Abstract:
One embodiment of an improved ozone generator is comprehensively disclosed by descriptions of computer generated drawings depicting the first commercial version of the invention, which combines the following features: an extruded base with longitudinal channels for receiving connections at distributed points; an extruded cover for detachably engaging the base at each opposing sides and covering a substantial portion of said base; a central baffle that is integral with the cover fro dividing the enclosed volume into a reaction chamber and a circuitry chamber; one or more ultraviolet light sources mounted to connection points on a channel within the reaction chamber; electronic circuitry mounted to connection points on a channel within the circuitry chamber for controlling and transforming an input voltage to drive the light sources; sliding end caps secured to channels in the base for separately covering apertures formed by the ends of the cover and base and for detachably connecting the cover to the base; and a selectively restricted outlet conduit for providing fluid communication between the reaction chamber and an external point of ozone injection.

Description:
BACKGROUND 
       [0001]    The invention relates to an improved ozone generator for use in water treatment and other applications and, more particularly, an ultraviolet ozone generator that can accommodate different light sources to more effectively produce a range of ozone outputs matched to individual demand, that produces higher peak levels of ozone output and that can be made and used with greater cost-effectiveness, reliability and simplicity. 
         [0002]    Ozone is well-known as a highly effective oxidization agent frequently used in a range of sanitation applications. It is particularly effective in the treatment of water. In cases where large volumes of ozone are required, methods such as corona discharge and cold plasma are preferred. However, smaller volumes of ozone can be very effectively and efficiently generated over time through the controlled exposure of ambient air (containing oxygen) to moderately intense ultraviolet radiation. 
         [0003]    Ultraviolet ozone generators utilize one or more ultraviolet lamps, which generate light having a wave length distribution mostly in the 185 nm range. When air is passed over an ultraviolet lamp a portion of the oxygen (O 2 ) molecules in the gas are split. The resulting oxygen atoms (O 1 ), seeking stability, attach to oxygen molecules, forming ozone (O 3 ). The output gas from the generator is injected into the water being treated and the ozone in the gas inactivates, by oxidation, organic contaminants. Ozone also produces flocculation of suspended contaminants into clusters that can be more readily removed by passing the flow through an in-line filter. 
         [0004]    Ultraviolet ozone generators have been used in the past to treat circulated water in swimming pools and spas. Two examples of prior art ozone generators designed for use in treating swimming pool water are the “QuikPure2” manufactured and sold by A&amp;A Manufacturing of Phoenix Ariz. and the Paramount “Modular Ozone Generator” described in U.S. Patent Application Publication 2006/0144689A1. However these generators have been limited in their range of applications, have been inefficient in terms of peak ozone production, have been expensive and inconvenient to manufacture and have been difficult to service in the field. The object of the present invention is to overcome these shortcomings. 
       SUMMARY OF THE INVENTION 
       [0005]    An ultraviolet ozone generator including an extruded base having a plurality of channels and an extruded cover that is detachably connected to the base in cooperation with two opposing end caps that engage the channels and enclose one or more ultraviolet light sources in one internal chamber and electronic circuitry to drive and control the light sources in another internal chamber, the end caps, bulbs and circuitry being secured to the base by connections to the channels therein, as more fully described in the claims appended to this specification. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0006]    Most of the accompanying drawings that depict assembled portions of the invention are derived from the same CAD drawings used to guide the actual production of the preferred embodiment described in detail in the following section. 
           [0007]      FIG. 1  is an external view of the preferred embodiment showing the main external features. 
           [0008]      FIG. 2  shows the internal portion of the preferred embodiment with the cover removed to an adjacent position. 
           [0009]      FIG. 3  is an end view of the cover and base in proximate locations and aligned for engagement. 
           [0010]      FIG. 4  is a diagram showing the elements of a simple swimming pool water circulation system and the functional relation of the ozone generator to that system. 
           [0011]      FIG. 5  is a perspective view of the output end of the ozone generator, showing the features of the base, channels, cover, end cap, outlet and optional mounting tabs. 
           [0012]      FIG. 6  is a perspective view of the output end of the ozone generator showing the inner features of the end cap and the relative locations of the ozone outlet, switch assembly, bulbs, ballast, tabs and channels. 
           [0013]      FIG. 7  is a rotated perspective view of the same area shown in  FIG. 6 , with the end cap appearing partially transparent. 
           [0014]      FIG. 8  is a circuit diagram showing the wiring of the components shown in  FIG. 2  and the general location of the baffle that separates the reaction chamber from the circuitry chamber. 
           [0015]      FIG. 9  shows one of two lamp clips used to mount the ultraviolet bulbs to the base. 
           [0016]      FIG. 10  is a detailed view of one of the mounting tabs shown in  FIGS. 1-2  and  5 - 7 . 
           [0017]      FIG. 11  is a sectional view of the ozone outlet conduit showing the flow restrictor and the back flow restrictor located therein. 
           [0018]      FIG. 12  shows the switch assembly (left) and the components thereof (exploded, right). 
           [0019]      FIG. 13  is a plan view of the switch assembly installed in relation to the end cap, with lines added to indicate the location of the cover&#39;s sidewalls and baffle. 
           [0020]      FIG. 14  is a perspective view of the fixed end of the ozone generator showing the inner features of the end cap and the wire retention structures molded as an integral part thereof. 
           [0021]      FIG. 15  is a perspective view of the end of the cover showing the location of the notch that provides clearance for wiring between the internal chambers. 
           [0022]      FIG. 16  is a sectional view taken at section  16 - 16  in  FIG. 15 . 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENT 
       [0023]    Basic Elements 
         [0024]      FIG. 1  provides an overview of the principal structural elements of the preferred embodiment of the present invention. The ozone generator  41  is constructed from an extruded base  1  that is characterized by a plurality of longitudinal channels  8 ,  9 ,  10  and  11  as more fully illustrated in  FIGS. 2-3  and  5 - 7 . An extruded cover  2  extends most of the length of the base I and is enclosed by opposing end caps  3 , which also serve to lock the cover  2  firmly into place on the base  1 . While the base  1  and cover  2  in the preferred embodiment were extruded from aluminum, these components could also be extruded from thermoplastic materials having excellent resistance to ozone and ultraviolet light. 
         [0025]      FIG. 2  provides a perspective view of the internal components and structural elements included in one embodiment of the invention as seen with the cover  2  removed from the base  1 . In this embodiment there are two ultraviolet tubes  13 , each separately connected to the output side of corresponding ballast  14 , which is, in turn, connected to a source of electrical power. For visual simplicity, the wires interconnecting the electrical components are not shown in any of the drawings, except the wiring diagram of  FIG. 8 . 
         [0026]      FIGS. 1 and 2  show the location of an electrical feed-through  5 , which secures and protects the wires connected between an external source of 110 or 220 VAC power and the internal electronics of the ozone generator. An electrical ground lug  6  may be incorporated internally or externally by securing the ground lug  6  at a suitable location along one of the symmetrically arrayed channels  8  or  9  using a screw and nut.  FIGS. 1 and 2  also show the location of an ozone outlet conduit  4 , which will be further described in relation to  FIGS. 4 and 11 . 
         [0027]    Description of Mounting Tabs 
         [0028]    The ozone generator optionally includes adjustable mounting tabs  7  that slide within at least one of the channels  11  that extend along the bottom edges of the base  1 , as best shown in  FIG. 5 . As shown in  FIG. 10 , the tabs  7  are segments of an extrusion that have been punched to form a keyhole  26  to receive a mounting screw or bolt during installation. The tabs  7  also include a rail  25  that is sized to slide smoothly within the channels  11 . The position of the mounting tabs  7  within channels  11  can be easily adjusted in the field, allowing the ozone generator  41  to be mounted on or between points on almost any surface or structure. 
         [0029]    Description of Cover 
         [0030]    Referring to  FIGS. 2 and 3 , the cover  2  includes a co-extruded partition or baffle  16  running its entire length. When the cover  2  is in place over the base  1 , the baffle  16  divides the internal portion of the ozone generator  41  into two separate chambers: a reaction chamber that contains the sources of ultraviolet light and a circuitry chamber that contains the electronic components. 
         [0031]    As best shown in  FIG. 3 , the cover  2  includes a top  19  which transitions through shoulders  20  into opposing sidewalls  21 . Each sidewall  21  terminates in a lower edge  23  and offset flange  22 . The partition or baffle  16  terminates in a twin flange  17 . When the cover  2  is fully engaged over the base I the edges  23  of both sidewalls  21  fit into channels  10  and the bottom surface of the twin flange  17  is in close contact with the upper surface of the base  1 , thereby defining the circuitry and reaction chambers referred to above and shown in  FIG. 3 . 
         [0032]    The cover  2  also includes a number of ribs  24  spaced from the outer portion of the top surface  19  to above the edge  23 . These ribs  24 , which extend over the entire length of the cover  2 , serve a number of purposes: they provide rigidity to the structure, they limit deformation of the extrusion, they provide radiation to dissipate heat generated by the enclosed bulbs and they provide a gripping mechanism for removing and installing the cover  2  on the base  1 . The top surface  19  is preferably flat to receive labeling and other printed or engraved indicia. 
         [0033]    Description of Base 
         [0034]      FIG. 3  also shows a detailed end view of the extruded base  1  with the integrally formed channels  8 ,  9 ,  10  and  11 . There are two sets of these channels symmetrically disposed in relation to the centerline of the base  1 . As described above, channel  11  receives the mounting tabs  7  and channel  10  receives the edges  23  of the cover  2 . Channels  8  and/or  9  are used to secure both of the end caps  3 , the switch assembly  15  the ballasts  14  the ground lug  6  and, as further described in relation to  FIG. 9 , the bulb clips  55  used to detachably mount the bulbs  13  to the base  1 . 
         [0035]    The channels  8  are configured to receive and prevent rotation of either a bolt head or a nut (preferably square). When the head of a bolt is engaged in a channel  8 , the threaded portion of the bolt extends upward through the continuous slot into one of the two chambers that are defined and separated by the baffle  16 . To make a connection the threaded portion of the bolt extends through a slot or aperture in the structure to be secured and a nut, threaded on the end of the bolt, is tightened to secure the structure to the base. Alternatively, a nut can be engaged in channel  8  and a bolt, extending from above the base I can be threaded into the nut to secure the structure. Since channel  8  is deeper than the thickness of a standard nut, a tightened bolt can draw the nut firmly to the top of the channel and the end of the bolt can extend beyond the nut into the lower portion of the channel. 
         [0036]    The channels  9  are relatively shallow and, while they can be used to receive the head of a bolt with its threads extending upward into one of the chambers, they are also used to receive parallel T-rails formed on the bottom of each end cap  3  (not shown). These T-rails allow the end caps  3  to slide into and out of engagement with the cover  3  during manufacture and maintenance of the ozone generator  41 . In all cases the structures to be secured can be located anywhere along the length of the base and the attachment process can be accomplished solely by working from the top of the base  1 , using either a screwdriver or a nut driver. 
         [0037]    The assembly process is facilitated by pre-assembling the nut onto the end of the bolt before sliding the combination into one of the channels  8 . As shown in the drawings, the bases of the end caps  3  and the ballasts  14  are slotted and can be easily connected without disassembling the nut and bolt. Both the switch assembly ( FIG. 12 ) and the lamp clip ( FIG. 9 ), have mounting holes (items numbered  50  and  56  respectively) rather than slots. These components can be easily installed by first loosely assembling a bolt and nut through the mounting hole and then sliding the combination into the desired channel  8  to the desired location on the base  1 . 
         [0038]    Description of Lamps 
         [0039]    In the dual-bulb embodiment of the invention shown in  FIG. 2 , the cover  2  is approximately 17 inches in length. This same configuration can also accommodate a single bulb  13  and single ballast  14  for use in applications requiring a lower volume of ozone output. High intensity ultraviolet bulbs, which are more expensive and are often characterized by shorter useful lives, can be used in both the single-bulb and dual-bulb embodiments. High intensity bulbs generally have the same dimensions as regular bulbs. 
         [0040]    Lower capacity ultraviolet bulbs are also available in shorter lengths. These shorter bulbs can be incorporated into the ozone generator  41  in both a single-bulb and dual-bulb configurations. Both of these shorter configurations dictate the use of a cover  2  that is approximately 11 inches in length. This version of the invention is particularly adapted for use on free-standing spas and hot tubs as well as fish tanks and air-injection systems. Ultraviolet bulbs suitable for use in the present invention are available from a number of domestic and foreign manufacturers and suppliers. For example, the bulbs used in the commercial version of the present invention were supplied by Atlantic Ultraviolet of Hauppauge, N.Y. 
         [0041]      FIG. 9  shows a wire-formed clip  55  that is inexpensive and works well in supporting the ultraviolet bulbs  13  used in various embodiments of the invention. One end of the clip  55  is formed into a connection loop  56  which receives a screw that secures the clip at an appropriate location along one of the channels  8  in base. The other end of the clip  55  is formed into a partial, bulb-retention loop  57  which is characterized by (a) a diameter approximately equal to that of the bulbs to be retained (nominally 0.75 inches), (b) just over 180 degrees of included arc, (c) a spatial orientation that is at ninety degrees with respect to the plane of connection loop  56 , and (d) a short terminal segment  58  that can be slightly displaced to open the loop  57  to release the bulb  13 . 
         [0042]    Since the extruded lengths from which the base  1  and cover  2  are cut typically come in lengths between 12 and 24 feet, individual parts can be cut to the desired length based on actual demand. The end caps  3  work equally well with any of the at least eight alternative configurations possible with available bulbs (normal or high-intensity, regular or short length, single- or dual-bulb). This wide degree of adaptability eliminates the need for multiple special configurations and reduces the costs associated with manufacture and inventory maintenance. 
         [0043]    While light emitting diodes can be fabricated to emit light in the 185 nm range, this form of ultraviolet light source is not currently available at commercial pricing levels. However, when these and other solid state light sources become generally available, they can be readily incorporated into even shorter, less expensive and more efficient embodiments of the present invention, all without the need for retooling. 
         [0044]    Description of Ozone Outlet 
         [0045]    The ozone generator  41  can be used in many different applications. One area of highly effective application involves water circulation systems installed on residential swimming pools.  FIG. 4  shows the simplest form of swimming pool circulation system, which includes a swimming pool  44  from which water is circulated by an electric motor driven pump  42  through a filter  43  and back into the pool. The electric motor is typically controlled by a timer (not shown), which limits operation to certain limited periods during any 24-hour cycle of operation. 
         [0046]    In the general application of  FIG. 4 , the ozone generator  41  is connected to the inlet side of the pump  42  by a conduit or tube  45  which defines a flow path between the two. Suction from the pump draws ozone from the generator  41  into the circulating water were it oxidizes microorganisms, particulates, and other organic matter in the water. The oxidation of these pollutants inactivates living matter and improves filter effectiveness by binding smaller particulates and creating larger, more filterable particles. 
         [0047]    The amount of ozone that is injected into the swimming pool circulation system can be controlled by a simple restrictor inserted in conduit  45  to limit the flow between the generator and the inlet to pump  42 . For example, where the conduit  45  is a tube having a 0.25″ diameter, a flow restrictor  46  having a 0.020″ inside diameter may be inserted into the flow path  45  distal to the generator output. The purpose of the 0.020″ restrictor  46  is to limit the amount of ozone that can be drawn into the circulation system by the pump  42 . If too much ozone is delivered it may result in cavitation at the pump, resulting in a loss of circulation efficiency and possible damage to the pump impeller. If too little ozone is injected into the circulating water, there will not be a sufficient volume to effectively perform the desired oxidization/disinfection processes. 
         [0048]    The cross-sectional view of  FIG. 11  shows a segment of conduit  45 , including the flow restrictor  46 . A back-flow restrictor  47 , having an inside diameter of approximately 0.040″, is also located within the flow path  45 , before it joins with the inlet to pump  42 . The purpose of the 0.040″ restrictor  47  is to prevent water from pulsing into flow path  45  and toward the generator  41  during transient back pressure pulses caused, for example, by the flow inertia immediately following the shut down of pump  42 . Preferably, the two restrictors  46  and  47  are located within approximately 6″ of one another in a short segment of line  4  that extends from the end cap  3  as shown in  FIG. 5 . In the field, an additional length of tubing can be use to connect the ozone outlet  4  to the inlet of the pump  42 . 
         [0049]    Description of Wiring 
         [0050]    The wiring diagram of  FIG. 8  shows the simple interconnection of the bulbs and electrical components of the preferred embodiment shown in the drawings. The layout of  FIG. 8  generally corresponds to the physical location of the corresponding elements shown in  FIGS. 2 ,  5 - 7  and  13 . The electrical source (e.g., 110 or 220 VAC) is connected in parallel across the inputs to the two ballasts  14 , with one line interrupted by the position-sensitive micro switch  35 . The output lines from each of the two separate ballasts are connected to the corresponding bulb inputs. While  FIG. 8  shows a dual-bulb system, the wiring of a single-bulb system is the same, only the leads to and from the second ballast are eliminated. 
         [0051]    The electrical function of the switch  35  is to detect an opening of the enclosure formed by the base  1 , the cover  2  and the end caps  3 . During normal operation, the position-sensing arm or plunger which controls the on/off state of switch  35  is contracted and the switch is in the on or conductive state. The switch  35  remains in this state until the end cap  3  that is in contact with switch  35  is moved slightly outward causing the position sensing arm or plunger to extend toward its normally open position, breaking the circuit between the electrical source and the two ballasts  14 . Switch  35  performs a two-part safety function by detecting when the enclosure is open or about to open and turning off the bulbs  13  in response to the detected condition. Turning off the bulbs  13  terminates the generation of ozone and prevents any eye or skin damage that might result from significant exposure to ultraviolet radiation. 
         [0052]    Description of Switch Assembly 
         [0053]    The switch assembly  15  is generally depicted in  FIGS. 2 ,  6  and  7  and shown in detail in  FIG. 12  and in the plan view of  FIG. 13 . The complete assembly  15  is shown on the left of  FIG. 12  and the three components are shown individually in the exploded view on the right of  FIG. 12 . The micro switch  35  includes an actuator  37  that closes the internal contacts when depressed and opens the internal contacts when extended as shown in  FIG. 12 . In traditional terms this is a normally-open, single-pole, single-throw micro switch. Switch  35  further includes connector points  36  and mounting holes  49 . 
         [0054]    Accurately and positively positioning the switch  35  during assembly of the ozone generator  41  is often sensitive and difficult. To assure precise positioning, the switch  35  is mounted between an upper retainer  38  and a lower retainer  39 . Both of the retainers  38  and  39  include alignment pins  48  that fit closely into mounting holes  49  in the body of switch  35  and prevent lateral and rotational motion between the components. The lower retainer  39  includes a rail  50  that fits and slides in the open slot at the top of channel  8  or  9  on base  1 . 
         [0055]    The switch assembly  15  is secured to base I by extending a screw through the holes  40  in the upper and lower retainers  38  and  39  and securing the screw to a nut retained within one of the channels  8  or  9 . This arrangement allows the switch assembly to be moved within one of the channels to a precise location and then firmly secured by tightening the screw through holes  40 , while the rail  50  prevents transverse and rotational movement. 
         [0056]      FIG. 13  is a plan view of the base  1  with end cap  3  and switch assembly  15  in their final positions. The actuator  37  depressed and the switch  35  is in its conductive state. The central line  51  indicates the installed location of baffle  16 . The two outer lines  54  indicate the location of the sidewall edges  23  of cover  2  ( FIG. 3 ). As can be seen in  FIG. 13 , the internal ribs  31  on end cap  3  extend into the area between the sidewalls  21  of cover  2  and the baffle  16 , closing off the end of cover  2 . When the end cap  3  is slightly moved out of this engagement with the cover  3 , the actuator  37  on switch  35  moves outward, breaking the circuit to the ballasts  14  and turning off the bulbs  13 . 
         [0057]    Description of End Caps 
         [0058]    As seen in  FIG. 6 , the end caps  3  have two sets of internal ribs  31  that closely conform to the inner surfaces of the cover  2  and provide a tight closure of the opening between the ends of the cover  2  and the base  1 . The vertical portions of the ribs  31  in the center of the end cap are spaced apart and define a vertical retention slot that receives the end of the baffle  16 . At the bottom of this retention slot the ribs are offset to form a horizontal slot  33  to receive and retain the flange  17  located at the bottom of baffle  16  ( FIG. 3 ). The ribs  31  are also offset on both sides of the end cap to form slots  32  that receive the flanges  22  extending inward from the sidewalls  21  of the cover  2  ( FIG. 3 ). 
         [0059]    As illustrated in  FIG. 14 , the end cap  3  that includes the electrical feed through  5  also includes internal ribs  31  that closely conform to and engage the inner surfaces of the cover  3 . In  FIG. 14  this end cap further includes adjacent wire retainers  34  that are partial extensions of the two central ribs  30 . Each of the wire retainers  34  includes a hole  29  that receives the electrical wires connecting the bulbs  13  in the reaction chamber to the corresponding baffles  14  in the circuitry chamber. The retainers  34  hold the lamp wires in position when the cover  2  is placed over or removed from the ozone generator  41 . 
         [0060]    In the preferred assembly of the ozone generator  41 , the end cap  3  shown in  FIG. 14  is first engaged on the base  1  by sliding the two parallel T-rails formed on the bottom of the end cap into channels  9  and moving it to the desired position. The end cap is then secured in this position, permanently or semi-permanently, by means of rivets or tamper-proof screws joining the two slotted portions of the end cap firmly to the channel  8  formed in the base  1 . This fixed end cap  3  provides a reference for the placement of other components, particularly the switch assembly  15  and the end cap  3  located at the opposite end of the ozone generator. The precise location of these other components will vary depending on the finished length of the cover  2 , but any variations can be easily accommodated by the longitudinal adjustability made possible by the channel connection system. 
         [0061]    To accommodate the wires passing through holes  29  ( FIG. 14 ) from the circuitry chamber to the reaction chamber, it is necessary to create a notch  18  in the baffle  16 , as shown in the perspective view of  FIG. 15  and in the sectional view of  FIG. 16 . During final assembly of the ozone generator  41 , when the cover  2  is installed over the base  1 , its edges  23  are placed in channels  10  ( FIG. 3 ) and the cover  3  is moved into full engagement over the internal ribs  31  on the end cap  2  shown in  FIG. 14 . The upper portion of baffle  16  is retained between the two central ribs  30  and the notch  18  ( FIGS. 15 and 16 ) provides clearance for the wires passing through holes  29  in wire retainers  34 . The flanges  22  on the cover  2  ( FIG. 3 ) slide into and are retained by slots  32  formed at the bottom of the outer ribs  31 . The slots  32  cooperate with flanges  22  to prevent vertical displacement of this end of the cover  2 . 
         [0062]    When the opposing end cap  3  ( FIGS. 6 and 7 ) is secured in position, corresponding slots  32  and  33  retain flanges  22  and  17  ( FIG. 3 ) and prevent vertical displacement of that end of the cover  2 . The end cap  3  shown in  FIGS. 6 and 7  is fixed to the base  1  by means of two T-rails on the under side of the end cap. These T-rails allow the end cap  3  to move longitudinally in and out of engagement with the cover  2  without becoming detached from the base  1 . When in its final position, this end cap is further secured in position by detachable connections through the two slots and into channels  8 . As the end cap  3  shown in  FIGS. 6 and 7  slides on its T-rails into full engagement with the adjacent end of cover  2 , the actuator  37  on switch  35  is depressed, allowing the bulbs  13  to be energized when the power to the ozone generator is activated. With both end caps  3  secured to the base  1 , displacement of the cover  2  is fully restricted. 
         [0063]    Installation of the ozone generator  41  involves mounting the device in a suitable location using the adjustable tabs  7 , connecting the ozone outlet  4  (which includes the restrictors  46  and  47  shown in  FIG. 11 ) to the ozone injection point ( FIG. 4 ) and connecting the electrical leads to an appropriate electrical source ( FIG. 8 ). Servicing the internal components of the ozone generator  41  can be accomplished by loosening the screws that retain the end cap  3  shown in  FIGS. 6 and 7 , sliding the end cap toward the adjacent end of the base  1 , and disengaging the cover  2  from the opposing end cap  3  shown in  FIG. 14 .