Patent Publication Number: US-10322205-B2

Title: Flexible ion generation device

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 15/412,825 filed Jan. 23, 2017 and entitled “FLEXIBLE ION GENERATION DEVICE”, which claims the benefit of U.S. Provisional Patent Application No. 62/281,318, filed on Jan. 21, 2016, and entitled “FLEXIBLE ION ELECTRODE,” the contents of which are incorporated in full by reference herein. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to the field of air treatment, and more particularly to the treatment of air using ionization that is produced using a flexible ion generation device for dispersing the ions into a conduit or a duct. 
     BACKGROUND OF THE INVENTION 
     Air and other fluids are commonly treated and delivered for a variety of applications. For example, in heating, ventilation and air-conditioning (HVAC) applications, air may be heated, cooled, humidified, dehumidified, filtered or otherwise treated for delivery into residential, commercial or other spaces. 
     Needs exist for improved systems and methods of treating and delivering purified air for these and other applications. It is to the provision of improved systems and methods meeting these needs that the present invention is primarily directed. 
     BRIEF SUMMARY OF THE INVENTION 
     According to an embodiment of the present invention, the flexible ion generation device includes at least one dielectric layer, at least one trace having a first end and a second end, the at least one trace is engaged to the at least one dielectric layer, and at least one emitter engaged to the trace for emitting ions. 
     According to another embodiment of the present invention, the flexible ion generation device includes an emitter with a first end and a second end, the first end of the emitter is engaged to the trace and the second end extends away from the trace and contains a point for emitting ions. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a trace composed of copper. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a first dielectric layer and a second dielectric layer with a trace disposed therebetween. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a connector engaged to the first end and the second end of the trace. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a brush containing a plurality of bristles, wherein the brush is engaged to the trace. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a brush, containing a plurality of bristles, wherein the brush is engaged to the emitter. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a first dielectric layer having a top portion, a bottom portion, a top side, a bottom side, a left side, and a right side, and a second dielectric layer having a top portion, a bottom portion, a top side, a bottom side, a left side, and a right side. A trace is positioned between the first dielectric layer and the second dielectric layer. A plurality of emitters are engaged to the trace and extend outward from the trace to either the top side or the bottom side of the first dielectric layer and the second dielectric layer. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a point positioned on the emitter for emitting ions. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a second dielectric layer with a plurality of openings that are located over a portion of the emitter for allowing ions to be emitted. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a brush engaged to the trace for emitting ions. 
     According to yet another embodiment of the present invention, the flexible ion generation device includes a second trace engaged to the top portion of the second dielectric layer and a third dielectric layer having a top portion and a bottom portion, wherein the bottom portion of the third dielectric layer is engaged to the second trace and the top portion of the second dielectric layer. 
     According to yet another embodiment of the present invention, the flexible ion generation device wherein the device is mounted adjacent a heat exchanger located within a conduit. 
     According to yet another embodiment of the present invention, a method of producing ions that includes providing a flexible ion generation device that includes at least one dielectric layer, at least one trace having a first end and a second end, the at least one trace is engaged to the at least one dielectric layer, and at least one emitter engaged to the trace for emitting ions. The flexible ion generation device is mounted within a conduit, and positioning the at least one emitter within the airflow within the conduit. 
     According to yet another embodiment of the present invention, a method of producing ions that includes a power source engaged to at least one connector. 
     According to yet another embodiment of the present invention, a method of producing ions that includes mounting the flexible ion generation device after a filter and before a cooling coil. 
     According to yet another embodiment of the present invention, a method of producing ions that includes at least one brush engaged to the emitter for dispensing ions. 
     According to yet another embodiment of the present invention, a method of producing ions that includes a connector engaged to the first end and the second end of the at least one trace. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention is illustrated and described herein with reference to the various drawings, in which like reference numbers denote like method steps and/or system components, respectively, and in which: 
         FIG. 1  is a top view of one embodiment of the flexible ion generation device; 
         FIG. 2  is an exploded view of one embodiment of the flexible ion generation device; 
         FIG. 3  is a top view of another embodiment of the flexible ion generation device; 
         FIG. 4  is a top view of another embodiment of the flexible ion generation device; 
         FIG. 5  is a cross-sectional view of another embodiment of the flexible ion generation device; 
         FIG. 6  is a cross-sectional view of another embodiment of the flexible ion generation device; and 
         FIG. 7  is a top perspective view of another embodiment of the flexible ion generation device. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention may be understood more readily by reference to the following detailed description of the invention taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Any and all patents and other publications identified in this specification are incorporated by reference as though fully set forth herein. 
     Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. 
     Referring now specifically to the drawings, a flexible ion generation device is described herein and illustrated in  FIG. 1  and is shown generally at reference numeral  10 . The flexible ion generation device  10  has at least a first dielectric layer  12  and, optionally, a second dielectric layer  14 . The first dielectric layer  12  contains a top portion, a bottom portion, a top side, a bottom side, a left side, and a right side, wherein the top side and the bottom side are opposed to each other and the left side and the right side are opposed to each other. The second dielectric layer  14  contains a top portion, a bottom portion, a top side, a bottom side, a left side, and a right side, wherein the top side and the bottom side are opposed to each other and the left side and the right side are opposed to each other. 
     In one embodiment, the flexible ion generation device  10  includes a first dielectric layer  12  having a trace  16  disposed thereon. In another embodiment, the flexible ion generation device  10  includes a first dielectric layer  12  and a second dielectric layer  14  having a trace  16  disposed therebetween (the trace  16  will be considered a first trace when more than one trace is utilized with two or more dielectric layers). The trace  16  has a first end and a second end. The flexible ion generation device  10  may have one or more traces  16 , such as copper traces, positioned on the top portion of the first dielectric layer  12 . The bottom portion of the second dielectric layer  14  is formed over the trace  16  and coupled to the first dielectric layer  12 . It will be appreciated that while the trace  16  as illustrated in  FIG. 1  is positioned on the top portion of the first dielectric layer  12 , the trace  16  may also be positioned on the bottom side of the second dielectric layer  14 , and the first dielectric layer  12  is formed over the trace  16  and coupled to the second dielectric layer  14 . 
     As illustrated in  FIG. 1 , the trace  16  extends longitudinally along the length of the flexible ion generation device  10 . In other words, the trace  16  extends from the left side to the right side of the first dielectric layer  12  and the second dielectric layer  14 . The trace  16  contains a first end and a second end, whereby the first end is disposed adjacent the right side of the first dielectric layer  12  and second dielectric layer  14  and the second end is disposed adjacent the left side of the first dielectric layer  12  and the second dielectric layer  14 . The first end and the second end of the trace  16  may extend beyond the right side and left side of the first dielectric layer  12  and the second dielectric layer  14 . A conductive pad or connector  18  may be disposed on the first end and/or the second end of the trace  16 . The connector  14  is engaged to a power supply for supplying power to the flexible ion electrode  10 , and more specifically the trace  16 . 
     An emitter  20  may be engaged or etched into the trace  16 . As illustrated, the emitter  20  extends to at least the first side and/or second side of the flexible ion electrode  10 . As illustrated in  FIGS. 1 and 2 , the emitter  20  extends to the top side and/or the bottom side of the first dielectric layer  12  and second dielectric layer  14 . The emitter  20  extends from the trace  16  to either the top side or bottom side of the first dielectric layer  12  and the second dielectric layer  14 . All emitters  20  of the trace can extend to the same side of the dielectric layer, may alternate sides of the dielectric layer, or may extend to different sides of the dielectric layer at different intervals. The first end of the emitter  20  is etched into the trace  16  and the second end of the emitter  20  extends to a point  22 . As illustrated, the emitter  20  at the second end has a gradually reducing width that terminates at a sharp point  22 , allowing ions to flow therefrom. The point  22  of the emitter  20  is not connected, coupled, or engaged to the first dielectric layer  12  and second dielectric layer  14  and may extend outwards from these layers ( 12 ,  14 ). In other words, the emitter  20  and/or point  22  may extend beyond the top side or bottom side of the first dielectric layer  12  or and second dielectric layer  14 . The point  22  may be coated or plated with a corrosion resistant layer such as gold or other coating material. 
     The point  22  disposed on the second end of the emitter  20  allows ions to flow therefrom. The trace  16  contains at least one emitter  20 , preferably at least two emitters  20 , and more preferably a plurality of emitters  20 . It is important to note that the first dielectric layer  12  and the second dielectric layer  14  does not cover the point  22 , thus allowing ions to flow from the point  22  and into the surrounding area. The dielectric layers ( 12 ,  14 ) adjacent the point may be cut-away, pulled back, or otherwise removed, allowing ions to freely flow from the end of the point  22 . In another alternative embodiment, only one dielectric layer may be cut-way, pulled back, or otherwise removed from the point  22  of the emitter. For example and as illustrated in  FIGS. 2 and 3 , the trace  16  and emitter  20  are disposed on the top portion of the first dielectric layer  12 , and the second dielectric layer  14  is formed over the trace  16  and emitter  20  and coupled to the first dielectric layer  12 . The point  22  of the emitter  20  does not extend outward from the first dielectric layer  12  and second dielectric layer  14 . Instead, the portion of the second dielectric layer that would be cover or be over top the point  22  is cut-away, pulled back, or otherwise removed, forming an opening  24  and allowing ions to emit from the point and into the surrounding area. 
     In another alternative embodiment, the second dielectric layer  14  may be pre-cut with a portion removed from the top side and/or bottom side in the area where the second dielectric layer  14  will be adjacent or overtop the point  22  forming an opening  24 . Therefore, when the second dielectric layer  14  is formed over the trace  16  and emitter  20 , the opening  24  is adjacent the point  22 , wherein the second dielectric layer  14  does not cover the point  22 . In another alternative embodiment, the first dielectric layer  12  and second dielectric layer  14  both are precut with the portion of the respective layer ( 12 ,  14 ) that may be adjacent or overtop the point  22  are removed forming openings  24 . Therefore, when the trace  16  and emitter  20  are engaged to the top portion of the first dielectric layer  12 , the point  22  is positioned within the opening  24 , such that the first dielectric layer  12  will not cover the point  22  and the point  22  is within the opening  24 . As the second dielectric layer  14  is formed over the trace  16  and emitter  20 , the opening  24  is placed adjacent the point  22 , so that the second dielectric layer  14  does not cover the point  22 . 
     An insulating jacket  24  may be positioned over at least a portion of the flexible ion generation device  10 . In the cross section shown in  FIG. 5 , the insulating jacket may encompass the first dielectric layer  12  and second dielectric layer  14  (including trace  16  and a portion of the emitter  20  contained therein). The insulating jacket  24  may surround and protect the dielectric layers ( 12 ,  14 ), including the trace  16  and emitter  20 . It should be noted, the insulating jacket  24  does not cover the point  22 . 
     In another alternative embodiment and as shown in  FIG. 5 , the flexible ion generation device  10  may include a second trace  28  and a third dielectric layer  30  (in this embodiment the trace  16  becomes the first trace). The third dielectric layer  30  contains a top portion, a bottom portion, a top side, a bottom side, a left side, and a right side, wherein the top side and the bottom side are opposed to each other and the left side and the right side are opposed to each other. 
     In this embodiment, the second dielectric layer  14  and third dielectric layer  30  contain the second trace  28  therebetween (and the first trace  16  is disposed between the first dielectric layer  12  and the second dielectric layer  14 ). The second trace  28  has a first end and a second end. The second trace  28  is positioned on the top portion of the second dielectric layer  14 . The bottom portion of the third dielectric layer  30  is formed over the second trace  28  and coupled to the second dielectric layer  14 . It will be appreciated that while the second trace  28  may be positioned on the top portion of the second dielectric layer  14 , the second trace  28  may also be positioned on the bottom side of the third dielectric layer  30 , and the second dielectric layer  14  is formed over the second trace  28  and coupled to the third dielectric layer  30 . 
     As illustrated in  FIG. 4 , the second trace  28  extends longitudinally along the length of the flexible ion generation device  10 . In other words, the second trace  28  extends from the left side to the right side of the second dielectric layer  14  and the third dielectric layer  30 . The second trace  28  contains a first end and a second end, whereby the first end is disposed adjacent the right side of the second dielectric layer  14  and third dielectric layer  30  and the second end is disposed adjacent the left side of the second dielectric layer  14  and third dielectric layer  30 . The first end and the second end of the second trace  28  may extend beyond the right side and left side of the second dielectric layer  14  and third dielectric layer  30 . A conductive pad or connector  18  may be disposed on the first end and/or the second end of the second trace  28 . The connector  14  is engaged to a power supply for supplying power to the flexible ion electrode  10 , and more specifically, the first trace  16  and second trace  28 . 
     An emitter  20  may be engaged or etched into the second trace  28 . As illustrated, the emitter  20  extends to at least the first side and/or second side of the flexible ion electrode  10 . As illustrated in  FIG. 5 , the emitter  20  extends to the top side and/or the bottom side of the flexible ion generation device  10 . The emitter  20  extends from the second trace  28  at an angle of about 90° to either the top side or bottom side of the flexible ion generation device  10  and away from the second trace  28 . The first end of the emitter  20  is etched into the second trace  28  and the second end of the emitter  20  extends to a point  22 . The point  22  of the emitter  20  is not connected, coupled, or engaged to the second dielectric layer  14  and third dielectric layer  30  and extends outwards from these layers ( 14 ,  30 ). 
     The point  22  disposed on the second end of the emitter  20  allows ions to flow therefrom. The second trace  28  contains at least one emitter  20 , preferably at least two emitters  20 , and more preferably a plurality of emitters  20 . It is important to note that the second dielectric layer  14  and third dielectric layer  30  does not cover the point  22 , thus allowing ions to flow from the point  22  and into the surrounding area. The dielectric layers ( 14 ,  30 ) adjacent the point may be cut-away, pulled back, or otherwise removed, allowing ions to freely flow from the end of the point  22 . The emitter  20  etched into the second trace  28 , extends outward from the second trace  28  and in an opposite direction than the emitter  20  of the first trace  16  extends. In other words, the emitter  20  of the first trace  16  and the emitter  20  of second trace  28  extend in opposite directions and towards opposite sides of the respective dielectric layer ( 14 , 30 ) as illustrated in  FIG. 5 . 
     In another alternative embodiment, only one dielectric layer may be cut-way, pulled back, or otherwise removed from the point  22  of the emitter  20 . For example and as illustrated in  FIG. 5 , the second trace  28  and emitter  20  are disposed on the top portion of the second dielectric layer  14 , and the third dielectric layer  30  is formed over the second trace  28  and emitter  20  and coupled to the second dielectric layer  14 . The point  22  of the emitter  20  does not extend outward from the second dielectric layer  14  and the third dielectric layer  30 . Instead, the portion of the third dielectric layer  30  that would cover or be over top the point  22  is cut-away, pulled back, or otherwise removed, forming an opening  24  and allowing ions to emit from the point and into the surrounding area. 
     In another alternative embodiment, the third dielectric layer  30  may be pre-cut with a portion removed from the top side and/or bottom side in the area where the third dielectric layer  30  will be adjacent or overtop the point  22  forming an opening  24 . Therefore, when the third dielectric layer  30  is formed over the trace  16  and emitter  20 , the opening  24  is adjacent the point  22 , wherein the third dielectric layer  30  does not cover the point  22 . The second dielectric layer  14  and the third dielectric layer  30  both are precut with the portion of the respective layer ( 14 ,  30 ) that may be adjacent or overtop the point  22  are removed forming openings  24 . Therefore, when the trace  16  and emitter  20  are engaged to the top portion of the second dielectric layer  14 , the point  22  is positioned within the opening  24 , such that the second dielectric layer  14  will not cover the point  22  and the point  22  is within the opening  24 . As the third dielectric layer  30  is formed over the second trace  28  and emitter  20 , the opening  24  is placed adjacent the point  22 , so that the third dielectric layer  30  does not cover the point  22 . Additionally, both sides of the third dielectric layer  30  may have openings on the top side and bottom side, so that the third dielectric layer  30  does not cover the point  22  of the first trace  16 . 
     An insulating jacket  24  may be positioned over at least a portion of the flexible ion generation device  10 . The insulating jacket may encompass the first dielectric layer  12 , second dielectric layer  14 , and third dielectric layer  30  (including the first trace  16 , the second trace  28 , and a portion of the emitters  20  contained therein). The insulating jacket  24  may surround and protect the dielectric layers ( 12 ,  14 ,  30 ), including the trace  16  and emitter  20 . It should be noted, the insulating jacket  24  may surround and protect the flexible ion generation device  10 , while leaving the points  22  unobstructed for allowing the ions to flow freely and the connectors  18  to facilitate coupling of the flexible ion generation device  10  to a power supply. 
     In other alternative embodiments of the present invention, any number of dielectric layers may be used with or without a conducting trace in-between each dielectric layer. 
     The dielectric layer may be a polyamide tape, a silicon tape, or the like that has dielectric properties. One suitable tape sold by DuPont is Kapton®. The traces may be formed from any substance that can conduct electricity, such as metal, nickel, gold, copper, or copper with nickel/gold plating. 
     In another alternative embodiment, the present invention consists of first dielectric layer  12  adjacent a first trace  16  that has a top portion and a bottom portion. The bottom portion of the first trace  16  is connected to the top portion of the first dielectric layer  12  and the top portion of the first trace  16  is engaged to a metal object that is grounded to ground the flexible ion generation device  10 . 
     The connectors  18  of the trace ( 16 ,  28 ) are engaged to a power supply providing alternating current or direct current, with constant or varying frequency, constant or varying voltage and constant or varying current. Multiple flexible ion electrodes  10  may be engaged to each other. In this arrangement, each flexible ion generation device includes a first connector and a second connector, and the second connector of a first flexible ion electrode and the first connector of a second flexible ion electrode are engaged to each other. In one example, a copper trace is disposed on the second connector and first connector for selectively securing the first flexible ion electrode and second flexible ion electrode together. Alternatively, any other conducting metal, composition, or substance may be used. 
     In another alternative embodiment, a brush  32  may be engaged to the trace ( 16 ,  28 ) or the emitter  20 , as shown in  FIGS. 8 and 9 . The brush  32  contains a cap  34  and a plurality of bristles  36  that extend outwardly away from the brush  32 . The brush  32  and its bristles may be made of any material that conducts electricity. The cap  34  is preferably composed of metal that conducts electricity and retains the bristles  36  within an interior cavity of the cap  34 . The cop  34  may be soldered to the trace ( 16 ,  28 ) or emitter  20 , allowing electrical current to flow from the trace ( 16 ,  28 ) or emitter  20 , through the cap  34 , and outward through the bristles  36  by dispensing ions from the bristles  36  to the surrounding area. 
     In one embodiment, the bristles of the brush  32  are composed of a thermoplastic polymer imbedded with conductive material that allows the polymer to conduct electricity. For example, the bristles of the brush  32  may be composed of polypropylene or polyethylene and impregnated with carbon. Generally, the bristles of the brush  32  may contain between about 20 to about 80 wt % polypropylene copolymer or polyethylene copolymer, between about 5 to about 40 wt % talc, and from about 5 to 40 wt % carbon black. However, any other resistive, inductive, reactive or conductive plastic or non-metallic material may be utilized for the bristles of the brush  32 . The flexible ion generation device  10  may include a stiffening element within the device  10  or located at an end of one of the dielectric layers ( 12 ,  14 ,  30 ). The stiffening element may include one or more dielectric layers affixed to an adjacent dielectric layer within a trace disposed therebetween. 
     The device may be positioned and secured in place within a conduit or the housing of the air handler unit, such as a duct, such that the points  22  of the emitters  20  are aligned generally perpendicularly to the direction of the airflow across the device, to prevent recombination of the positively charged ions with the negatively charged ions, if the flexible ion electrode  10  produces both negative and positive ions, as opposed to unipolar ionization of negative ions or positive ions. 
     The treatment of air by delivery of unipolar or bipolar ionization to an airflow within a conduit according to the systems and methods of the present invention may be utilized for various purposes. For example, application of bipolar ionization to an airflow within an HVAC conduit such as an air handler housing or duct may be utilized to abate allergens, pathogens, odors, gases, volatile organic compounds, bacteria, virus, mold, dander, fungus, dust mites, animal and smoke odors, and/or static electricity in a treated air space to which the airflow is directed. Ionization of air in living and working spaces may reduce building related illness and improve indoor air quality; and additionally can reduce the quantity of outside air needed to be mixed with the treated indoor air, reducing heating and cooling costs by enabling a greater degree of air recirculation. 
     The flexible ion electrode  10  may be used in a variable refrigerant volume (VRV) system having a shared outdoor heat exchanger and a plurality of individual air handler units. Alternatively, the HVAC system can take the form of a variable air volume (VAV), constant air volume (CAV), variable refrigerant flow (VRF) or other forms of heating, ventilation and air conditioning system. 
     In typical fashion, the shared outdoor heat exchanger comprises a condenser coil, compressor and fan; the individual air handler units each comprise a fan, expansion valve, heating/cooling coil(s), and a filter; and refrigerant lines connect the shared outdoor heat exchanger to the individual air handler units. Return air from the conditioned space and/or fresh air from an exterior space is treated and delivered to a conditioned air space via the individual air handler units. The outdoor heat exchanger discharges waste heat from the conditioned air space to the ambient surroundings, and/or transfers heat from a cooled zone to a heated zone. The flexible ion device  10  may be mounted after the filter and before the heating or cooling coil. Alternatively, the flexible ion generation device  10  may be mounted adjacent the heat exchanger located within the conduit. 
     Inlet airflow flows through a conduit such as the housing of the air handler unit or a duct is filtered through a filter such as a mesh, screen, paper, cloth or other filter media. A filtered airflow downstream of the filter is treated by discharge of bipolar ionization  36  from the flexible ion electrode  10  to form an ionized airflow. The flexible ion electrode comprises a stream of negatively charged (−) ions and/or a stream of positively charged (+). The ionized airflow enters the inlet of a fan or blower for delivery to the treated air space, and is optionally heated or cooled by passing across or through a cooling coil or heating element. The coil, filter, ion generator, and fan are optionally mounted within a housing of the air handler unit. Example modes of attachment of the flexible ion electrode include, without limitation, adhesive, hook-and-loop fasteners, straps, screws, clips or other mechanical fasteners, magnetic mounting, and/or mounting brackets or carriers affixed to or through the housing or associated ductwork. 
     The length and thickness of the flexible ion generation device  10  may vary according to a number of physical or electrical parameters and desires by the user. 
     Although the present invention has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples may perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the present invention and are intended to be covered by the following claims.