Abstract:
Ionization systems configured with a catalyst-bearing sleeve provide improved filtration while keeping ozone levels within acceptable limits. Modular configurations provide for serviceability and replaceability. System controls monitor particulates, temperature, humidity, and other relevant factors and adjust an ionization level accordingly for optimal performance.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to air purification, and in particular to removal of particulates via ionization. 
       SUMMARY OF THE INVENTION 
       [0002]    Disclosed is an air ionization unit that includes an ozone dampening catalyst surrounding the air ionization tube. The ozone dampening catalyst removes much or all of the ozone created by ionizing molecules in the air. In one embodiment, rather than the air passing by the ionization tube and being ionized in a known manner, air is drawn into an ionization module through a filter that may be contained in the module. The filtered air is then expelled, preferably by a fan, outward into a space between the ionization tube and the ozone dampening catalyst. The air is ionized in a standard manner, and ozone is partially or totally removed by the ozone absorption tube. 
         [0003]    The air ionization unit may be an integral, one-piece unit, so it can be removed and replaced without having to disassemble it. In a preferred embodiment, the air ionization unit has a support plate that mounts directly or indirectly to the outside surface of an air passageway duct or other space (collectively, “duct”) that includes air to be cleaned. The air ionization tube and ozone dampening catalyst preferably extend outward from the support plate and into the air duct. Fasteners on the outside of the air duct can be removed to remove and/or replace the entire air ionization unit. 
         [0004]    The invention may also include a controller that (1) measures the amount of particulate in the air, (2) measures the amount of negative and/or positive ions in the air, (3) measures the amount of ozone in the air, (4) measures the amount of carbon monoxide in the air, (5) measures the air temperature and humidity, and/or (6) adjusts the amount of ions being released into the air based on one or more measured parameters. 
         [0005]    The contents of this summary section are provided only as a simplified introduction to the disclosure, and are not intended to be used to limit the scope of the appended claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    With reference to the following description, appended claims, and accompanying drawings as attached: 
           [0007]      FIG. 1  is an exploded view of an air ionization unit in accordance with embodiments of the invention. 
           [0008]      FIG. 2  is an assembled, perspective side view of the air ionization unit of  FIG. 1 . 
           [0009]      FIG. 3  is an assembled side view of the air ionization unit of  FIG. 1 . 
           [0010]      FIG. 4  is a cross-sectional, side view of the air ionization unit of  FIG. 3  taken along lines A-A. 
           [0011]      FIG. 5  is an end view of the air ionization unit of  FIG. 3 . 
           [0012]      FIG. 6  is the opposite end view of the air ionization unit of  FIG. 3 . 
           [0013]      FIG. 7  is an exploded view of an ozone dampening module according to aspects of the invention. 
           [0014]      FIG. 8  is a perspective, side view of the assembled ozone dampening module of  FIG. 7 . 
           [0015]      FIG. 9  is an exploded view of an ionization module according to aspects of the invention. 
           [0016]      FIG. 10  is an assembled, perspective side view of the ionization module of  FIG. 9 . 
           [0017]      FIG. 11  is an assembled, side view of the ionization module of  FIG. 9 . 
           [0018]      FIG. 12  is a cross-sectional, side view of the ionization module of  FIG. 11  taken along lines A-A. 
           [0019]      FIG. 13  is a rear, perspective view of a control unit according to aspects of the invention. 
           [0020]      FIG. 14  is a front, perspective view of the control unit of  FIG. 13 . 
           [0021]      FIG. 15  is a front view of the control unit of  FIG. 13 . 
           [0022]      FIG. 16  is a side view of the control unit of  FIG. 13 . 
           [0023]      FIG. 17  is a rear view of the control unit of  FIG. 13 . 
           [0024]      FIG. 18  is a perspective, side view of an ionization system in accordance with aspects of the invention with the housing opened. 
           [0025]      FIG. 19  is a perspective, side view of the ionization system according to  FIG. 18  with the control unit and energy converter removed. 
           [0026]      FIG. 20  is a partial exploded view of the ionization system of  FIG. 18  showing the ionization module removed from the housing, and the housing removed from a support plate. 
           [0027]      FIG. 21  shows a front, perspective view of an ionization system according to the invention. 
           [0028]      FIG. 22  shows a display that may be used in accordance with aspects of the invention. 
           [0029]      FIG. 23  shows a sensor that may be used in accordance with aspects of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    The following description is of various exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the present disclosure in any way. Rather, the following description is intended to provide a convenient illustration for implementing various embodiments including the best mode. As will become apparent, various changes may be made in the function and arrangement of the elements described in these embodiments without departing from the scope of the appended claims. 
         [0031]    For the sake of brevity, conventional techniques for ionization, air filtration, ozone removal, and/or the like may not be described in detail herein. Furthermore, the connecting lines shown in various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical ionization system or related methods. 
         [0032]    Prior approaches to air filtration and/or ionization suffer from various drawbacks. For example, certain air ionization systems, in order to avoid releasing an unacceptable level of ozone, generate ionization levels that are insufficient to fully clean and/or sanitize a particular air stream. Moreover, other air ionization systems have suffered from a lack of configurability and/or intelligent control. Yet other air ionization systems have been complex, expensive, and/or lacking in modular configuration and/or serviceability. These and other drawbacks of prior approaches may remedied by principles of the present disclosure. 
         [0033]    Turning now to  FIGS. 1 through 6 , a module  100  for ionizing air is shown. Module  100  as shown preferably has an end cap or “base”  102 , an adapter  104 , a coupler  106 , an ion dispenser  108 , a tube  110 , an outer electrode  112 , and an inner electrode  114 . Base  102  is preferably comprised of any suitable plastic, for example injection-molded ABS (but not ABS-PC) although any suitable material may be used. The purpose of base  102  is to receive coupler  106 , ion dispenser  108 , and tube  110 . 
         [0034]    Coupler  106  has a first end  105 , a second end  107 , an outer surface  106 A, and a passageway  106 B extending therethrough. In some embodiments, coupler  106  comprises a hollow aluminum rod. Moreover, coupler  106  may comprise a solid bar with an internal thread on each end. Coupler  106  may be configured to conduct electricity. 
         [0035]    Adapter  104  as shown is a threaded shaft that bases through an opening (not shown in these Figures) of second end  118  of base  102  and is threadingly received in a passageway  106 B at the first end  105  of coupler  106 . The opening in second end  118  may also be threaded so as to threadingly receive adapter  104 . In the preferred embodiment shown, adapter  104  is a threaded shaft with a first end  104 A and a second end  104 B. A nut  104 C is threadingly received on the threaded shaft, end  105  of coupler  106  is aligned with the opening on the inside of second end  118 . First end  104 A passes through the opening and is threadingly received in passageway  106 B of coupler  106  to retain coupler  106  against second end  118 . In some exemplary embodiments, adapter  104  may comprise a solid stainless steel adapter with threaded ends and a central integral hex feature to facilitate rotation thereof. 
         [0036]    An ion dispenser (also called an “umbrella shaped conductor”)  108  is attached to second end  107  of coupler  106 . In various exemplary embodiments, ion dispenser  108  may be configured with an umbrella-like shape. However, ion dispenser  108  may be configured with any suitable shape, as desired. Ion dispenser  108  operates to dispense electricity into inner electrode  114 . Ion dispenser  108  as shown in this preferred embodiment is comprised of stainless steel (for example, stainless steel having a thickness of between about 0.006 inches and about 0.015 inches), has a top  108 A for attachment to coupler  106 , and a plurality of downward extending fingers  108 B. In this preferred embodiment, ion dispenser  108  is attached to coupler  106  by aligning an opening in top  108 A with passageway  106 B at end  107  of coupler  106 . Then fastener  113 , which as shown is a bolt, is passed through opening  108 C and threaded into passageway  106 B. A lock washer  113 A may be positioned between top  108 A and the head of fastener  113 . 
         [0037]    Inner electrode  114  typically comprises a rolled perforated aluminum sheet, but may comprise any suitable material or combination of materials configured to act as a first electrode for purposes of ionization. 
         [0038]    Outer electrode  112  typically comprises a tubular stainless steel wire mesh, for example a 0.008 in diameter Type 316 stainless steel wire mesh configured with a 20×20 per square inch grid. However, outer electrode  112  may comprise any suitable material or combination of materials configured to act as a second electrode for purposes of ionization. 
         [0039]    A tube  110  is preferably glass (for example, comprised of borosilicate) and retains coupler  106  and ion dispenser  108 . Tube  110  is also operative to insulate inner electrode  114  from outer electrode  112  and thus permit the development of a voltage potential therebetween in order to facilitate ionization. Tube  110  has a first, open end  110 A, an outer surface  110 B, and a second end  110 C. Preferably, after cap  102 , coupler  106 , and ion dispenser  108  are assembled, inner electrode  114  is placed within tube  110 , the first end  110 A of tube  110  is positioned over ion dispenser  108  and coupler  106 , and is received in cap  102  in a snug to slightly loose fit. Outer electrode  112 , which has a first end  112 A, an outer surface  112 B, a second end  112 C, and an inner passage  112 D, is positioned over tube  110 . In the preferred embodiment shown, outer electrode  112  does not cover second end  110 C of tube  110  or extend to cap  102 . 
         [0040]    In the preferred embodiment, when module  100  is assembled, coupler  106  and ion dispenser  108  are positioned approximately 50-60% inside the length of tube  110 . In this manner, electrical current is delivered to approximately the center of inner electrode  114 . 
         [0041]    With reference now to  FIGS. 7 and 8 , an ozone removal assembly  400  comprises a tubular inner wall  406 , a tubular outer wall  410 , and a pair of ends  404 . Inner wall  406 , outer wall  410 , and ends  404  may be coupled together to form a container for a catalyst media  408 . In an exemplary embodiment, inner wall  406  and outer wall  410  are coupled to a first end  404  (for example, via RTV silicone). First end  404  is disposed on a surface, and the space between inner wall  406  and outer wall  410  is filled with catalyst media  408 . Second end  404  is then coupled to inner wall  406  and outer wall  410 , securing catalyst media  408  in the resulting assembly. Inner wall  406  and outer wall  410  are configured to be at least partially permeable to air. For example, inner wall  406  and outer wall  410  may comprise rolled stainless steel mesh screen or the like. 
         [0042]    In various exemplary embodiments, catalyst media  408  is configured to convert, neutralize, and/or otherwise remove and/or reduce an undesirable compound in the air, for example ozone. Catalyst media  408  may also be referred to as a “catalyst bed”, “reaction bed”, “ozone destruction catalyst”, and/or the like. Catalyst media  408  may be granulated or otherwise shaped or formed to form part of ozone removal assembly  400 . Catalyst media  408  typically comprises manganese dioxide, copper oxide, and/or the like, or combinations of the same. In some embodiments, catalyst media  408  comprises Carulite  200  offered by Cams Corporation (Peru, Ill.). However, any suitable catalyst configured to neutralize and/or remove ozone from an airstream may be utilized. 
         [0043]      FIGS. 9 through 12  show an ionization and filter cartridge  200  according to a preferred embodiment of the invention. Cartridge  200  includes previously described module  100 . It also generally includes a housing and support structure, a fan assembly (or fan)  300 , an ozone removal assembly  400 , and an air filter  450 . Air filter  450  may comprise polypropylene, natural fibers, and/or the like. Air filter  450  is operative to reduce the amount of dust and other airborne particulates entering ozone removal assembly  400 , as accumulation of dust on catalyst media  408  reduces its efficacy. 
         [0044]    The support structure of cartridge  200  includes a section for supporting module  100  and ozone removal assembly  400 , and a section for supporting fan assembly  300 , wherein, in the preferred embodiment, when cartridge  200  is fully assembled, it is a single unit that may be removed and replaced when desired. 
         [0045]    Turning now to  FIGS. 13 through 23 , an exemplary ionization and filtration system  600  utilizes module  100  and cartridge  200 . System  600  further comprises electronic controls  500 . In various exemplary embodiments, electronic controls  500  are configured to control module  100  to generate an ionization level in excess of 66% negative ions; a negative ionization level significantly higher than previous systems. In this manner, module  100  generates a net excess of negative ions, and thus improved air filtration and clearing is achieved. In contrast, prior ionization systems typically generated approximately 50% positive ions and 50% negative ions, thus achieving limited efficacy as many ions quickly recombined and/or neutralized one another and were thus no longer available for air filtration and clearing. In some exemplary embodiments, electronic controls  500  pulse power convertors  520  in a manner suitable to positively bias power convertors  520  with respect to circuit ground; this results in generation of excess negative ions in module  100 . 
         [0046]    Additionally, electronic controls  500  may further comprise and/or communicate with various inputs (e.g., sensors) which monitor ionization levels, the density of particulates in the air, the ambient humidity, temperature, and/or the like. Based at least in part on the sensor inputs, electronic controls  500  adjust the operation of system  600  to achieve a desired level of filtration, ionization level, and/or the like. 
         [0047]    With reference now to  FIGS. 13 through 17 , electronic controls  500  typically comprise various electronic components, for example: a printed circuit board; RF module  510  for wireless communication via a suitable wireless protocol or protocols (for example, IEEE 802.11 (“WiFi”), IEEE 802.15.4 (“ZigBee”), Bluetooth, GSM, and/or the like); power convertor(s)  520  for creating, modulating, transforming, and/or converting AC and/or DC current, for example for use in operating module  100  to produce ions; wired communication and/or input programming port(s)  530 ; together with various resistors, capacitors, inductors, transistors, diodes, light-emitting diodes, switches, traces, jumpers, fuses, amplifiers, antennas, and so forth as are known in the art. In various exemplary embodiments, electronic controls  500  further comprise a microprocessor and/or microcontroller (for example, an 8-bit or 16-bit microcontroller, such as the PIC16F1503T-I/SL microcontroller offered by MicroChip Corporation of Chandler, Ariz.). The microcontroller is operative for algorithmic (i.e., pre-programmed) operation, as well as responsive (i.e., pursuant to sensor inputs, communications, etc) operation of system  600 . 
         [0048]    In one operating mode, electronic controls  500  are configured to operate module  100  at an 80% duty cycle (for example, 4 minutes in an ion generation mode, followed by one minute powered down, followed by 4 minutes in an ion generation mode, and so forth). In another operating mode, electronic controls  500  are configured to operate module  100  at a 100% duty cycle (always on). However, any suitable duty cycle may be utilized. 
         [0049]    In various exemplary embodiments, electronic controls  500  are configured to generate up to 6000 volts at frequencies between 1 kHz and 2 kHz for use in ionization. Electronic controls  500  typically draw between about 700 milliamps and about 900 milliamps. Power supplied to module  100  via electronic controls  500  may be digitally managed, for example via a pulse width modulation (PWM) technique utilizing a fixed voltage and variable duty cycle. Moreover, operating parameters for electronic controls  500  may be remotely managed. 
         [0050]    In various exemplary embodiments, electronic controls  500  employ a “white noise” mode wherein power convertors  520  are turned on and/or off via randomized timing. In this manner, transformer “whine” or “power line hum” may be reduced and/or eliminated, making the resulting system quieter and/or more suitable for indoor use. 
         [0051]    In yet another operating mode, electronic controls  500  are configured to operate system  600  in an “ozone depletion mode” whereby module  100  is powered down and does not create ionization, but air is still passed through catalyst media  408 , for example responsive to operation of fan assembly  100  (and/or as a result of ambient airstream movement, for example in an HVAC duct). In this manner, system  600  is operative to remove ozone from the ambient air. 
         [0052]    In various exemplary embodiments, electronic controls  500  monitor the performance of module  100  and/or ozone removal assembly  400 , and may signal when a component of system  600  needs replacing (for example, due to deterioration of ionization components in module  100 , due to dust accumulation on catalyst media  408  in module  400 , and/or the like). 
         [0053]    Electronic controls  500  are configured to monitor and control various operational characteristics of system  600 , for example for safety. In various embodiments, electronic controls  500  monitor fan  300  speed and current draw, as well as module  100  voltage and current draw. System  600  may be shut down and/or restarted if an anomaly is detected. Additionally, electronic controls  500  may monitor status and error conditions, turn an ozone depletion mode on or off, monitor temperature limits for operation, and/or adjust a duty cycle associated with operation of module  100 . 
         [0054]    With reference now to  FIGS. 18 through 21 , system  600  may be configured to be installed in a ventilation duct, for example an existing HVAC duct of a building. System  600  may be installed in connection with a new build, or as a retrofit. 
         [0055]    While various exemplary embodiments of system  600  may be discussed in the context of a residential HVAC installation, it will be appreciated that embodiments of the invention may be deployed in a wide variety of form factors, installation locations, and uses. For example, system  600  may be configured as: a desktop unit for placing on an office desk; a freestanding unit (for example, similar in form factor to a tower-style fan); a unit for installation in a vehicle such as an automobile, bus, or airplane; or a high-volume unit for use in connection with a hospital, school, food processing plant, restaurant, and/or the like. In particular, system  600  may desirably be utilized to sanitize and deodorize air that is exposed to or contains strong-smelling organic contaminants, reducing and/or eliminating undesirable odors. 
         [0056]    In some embodiments, with reference to  FIG. 22  system  600  may further comprise a control panel  700 . Control panel  700  comprises a display and various inputs, buttons, and the like. Control panel  700  is in wired and/or wireless communication with control electronics  500 . Via control panel  700 , a user may view statistics regarding operation of system  600 , give commands to system  600 , view error messages or other system  600  communications, and the like. 
         [0057]    In various embodiments, with reference to  FIG. 23  system  600  may further comprise one or more remote sensors  800 . Remote sensor  800  is in wired and/or wireless communication with control electronics  500 . Remote sensor  800  comprises various sensors, for example a temperature sensor, particulate sensor, ozone sensor, carbon monoxide sensor, humidity sensor, and/or the like. Responsive to information received from remote sensor  800 , control electronics  500  may modify operation of system  600 , for example turning module  100  on or off, turning fan  300  on or off, and/or the like. For example, when remote sensor  800  reports ambient ozone above a target threshold, control electronics  500  may operate system  600  in an ozone depletion mode for a period of time until ambient ozone is below a target threshold. Likewise, when remote sensor  800  reports that particulates are above a target threshold, control electronics  500  may increase the duty cycle of module  100  in order to generate increased ionization and thus increase the rate of particulate removal. Remote sensor  800  may be battery powered, or may be configured to be plugged into a power outlet. Multiple sensors  800  may be utilized to provide information regarding an operational environment to control electronics  500 . 
         [0058]    In various exemplary embodiments, operating parameters for system  600  may be monitored and changed remotely, for example via wireless communication. Changes for system  600  may be supplied via a connected software application operable on a tablet or smartphone, via control panel  700 , via a universal serial bus connection to control electronics  500 , and/or the like. 
         [0059]    While the principles of this disclosure have been shown in various embodiments, many modifications of structure, arrangements, proportions, the elements, materials and components, used in practice, which are particularly adapted for a specific environment and operating requirements may be used without departing from the principles and scope of this disclosure. These and other changes or modifications are intended to be included within the scope of the present disclosure and may be expressed in the following claims. 
         [0060]    In the foregoing specification, the invention has been described with reference to various embodiments. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the specification is to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention. Likewise, benefits, other advantages, and solutions to problems have been described above with regard to various embodiments. However, benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or element of any or all the claims. 
         [0061]    As used herein, the terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Also, as used herein, the terms “coupled,” “coupling,” or any other variation thereof, are intended to cover a physical connection, an electrical connection, a magnetic connection, an optical connection, a communicative connection, a functional connection, and/or any other connection. When language similar to “at least one of A, B, or C” or “at least one of A, B, and C” is used in the claims, the phrase is intended to mean any of the following: (1) at least one of A; (2) at least one of B; (3) at least one of C; (4) at least one of A and at least one of B; (5) at least one of B and at least one of C; (6) at least one of A and at least one of C; or (7) at least one of A, at least one of B, and at least one of C. The word “exemplary” is used herein to mean “serving as an example, instance or illustration”. Any embodiment described as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments.