Patent Publication Number: US-2023155356-A1

Title: Self-cleaning ion generator device

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION 
     The present patent application/patent is a continuation of U.S. patent application Ser. No. 16/434,591 filed on Jun. 7, 2019 titled “SELF-CLEANING ION GENERATOR DEVICE, 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 has a self-cleaning mechanism for cleaning the electrodes of an ionization device without having to remove the device from the conduit or 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 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 a self-cleaning ion generator device includes a rectangular housing having a bottom portion and a top portion selectively secured to each other, the top portion contains a base portion extending to an outer edge and having an internal side and an external side. A first pair of opposed sidewalls and a second pair of opposed sidewalls extend from the outer edge of the base portion forming a cavity therein. At least one ion terminal extends from the housing and a cleaning apparatus for cleaning the at least one ion terminal. 
     According to another embodiment of the present invention, the self-cleaning ion generator device includes a rib for cleaning the at least one ion terminal. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a cleaning apparatus powered by a motor for rotation during periodic intervals. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes an ion generator coupled to the at least one ion terminal. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes an ion terminal consisting of a hollow column encircling a high voltage wire. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a high voltage wire with a brush engaged thereto with a plurality of bristles composed of material that conducts electricity. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes at least two ion terminals spaced apart and extending from the housing. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device that includes at least one bore disposed on the top portion for receiving an ion terminal having a first portion and a second portion, wherein the second portion of the ion terminal extends into the cavity and the first portion of the ion terminal extends above the housing. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a cleaning apparatus having a horizontal portion and a vertical portion forming a t-shape. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes ion terminals that emit either positive or negative ions or positive and negative ions. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a rectangular housing having a bottom portion and a top portion selectively secured to each other. The top portion contains a base portion extending to an outer edge and having an internal side and an external side. A first pair of opposed sidewalls and a second pair of opposed sidewalls extend from the outer edge of the base portion forming a cavity therein. At least two ion terminals extend from the housing, and a cleaning apparatus for cleaning the two ion terminals. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes an ion generator housed within the cavity and coupled to the at least two ion terminals. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a motor housed within the housing and a rotational arm is engaged to the motor. The cleaning apparatus is engaged to the rotational arm. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a vertical and a horizontal fastening device. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a rectangular housing having a bottom portion and a top portion selectively secured to each other, the top portion contains a base portion extending to an outer edge and having an internal side and an external side. A first pair of opposed sidewalls and a second pair of opposed sidewalls extend from the outer edge of the base portion forming a cavity therein. The device includes at least one ion terminal assembly comprised of an ion terminal, an ion terminal securing device, and an attachment device. The device further includes at least one bore within the top portion for receiving the ion terminal therein, and a cleaning apparatus for cleaning the at least one ion terminal. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a depression on the top portion for receiving the ion terminal securing device. 
     According to yet another embodiment of the present invention, the self-cleaning ion generator device includes a rib disposed n the cleaning apparatus for cleaning the at least one ion terminal. 
    
    
     
       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 perspective view of the self-cleaning ion generator device; 
         FIG.  2    is a top perspective view of the self-cleaning ion generator device; 
         FIG.  3    is a side view of the self-cleaning ion generator device; 
         FIG.  4    is a front view of the self-cleaning ion generator device; 
         FIG.  5    is a side view of the self-cleaning ion generator device; 
         FIG.  6    is a bottom view of the self-cleaning ion generator device; 
         FIG.  7    is a top view of the self-cleaning ion generator device; 
         FIG.  8    is a side view of the self-cleaning ion generator device; 
         FIG.  9    is an exploded view of the self-cleaning ion generator device; 
         FIG.  10    is another exploded view of the self-cleaning ion generator device; 
         FIG.  11    is a front side cut-away view of the self-cleaning ion generator device; 
         FIG.  12    is a front side perspective cut-away view of the self-cleaning ion generator device; 
         FIG.  13    is a backside cut-away view of the self-cleaning ion generator device; and 
         FIG.  14    is a backside perspective view cut-away view of the self-cleaning ion generator 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 self-cleaning ion generator device is illustrated in  FIGS.  1 - 14    and is shown generally at reference numeral  10 . The device  10  includes a housing having a bottom portion  12  and a top portion  14 . The bottom portion  12  is rectangular with a first side and a second side. The top portion  14  contains a base portion  16  extending to an outer edge and having an internal side and an external side. A first pair of opposed sidewalls  18  and a second pair of opposed sidewalls  20  extend upward from the outer edge of the base portion  16 . The first pair of opposed sidewalls  18  and the second pair of opposed sidewalls  20  intersect and the intersection is defined as a corner. The first pair of opposed sidewalls  18  and a second pair of opposed sidewalls  20  extend upward and to an upper edge  22 . The top portion  14  is rectangularly shaped with the first pair of opposed sidewalls  18  having a longer length than the second pair of opposed sidewalls  20 . A cavity  24  is formed within the base portion  16 , the first pair of opposed sidewalls  18 , and the second pair of opposed sidewalls  20 . 
     The top portion  14  and the bottom portion  12  are selectively secured to each other. When selectively secured, the upper edge  22  of the top portion  14  contacts the first side of the bottom portion  12 . At least one attachment device  26  selectively secures the top portion  14  to the bottom portion  12 . 
     A circuit board  28 , a stepper motor  30 , and an ion generator  32  are disposed within the cavity  24 , as shown in  FIGS.  9 - 14   . The circuit board  28  may include a power supply source for providing power to the device  10 . The circuit board  28  is communicatively coupled to the ion generator  32  to produce ions and the stepper motor  30 . The power supply provides the electricity to power the ion generator  32 , and thus, produce ions. Additionally, the circuitry also includes a timing circuit for timing the stepper motor  30  that engages or is activated at a predetermined time. 
     The base portion  16  of the top portion  14  may contain at least one bore  36 , and as illustrated in  FIGS.  9  and  10   , the base portion  16  of the top portion  14  may contain at least two bores  36 . The bores  36  extend from the external side to the internal side of the base portion  16  and into the cavity  24 . An ion terminal  38  extends through the at least one bore  36 . In one embodiment, the ion terminal  38  may consist of a high voltage wire or electrode that extends through the bore  36 . In another embodiment with a first bore  36  and a second bore  36 , a first high voltage wire or electrode extends through the first bore  36  and a second high voltage wire or electrode extends through the second bore  36 . 
     As illustrated, an ion terminal assembly  38  is disposed around and over the bore  36 . The ion terminal assembly  38  is comprised of an ion terminal  40 , an ion terminal securing device  42 , and an attachment device  44 . The ion terminal securing device  42  may be rectangular and having a first bore and a second bore extending from the top side to the bottom side of the ion terminal securing device  42 . The first bore received the ion terminal  40 , wherein a first portion of the ion terminal  40  extends above the top side of the ion terminal securing device  42  and a second portion extends below the bottom side of the ion terminal securing device  42 . The attachment device  44  extends through the second bore for selectively securing the ion terminal assembly  38  to the base portion  16  of the top portion  14 . 
     The ion terminal  40  may consist of a hollow column for providing support and protection to a high voltage wire. The hollow column may encircle high voltage wire. A first end of the high voltage wire may contain a brush that contains a plurality of bristles that extend outwardly away from the brush. The brush and its bristles may be made of any material that conducts electricity and the combination of the brush with its bristles and the high voltage wire or electrode may be collectively referred to herein as an electrode. In one embodiment, the bristles of the brush are composed of a thermoplastic polymer imbedded with conductive material that allows the polymer to conduct electricity. For example, the bristles of the brush may be composed of polypropylene or polyethylene and impregnated with carbon. Generally, the bristles of the brush 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. The brushes are replaceable and allowed to be easily disengaged and new bristles may be inserted and retained. 
     In one embodiment, the brush is engaged to the end of the high voltage wire. The brush may be crimped to the end of the high voltage wires extending outwardly from the ion terminal  40 . In another embodiment, the brush is engaged to the end of the high voltage wire by heat shrink. In an alternative embodiment, the ion terminal may consist of an electrode. The ion terminal  40  may deposit a stream of negative or positive ions into the surrounding air. When the device contains two or more ion terminals  40 , each ion terminal  40  may deposit either negative or positive ions. As illustrated, the device  10  contains two ion terminals  40 , wherein the first ion terminal  40  may emit negative ions and the second ion terminal  40  may emit positive ions. Alternatively, the first and second ion terminal  40  may both emit positive ions or both emit negative ions. 
     The area around the bore  36  on the top side of the base portion  16  of the top portion  14  may contain a depression that is identical to the shape of the ion terminal securing device  42 , for allowing the ion terminal securing device  42  to be placed within the depression. The depression also contains a threaded bore that extends from the top side of the depression to the bottom side. The ion terminal securing device is selectively secured within the depression by the attachment device  44  that extends through the bore of the ion terminal securing device  42  and the threaded bore of the depression. Preferably the bore within the ion terminal securing device is internally threaded, along with the bore of the depression, for receiving the externally threaded attachment device  44 , such as a screw, bolt, or the like. 
     The first portion of the ion terminal  40  extends upwards and above the top portion of the device  10 . The second portion of the ion terminal  40  extends within the cavity  24  of the device  10  and engages a plug  34  in a selectively secured arrangement. The second portion preferably has a conductive element for contacting a similar conductive element within the plug  34  for creating an uninterrupted path for ions to flow from the plug to the ion terminal  40  and through the ion terminal  40  and exit out of the ion terminal  40  from the bristles of the brush. Alternatively, the ions exit from the point of an emitter or like arrangement. A selectively secured arrangement means the ion terminal  40  may be engaged and disengaged to the plug  34 . This arrangement is beneficial, because the ion terminal  40  and the entire ion terminal assembly  38  is replaceable. Therefore, the ion terminal  40  may be disengaged from the plug  34  and a new ion terminal  34  may be engaged to the plug  34 . The ion generator  32  is communicatively coupled to the plug  34  and provides ions that flow through the plug  34  and into the ion terminal  40 . The plug  34  is disposed below the ion terminal  40  and within the cavity  24 . 
     After the ion terminal  40  has been used for a predetermined period of time or when the ion terminal  40  suffers a reduction in effectiveness, the ion terminal assembly  38  may be removed from the top portion  14  and new ion terminal assembly  38  can be selectively secured to the top portion  14  with the second portion of the ion terminal  40  selectively secured to the plug  34 . 
     The stepper motor  30  is positioned within the cavity  24 , as shown in  FIGS.  9 - 14   . The stepper motor  30  is used to power a cleaning apparatus  46 . The stepper motor  30  contains a terminal for receiving a power supply for providing power to the stepper motor  30 . A rotational arm  48  extends generally outwardly from the stepper motor  30  and through a generally centrally located bore  50  that extends from the external side to the internal side of the top portion  14 . The cleaning apparatus  46  is releasably engaged to the rotational arm  48  extending through the bore  50  of the top portion  14 . As illustrated, the cleaning apparatus  46  is releasably engaged to the rotational arm  48  by a fastening device  52 , such as a bolt. As illustrated in  FIGS.  9  and  10   , two bores  36  are disposed on the base portion  16  of the top portion  14  and positioned on opposite sides of the cleaning apparatus  46 . 
     The cleaning apparatus  46  may be T-shaped, or in an alternative embodiment L-shaped. As illustrated in  FIGS.  9 - 14   , the T-shaped cleaning apparatus  46  has a horizontal portion and a vertical portion. The vertical portion contains a hollow shaft that is releasably engaged to the rotational arm  48 . The horizontal portion extends outwardly from the vertical portion and optionally contains a cleaning head on each end of the vertical portions. The cleaning head  54  may contain any device that may clean the electrode or brushes of the ion terminal  40 . As illustrated, the cleaning apparatus  46  includes a rib  56  that extends downward from the horizontal portion. The rib  56  has a width smaller than the width of the horizontal portion and extends downwardly from the horizontal portion and touches the ion terminal  40  and preferably the brushes of the ion terminal  40 . As the cleaning apparatus  46  rotates, the rib  54  contacts the brushes on the ion terminal  40 , wiping away and dust or particulate matter to clean the ion terminal  40 . 
     The cleaning apparatus  46  is powered by the stepper motor  30  operationally connected to a timing circuit that activates the cleaning apparatus  46  at a predetermined interval. By way of example only, the cleaning apparatus  46  may be activated between every 12 to 24 hours. In one alternative embodiment, the cleaning apparatus may be “S” shaped or curved. In other words, when the cleaning apparatus  46  is viewed from above, the cleaning apparatus  46  has an “S” shaped or curved appearance, preventing both cleaning heads  54  from contacting the electrodes or brushes of the ion terminal  40  at the same time. While the cleaning apparatus  46  is activated, the device  10  ceases to produce ions, thus preventing any loose particles from sticking to the opposite polarity brush. The cleaning apparatus  46  may be straight, such as a bar or any other shape as desired by the user. 
     The device  10  may contain at least one retention flange  58 . As illustrated in  FIGS.  1  and  2   , the device  10  may consist of at least one horizontal retention flange  58  and at least one vertical retention flange  58 . The retention flange  58 , as illustrated, is generally square or rectangular with a bore  60  extending from the first side to the second side of the retention flange  58  for receiving a fastening device (not shown) for engaging the device  10  to the duct. Fastening devices may include a screw, bolt, self-tapping sheet metal screws, spring loaded wing nuts with bolts, and the like. When mounted to a duct or other conduit, the top portion  14  extends within the duct or conduit with the ion terminal  40  extending within the duct and conduit, releasing ions with the duct or conduit. The bottom portion  12  is visible on the exterior of the duct. Preferably, the device  10  is mounted after a prefilter and before the cooling coil in an HVAC system. Alternatively, the device  10  may be mounted on any conduit with air flow, a supply air duct, or a return air duct. The device  10  should be mounted so that air flows over the electrodes or brushes, such as air my flow through the goal posts on a football field. 
     The retention flange  58  may receive a magnet for attaching the device  10  to a metal object. The rectangular shape of the device  10  allows the device  10  to be mounted to the blower inlet of a fan housing and disperse ions throughout the blower inlet. 
     The device  10  may also include an alarm feature, including alarm contacts, that are communicatively coupled to a building management system that sends a signal to the building management system if ions are not produced by the device  10 . The building management system then sends an alert informing a user that the device  10  is not producing ions. A test button  64  may also be located on the device  10  to check the motor status during preventive maintenance and a light  62 , preferably a light emitting diode (LED) light, may be illuminated, indicating a cleaning test is being conducted. The light  62 , such as an LED light, may be positioned on the bottom portion  12  that is illuminated and indicating power is being supplied to the device  10 . 
     The device  10  may produce approximately equal amounts of positive and negative ions, regardless of airflow velocity or other conditions such as humidity or temperature. In example forms, the device  10  produces positive ions and negative ions in a concentration of at least about 10 9  ions/second, and operates on 24 VAC, 110 VAC or 200 VAC to 240 VAC without the use of an external transformer. In alternate embodiments, the device generates negative ions only, or positive ions only, or generate negative ions and positive ions in unequal quantities. The device  10  optionally utilizes nano-electronic components allowing the device to be very compact, requiring less than 1 watt/ion generator module, for example less than 0.5 watts/ion module, and in further examples less than 0.36 watts per ion module. The bottom portion  12  may contain terminals extending therefrom for connecting the 24 VAC, 110-240 VAC, and neutral input. 
     The device  10  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 electrodes  40   +  and  40   −  are aligned generally perpendicularly to the direction of the airflow across the device  10 , to prevent recombination of the positively charged ions with the negatively charged ions. 
     The treatment of air by delivery of 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. 
     During use, once power is provided to the device  10 , the device  10  initiates an internal check on all systems. After initializing and the check has confirmed all systems are operational, the light  62  will blink “on” and include a visible meter of how many days the device  10  has been powered. After each day of being powered, the display will add a number to the display indicating the number of days the device  10  has been powered. The device  10  can also include a button  64  that when depressed, initiates a cleaning cycle of the device  10 , causing the cleaning apparatus  46  to rotate and cleaning the ion terminals  40  or the brushes on the ion terminals  40 . 
     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.