresher air, and improved workplace, health and safety. 
         [0003]    The invention is directed to an ion chip operating module which has an ionising structure mounted on one side of a metal plate and a metal projection mounted on the other side, the metal projection is adapted to engage a metal lined recess physically and electrically. An ion chip base has a metal plate or surface, having a recess to engage the projection of the module. In use module and base form the ion chip, with the ionising structure providing an ion stream and the base providing an electrostatic repulsing field to direct the ion stream or flow from the ionising structure. Typically insulating walls are provided to protect and ambush the ionising structure. The purpose of the invention is to allow for the inevitable erosion of the ionising electrodes inherent in the ionising process and not now dependant on a single ionising needle or random surface threads of carbon fibre yarn to obtain and maintain systemic operation of the technology. In use the ion chip metallic surface is electrically connected to one pole of a high voltage generator. 
         [0004]    Although the invention is described and referred to specifically as it relates to specific modular ionising structure conductive surface combinations for generating atmospheric ions, it will be understood that the principles of this invention are equally applicable to similar ionising structure conductive surface combinations and accordingly, it will be understood that the invention is not limited to such modular ionising structure conductive surface combinations for generating atmospheric ions. 
       PRIOR ART AND BACKGROUND 
       [0005]    The invention is an improvement on the ion chip of U.S. Pat. No. 7,161,789 B2 issued Jul. 9, 2007 to instant applicant, which teaches an ionising structure physically mounted on and in electrical contact with a metallic surface of the ion chip. One pole of a high voltage generator is connected to the metallic surface to provide a high voltage. The ionising structure emits a stream of ions generated by corona discharge from one or more ionising electrodes, while the metallic surface provides an electrostatic repulsing field which directs the ion stream outward. Generally there are insulating walls projecting outward near the ionising structure forming a channel construction to protect it. Although the ionising structure can generate both positive and negative ions, in general for air cleaning, conditioning, freshening and purifying negatively charged atmospheric ions are generated. 
         [0006]    Negatively charged atmospheric ions have two primary effects in air cleaning, conditioning, freshening and purifying. One is the introduction of negative ions to change the ionic balance of the incoming ventilating air, which of itself is considered beneficial. In fact the metal ducts of modern air conditioning systems act as ground removing negatively charged ions from the air leaving positively charged ions. The second is to precipitate particulate matter from the air, most contaminants are particulate in nature, thus cleaning or purifying the air. In hospitals the particulate matter includes bacteria, As it is thought much iatrogenic (hospital generated) disease is caused by airborne bacteria, reducing particulate matter should reduce iatrogenic infection. Both effects are important when air is recycled or recirculated in buildings. The emitters can also be used to provide an ionic barrier across a doorway or corridor to reduce particulate matter, thus bacteria levels and so any resulting infection. 
       OBJECTS OF THE INVENTION 
       [0007]    The main thrust of the invention is to provide an improved ionising structure for the ion chip. The original carbon fibre yarn had few ionising electrodes which degraded over time. This is overcome in two ways, first by providing a replaceable ionising structure in the form of a module, and second by providing many more ionising electrodes in the ionising structure, which extends the effective life of the module. It is a principal object of the invention to provide an ionising module having a flat metal surface bearing an ionising structure extending substantially vertically from the metal surface and a metal projection extending from the other side of the surface, the metal projection being adapted to engage a recess, the ionising structure comprising a plurality of corona forming ionising electrodes, selected from the group consisting of ionising needles, conductive carbon coated fibres and mixtures thereof, whereby when sufficient high voltage is applied to said ionising structure through said metal surface and said metal projection said ionising structure generates ions. A subsidiary object of the invention is to provide an ionising module, where the surface is a metal plate, the projection is a pin and the recess is a socket. It is a further subsidiary object of the invention to provide an ionising module where the ionising structure is a plurality of ionising needles. It is a further subsidiary object of the invention to provide an ionising module where the ionising structure is conductive carbon coated fibres. It is a further subsidiary object of the invention to provide an ionising module wherein the ionising structure is at least one and preferably a plurality of carbon fibre brushes, both fibres and brushes being aligned substantially vertically to the metal surface, impaled on ionising needles or pins substantially vertical to the metal surface. It is a further subsidiary object of the invention that the brushes be bound with fine copper wire. It is a further principal object of the invention to provide an ion chip combining the ion module of the invention with an insulated base having a base metal surface having a socket to engage the projection of the ionising module. It is a subsidiary object of the invention to provide a pin as projection and a socket as recess. It is further subsidiary object of the invention to provide and ion chip having a plurality ion modules with projections engaging recesses in the metallic surface of said insulated base. It is a further subsidiary object of the invention to provide a surrounding insulated wall projecting from the base metal surface adjacent the module and projecting a greater distance from the base metal surface than the ionising structure. It is a further subsidiary object of the invention to provide a wedge shaped side of the insulated base opposed to said ionising structure to split airflow flowing past the ion chip from the insulated side to the ionising side. It is a further subsidiary object of the invention to provide a base metallic surface extending beyond the module metal surface to provide a repulsing electrostatic field when said high voltage is applied thereto. It is a further object of the invention to provide paired opposed parallel insulating walls projecting from the base metal surface adjacent the ionising structure of the module and the insulating walls project a greater distance from the base metal surface than said ionising structure to protect and ambush the ionising structure. Other objects of the invention will be apparent to those skilled in the art from the following specification, accompanying drawings and appended claims. 
       DESCRIPTION OF THE INVENTION 
       [0008]    In one broad aspect the invention is directed to an ionising module comprising a flat metallic surface having an ionising structure extending substantially vertically therefrom and a metal projection extending from the other side of said surface said metal projection being adapted to engage a recess. The ionising structure comprises a plurality of corona forming ionising electrodes, selected from the group consisting of ionising needles, conductive carbon coated fibres and mixtures thereof, whereby when sufficient high voltage is applied to said ionising structure through said metal surface and said metal projection said ionising structure generates ions. 
         [0009]    Preferably the metal surface is a metal plate and the projection is a pin and the recess is a socket. The ionising structure comprises a plurality of ionising needles; conductive carbon coated fibres; and mixtures thereof. The carbon fibres can be at least one and preferably a plurality of carbon fibre brushes, both brushes and the fibres in the brushes are preferably aligned substantially vertical to the metal surface or plate. Each brush is impaled on a pin or ionising needle substantially vertical to said metal surface. Ionising needles are preferred as providing more ionising electrodes. Preferably the carbon fibre-brushes are brushes are bound by copper wire. 
         [0010]    The invention in a further aspect is directed to an ion chip comprising the module of the invention in combination with an insulated base having a base metal surface. This base metal surface includes a recess to engage the projection of the module, and the base has an opposed side to said metal surface. Preferably the projection is a pin and the recess is a socket. The ion chip can have a plurality of ion modules with projections engaging recesses in the metal surface of the insulated base. The insulated base may have a surrounding insulated wall projecting from the metal surface adjacent the ionising structure of the module and the insulating wall projects a greater distance from the metal surface than the ionising structure, so as to protect the ionising structure. The opposed side of the insulating base may be wedge shaped to split airflow flowing past the ion chip from its insulated side to its ionising side. Preferably the base metal surface extends beyond the module metal surface to provide a repulsing electrostatic field when said high voltage is applied thereto. Paired opposed parallel insulating walls may project from the base metal surface adjacent the ionising structure of the module and the insulating wall projects a greater distance from the base metal surface than the ionising structure, to protect and ambush the ionising structure. The ion chip may have a plurality of ion modules with projections engaging recesses in the metal surface of the insulated base and these modules are between the insulating walls. Preferably the module has a pin engaging a metal socket in the metal surface of the base, the ionising structure being physically and electrically connected through the pin to the base metal surface, whereby when sufficient high voltage is applied to the base metal surface by a high voltage generator, the ionising structure generates ions directed in a stream by an electrostatic repulsing field on the module metal surface. The base metal surface may extend beyond the module metal surface whereby when sufficient high voltage is applied to the base metal surface by a high voltage generator, the ionising structure generates ions directed in a stream by an electrostatic repulsing field on both the module metal surface and the base metal surface. In this case preferably an insulating wall projects from the base metal surface adjacent the ionising structure of the module and the insulating wall projects a greater distance from the base metal surface than the ionising structure, to protect the ionising structure, the base metal surface extending beyond the insulating wall. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  shows a sectional view of an embodiment of an ion chip of the invention. 
           [0012]      FIG. 2  shows a sectional view of a second embodiment of an ion chip of the invention. 
           [0013]      FIG. 3  shows a plan view the embodiment of  FIG. 1 . 
           [0014]      FIG. 4  shows a plan view of the embodiment of  FIG. 2 . 
           [0015]      FIG. 5  shows a sectional side view of a general embodiment of a module of the invention. 
           [0016]      FIG. 6  shows a sectional side view of a specific embodiment of the module of the invention. 
           [0017]      FIG. 7  shows a plan view of the embodiment of  FIG. 6 . 
           [0018]      FIG. 8  shows a plan view of another specific embodiment of  FIG. 5 . 
           [0019]      FIG. 9  shows a plan view of another specific embodiment of  FIG. 5 . 
           [0020]      FIG. 10  shows a side sectional view of another specific embodiment of  FIG. 5 . 
           [0021]      FIG. 11  shows a side sectional view of another specific embodiment of  FIG. 5 . 
           [0022]      FIG. 12  shows a side sectional view of another specific embodiment of  FIG. 5 . 
           [0023]      FIG. 13  shows a plan view of another specific embodiment of  FIG. 5 . 
           [0024]      FIG. 14  shows a side view of a carbon fibre ionising brush of the invention. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0025]    The invention is illustrated by reference to preferred embodiments thereof. In  FIG. 1  numeral  10  indicates an ion chip of the invention having module  12  and support  14 . Module  12 , about % inch (about 2 cm) across is shown with ionising structure  16 , plate  18  and pin  20  which engages recess or socket  22  in support  14  which has insulating base  24  on which is metal surface  26 , typically the metallic layer of a printed circuit board. Insulating walls  28  about ¼ inch (about 6 mm) across project about ¾ inch (about 2 cm) and are attached by pins  30  to base  24  and project from metal surface  26 . In use ions generated flow from ionising structure  16  channelled by walls  28  and directed by the electrostatic field of metal surface  26 . In  FIG. 2 , base  24  of support  14  is shaped as wedge  32  so that air flowing upstream past the ion chip from the bottom is split while the ion flow generated flows upward into the air flow downstream of the chip, this version directs its ion flow longitudinally into the air flow, and is intended to inject negatively charged ions into the air. As shown in  FIG. 3 , for illustrative purposes, several forms of ionising structure may be used: module  112  has an array  34  of three ionising brushes  36  each impaled by ionising needles  38  mounted on plate  18 ; module  212  has an array  34  of five ionising needles  38  mounted on plate  18 ; module  312  has with three ionising brushes  36  mounted on plate  18 . In these cases plate  18  is a metal disc, and metal surface  26  provides a repulsing electrostatic field as do plates  18 . In  FIG. 4 , similarly, again for illustrative purposes, several forms of ionising structure may be used: module  112  has an array  34  of three ionising brushes  36  each impaled by ionising needles  38  mounted on plate  18 ; module  212  has an array  34  of five ionising needles  38  mounted on plate  18 ; module  312  has with three ionising brushes  36  mounted on plate  18 . In these cases plate  18  is a metal disc, and metal surface  26  provides a repulsing electrostatic field as do plates  18 . The ion chips of  FIGS. 1 and 3 , are generally used to inject ions transversely into an air flow to precipitate particulate matter, metal surface  26  is used to direct and focus the ion flow or stream. The ion chips of  FIGS. 2 and 4  are used to inject ions longitudinally (downstream) into an airflow. In use one pole typically the negative pole of a high voltage generator is connected electrically to metal surface  26 . In  FIG. 5 , is shown a generic module  12  of the invention having ionising structure  16 , metal plate  18  and integral metal locating pin  20 . Metal plate  18  is preferably ¾ or 11/16 inch diameter disc (about 1¾ to 2 cm), 3/16 inch thick (about ½ cm), the plate can be smaller and thinner as appreciated by those skilled in the art. Metal pin  20  is typically 3/16 inch diameter and projects 3/16 inch (both about ½ cm). The metal is preferably high grade conductivity copper. Ionising structure typically extends outward from plate  18  about inch (about 1¼ cm). In  FIGS. 6 and 7  module  212  has ionising structure  16  which is an array  34  of ionising needles  38  embedded in holes  40  in plate  18 . Ionising needles  38  are hardened steel 21/32 inch long (about 1½ cm) and ⅛ inch diameter (about 3 mm) socketed in cylindrical holes  40  ⅛ inch less ten thousandths inch diameter for tight fit (about 3 mm) and ⅛ inch deep (about 3 mm), holes  40  can also be ⅛ inch less five thousandths of an inch diameter for tight fit, five ionising needles  38  are shown, but as those skilled in the art are aware, up to seven is possible, or even more by suitably close packing ionising needles  38  ⅛ inch diameter (3 mm) needles, with holes  40  suitably spaced so as not to be contiguous and weaken plate  18 . Although not preferred ionising needles  38  can be 1/16 inch diameter (about 1½ mm) sunk into holes  40  of 1/16 inch less five thousandths inch (about 1½ mm) diameter for tight fit and ⅛ inch deep (about 3 mm) can be used and a greater number can be placed on plate  18 .  FIG. 8  shows module  12  with ionising structure  16  having array  34  of three ionising needles  38 .  FIG. 9  shows module  312  with ionising structure  16  having an array  34  of three ionising brushes  36  of conductive carbon coated fibres impaled on three ionising needles  38  each 1/16 inch diameter (about 1½ mm).  FIG. 10  show a similar embodiment to  FIG. 9  of module  12  with array  34  of ionising brushes  36  impaled on ionising needles  38  each 1/16 inch diameter (about 1½ mm).  FIG. 11  show a similar embodiment to  FIGS. 9 and 10  using array  34  of pins  42  1/16 inch diameter (about 1½ mm) instead of ionising needles  38 .  FIG. 12  shows a related embodiment to  FIGS. 9 ,  10 ,  11  where module  12  has ionising structure  16  with ionising layer of carbon coated fibre yarn  44 , through which optional array  34  of ionising needles  38  pass either ⅛ inch (about 3 mm) or 1/16 inch (about 1½ mm), the latter preferred.  FIG. 13  shows ionising structure  16  with central ionising needle  38 , either ⅛ inch (about 3 mm) preferred, or 1/16 inch (about 1½ mm) diameter, impaling ionising brush  36 , surrounded by ionising needles  50  1/16 inch (about 1½ mm) diameter forming a cage to hold the brush in place.  FIG. 14  shows ionising brush  36  is a thick short stub of carbon fibre yarn  46  wound about by fine copper wire  48 , with its ionising end forming a mass of carbon fibre thread ends providing a multiplicity of potential ionising electrodes, typically the brush is ⅜ inch (about 1 cm) diameter and about ½ inch (about 1¼ cm) long. The preferred forms of ionising structure are: a short stub brush of twisted carbon fibre yarn material bound by fine copper wire held upright by being impaled on a metal support pin from a metal plate; a cluster of ionising needles as closely spaced as possible; a combination of ionising brush and needles, possibly the impaling metal pins can be ionising needles. While as in  FIG. 12  conductive carbon coated fibre yarn can be used, it has far fewer ionising electrodes and thus a much shorter life, and so is less preferred. Different arrangements of ionising structures within an emitter have different ion emission characteristics allowing modification of ion streams, as do different arrays of emitters. Although injection of ions into air flows and streams to improve air quality by changing ion balance, is different from injection of ions to precipitate contaminant particles, the identical module can be used in both cases. It is preferred to provide a metal surface for a repulsing electrostatic field to focus or direct the ion flow or stream in the case of precipitation so as to direct the ion stream across the air flow. The metal surface and repulsing electrostatic field are less necessary in improving air quality. As many ionising electrodes as possible are preferred per module as possible. Several ionising needles are needed to extend the life of the ionising structure, as the needles erode with use. Similarly ionising brushes provide even more carbon fibre end to act as ionising electrodes. As the ionising electrodes replace each other in turn, with only one ionising electrode working at a time, all the potential ionising electrodes must lie within a minimum distance, so that the corona discharge of the working ionising electrode suppresses other potential electrodes supported by plate  18 . This is the corona plasma stress cone suppression effect which is known, and permits only one dominant electrode to emit at a time. When this burns out another electrode will become dominant, as it is outside any corona cone and emit automatically it its turn. As a random dynamic discriminating sequence of events, some electrodes will leave and return to the pool of potential electrodes, extending the operating life of the module. The stub brush of carbon fibre yarn ends provides many more potential electrodes than the random surface of carbon fibre yarn previously used. The numbers of ionising needles and carbon fibre stub brushes shown are illustrative rather than restrictive. The farthest distance between electrodes should be chosen so that the corona discharge of one working ionising electrode suppresses other potential electrodes on the same plate or disc. The corona suppression cone is about ⅜ in, (about 1 cm) diameter so all the electrodes should lie within this distance of each other. As many electrodes as possible should lie within the corona suppression cone. If the ionising structure is larger than the corona suppression zone, then more than one electrode may emit ions at a time, which provided that the number is small, is acceptable, though not preferred. When ionising needles are used these are typically about ½ inch (about 1¼ cm) tall and up to ⅛ inch (about 3 mm) diameter. Generally the longest electrode activates first as ionising electrode, and is then replaced. With the thicker ionising needles a needle may activate then be replaced, and then become active again. In the precipitation ion chip, as for example shown in  FIGS. 1 and 3 , the base is perhaps 4 inches (10 cm) long, although this size is not critical, the channel is about ¾ inch (about 2 cm) across, the insulating walls are about ½ inch (about 1¼ cm) across and deep enough about ¾ inch (about 2 cm) to protect ionising needles, the structure is about 1¾ to 2 inch across (about 4½ to 5 cm), to allow metal surface  26  to direct or focus the ion flow or stream. While discs are shown in the figures, the shape is not critical, it is greatly preferred that all potential ionising electrodes lie within the suppressor cone of corona discharge of one of the electrodes, and that the plate fits between insulating walls. Two types of emitter are envisaged, one is to inject negative ions into incoming air of incoming ventilation air diffusers in a conventional HVAC  2  installation to correct known deficiencies in “electrical air quality” typically an excess of positive ions as normal country air has 1800 positive and 1600 negative ions per millilitre, excess positive ions being believed deleterious to healthy air. The emitters can be retrofitted or integral to the HVAC diffuser, the embodiment of  FIGS. 2 and 4  is preferred for this function, the upstream wedge structure splits incoming airflow to either side of the emitter, which will multiply the emitter static output (ion generation) as a function of ventilating air velocity. The same arrangement avoids any direct impingement of incoming air onto the ionising structure, thus protecting it from erosion or build up of contaminants from the incoming air to be treated. Alternatively the emitter is used to precipitate and immobilize air borne contaminants, of micrometric or submicrometric particle size (micrometre is 10 −6  metre) such as bacteria. The metallic surface layer of the ion chip base is extended to each side of the channel formed by insulating walls, to provide an electrostatic repulsing field to focus the ion flow or stream, as in  FIGS. 1 to 4 . Here the emitter should ideally be arranged directly above the polluting source. An emitter mounted on a ceiling tile would fit in well where false suspended ceilings exist, as downward ventilating air would assist downward flow of focussed ion streams or flows. A system of this sort (contaminant precipitating) has achieved demonstrated success in a wide range of industrial manufacturing and processing operations to achieve higher standards of workplace health and safety, increased productivity through reduced contamination of finished products (removal/reduction of airborne dust). Recent applications in dental and medical premises has controlled the spread of infection. A byproduct is that after precipitation some bacteria and viruses are rendered harmless and unable to colonise, when negative ion bombardment is continued. 
         [0026]    Module pin  20  and recess  22  preferably embody conventional engaging means, such as screw threads preferred, or a bayonet joint. 
         [0027]    The high voltage supply is preferably generated by an electronic ion generator which comprises a printed circuit board housed in a strong insulated box, with a uni-polar negative output, with full wave rectification and a miniature step-up instrument transformer of limited short circuit capacity to ensure minimum ignition energy cold sparking under fault and limited threshold CD value of about 7 kV to ensure limited ozone considerably within the EDA recommendation of 50 parts per billion, preferably much less. Such a generator can supply both positive and negative voltages and ions. 
         [0028]    The ion chips are designed to operate with the lesser negative voltage which generates ozone at acceptable levels (preferably none). By connecting the system to a suitable higher negative voltage the ion chip can actively generate ozone as a fumigating agent, for treating air borne bacteria such as pathogenic microbes, in the absence of humans and livestock. 
         [0029]    As those skilled in the art would realize these preferred described details and materials and components can be subjected to substantial variation, modification, change, alteration, and substitution without affecting or modifying the function of the described embodiments. 
         [0030]    Although embodiments of the invention have been described above, it is not limited thereto, and it will be apparent to persons skilled in the art that numerous modifications and variations form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention.