Patent Publication Number: US-2022233979-A1

Title: Electrolysis filtering system for dielectric fluids

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. application Ser. No. 16/911,057, entitled “Electrolysis Filtering System for Dielectric Fluids,” filed on Jun. 24, 2020, and issuing on Apr. 12, 2022 as U.S. Pat. No. 11,298,639, which is incorporated herein by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     Some implementations relate generally to electrolysis filtering system for dielectric fluids and more particularly to an inline apparatus which removes water at the micron level from dielectric fluids. 
     BACKGROUND 
     Several different types of methods have been used for the removal of fine particulate from dielectric fluids and in many cases with the uses of electrostatic filtration devices. In these electrostatic filters the fluid to be purified is pumped through an apparatus with charged electrodes. In some cases, high voltage is used on the electrodes and this can result in arcing if the electrodes are positioned too close to each other. Also, the spacing of the electrodes varies. In some cases, the space between the electrodes is a few inches and in other cases they are as close as an inch and this can cause a bottle neck slowing down the fluid making the pressure rise as it flows between the electrodes in the filter. As the fluid passes through the filter the small particles in the fluid are charged causing them to stick to a filter medium that is usually inside the filter housing in between and around the electrodes. Some of the filters in the prior art charge the fluid with a plurality of electrodes, which must be wired together either in series or in parallel. The wiring of the prior art filters has presented difficulties in fabrication in that a buss bar, wire or other separate electrical attaching system is required to link together the plurality of electrodes. In some cases, the electrodes can flex from the pressure and cause a short. While many of the electrostatic filters of the prior art have been effective in the removal of fine particles, they do not claim to remove water from the fluid. 
     Water can exist in oil in three states or phases. The first state, known as dissolved water, is characterized by individual water molecules dispersed throughout the oil. Dissolved water in a lubricating oil is comparable to moisture in the air on a humid day—the water may be there, but because it is dispersed molecule-by-molecule, it is too small to see. 
     For this reason, oil can contain a significant concentration of dissolved water with no visible indication of its presence. Most industrial oils such as hydraulic fluids, turbine oils, etc., can hold as much as 200 to 600 ppm of water (0.02 to 0.06 percent) in the dissolved state, with aged oils capable of holding three to four times more water in the dissolved state than new oil. 
     Once the amount of water has exceeded the maximum level for it to remain dissolved, the oil is saturated. At this point, the water is suspended in the oil in microscopic droplets known as an emulsion (the second state). In this case, the amount of moisture in the air exceeds the saturation point, resulting in a suspension of small droplets of moisture in a lubricating oil. This is often referred to as haze with the oil said to be cloudy or hazy. 
     The addition of more water to an emulsified oil/water mixture will lead to a separation of the two phases producing a layer of free water (the third state) as well as free and/or emulsified oil. This free water layer is usually found on the bottom of tanks and sumps. 
     Water in any of the three states mention above is not good for the bearings and/or other internal components of the equipment the oil is meant to lubricate. 
     Therefore, it would be useful to provide an improved filter which could be used without creating high pressure, and which could be fabricated without, the need for internal wiring and could remove water. 
     Embodiments were conceived in light of the above-mentioned problems and limitations, among other things. 
     SUMMARY 
     Some implementations can include an electrolysis filtering system for dielectric fluids that can be made from any suitable material. 
     Some implementations can include an electrolysis filtration system to filter dielectric fluids. The system can include an electrolysis filter having a front cover and a back cover, a first electrode plate with a first side and a second side, and a plurality of small apertures, and a second electrode plate with a first side and a second side, and a plurality of small apertures. In some implementations, the front cover can include a first terminal, a first large recessed channel, and a second large recessed channel. 
     In some implementations, the back cover can include a first large aperture, a second large aperture, a small aperture, a third large recessed channel, a fourth large recessed channel, and a second terminal. In some implementations, the front cover and the back cover can each have an inside and an outside. 
     In some implementations, the inside of each of the front and back covers can have a first plane, a second plane, a third plane, and a fourth plane. In some implementations, the insides of both covers meet at the first plane. In some implementations, the second plane of the front cover is defined by a front cover electrode plate recess in which the first side of the first electrode plate rests. 
     In some implementations, the second plane of the back cover is defined by a back cover electrode plate recess in which the first side of the second electrode plate rests. In some implementations, the third plane of the front cover is defined by distal ends of a first set of standoffs that protrude through the plurality of small apertures in the first electrode plate and make contact with the second side of the second electrode plate when the electrolysis filter is assembled. 
     In some implementations, the third plane of the back cover is defined by distal ends of a second set of standoffs that protrude through the plurality of small apertures in the second electrode plate and make contact with the second side of the first electrode plate when the electrolysis filter is assembled. In some implementations, the first electrode plate and the second electrode plate each have an electrode plate width, and the first electrode plate and the second electrode plate each have an electrode plate field parallel length. 
     In some implementations, the first set of standoffs and the second set of standoffs define an electrode plate field spacing. In some implementations, the fourth plane of the front cover is defined by the first large recessed channel and the second large recessed channel. In some implementations, the fourth plane of the back cover is defined by the third large recessed channel and the fourth large recessed channel. 
     In some implementations, the first large recessed channel and the third large recessed channel define a first void between the front cover and the back cover, and the second large recessed channel and the fourth large recessed channel define a second void between the front cover and the back cover, and wherein the first void and the second void are outside of an area of the electrode plate recesses of the front cover and the back cover. In some implementations, the first and second large apertures provide a passage from the first and second voids respectively to the outside of the back cover. 
     In some implementations, the small aperture provides a passage from the second void to the outside of the back cover. In some implementations, the first terminal is attached to the first electrode plate, and the second terminal is attached to the second electrode plate. 
     The system can also include a control panel having a power input source, a power switch, and a power output, a pump having a power input, a fluid input coupled to the second large aperture, a fluid output coupled to a fluid return line, and a high voltage power supply having a power input, a first and a second electrode, wherein the first electrode is connected to the first electrode plate, and wherein the second electrode is connected to the second electrode plate. 
     In some implementations, the first and second covers have a first small recessed channel and a second small recessed channel, where the first small recessed channel and the second small recessed channel are disposed near an outer edge of the inside of the front and back covers and are aligned when the electrolysis filter is assembled, where the first small recessed channel and the second small recessed channel provides support for sealing the front and back cover. 
     In some implementations, the first and second covers have a plurality of holes disposed outside of an area of the first and second small recessed channels and are near an outer edge and of the of the front and back covers, wherein a plurality of fasteners are placed through the plurality of holes to connect the front and back covers together. In some implementations, the first and second covers are held together with an adhesive. 
     In some implementations, the first large aperture is coupled to a fluid input source, and wherein the second large aperture is coupled to a pump. In some implementations, the first large aperture is coupled to a pump, and wherein the second large aperture is coupled to a fluid input source. 
     In some implementations, the relationship of the electrode plate field spacing to the electrode plate field parallel length is based on a diameter of the first large aperture. In some implementations, a DC voltage of the high voltage power supply is based on the electrode plate field spacing, and wherein current of the high voltage power supply is determined by the amount of dissolved water in the dielectric fluid. In some implementations, the electrode plate width is based on the electrolysis filter dimension, and wherein the electrode plate width is independent of the electrode plate parallel length. 
     In some implementations, the electrolysis filtering system further comprises a plurality of electrolysis filters connected in series. In some implementations, the electrolysis filtering system further comprises a filter medium disposed in one or more of the first and second voids. In some implementations, the electrolysis filter further comprises a plurality of electrode plate field spacings, wherein a total area of the plurality of electrode plate field spacings multiplied by the parallel length is about equal to an area of the first large aperture. 
     In some implementations, the front and back covers are formed of a non-conductive material. In some implementations, the first electrode plate and the second electrode plate are formed of a non-corrosive, electrically conductive material. 
     Some implementations can include an electrolysis filter for dielectric fluids, the electrolysis filter comprising a housing that contains a first large aperture as a fluid input, a second large aperture as a fluid output, and a small aperture as a relief vent. The electrolysis filter can also include a first electrode plate, and a second electrode plate, where the first electrode plate and the second electrode plate each have an electrode plate field parallel length, and wherein a distance between the first electrode plate and the second electrode plate, when installed in the housing, define an electrode plate field spacing. The electrolysis filter can include a first terminal, a second terminal, and a high voltage power supply, wherein the first terminal and the second terminal connect to a high voltage power supply. In some implementations, a voltage output level of the high voltage power supply is based on the electrode plate field spacing. In some implementations, the electrode plate field parallel length multiplied by the electrode plate field spacing is about equal to an area of the first large aperture or the second large aperture. 
     In some implementations, the electrolysis filter further comprises a plurality of electrode plate field spacings, where a total area of the plurality of electrode plate field spacings multiplied by the parallel length is about equal to an area of the first large aperture. In some implementations, the housing is formed of a non-conductive material. 
     In some implementations, the first electrode plate and the second electrode plate are formed of an electrically conductive, non-corrosive material 
     Some implementations can include an electrolysis filter for dielectric fluids, the electrolysis filter comprising a housing that contains a first large aperture as a fluid input, a second large aperture as a fluid output, and a small aperture as a relief vent. The electrolysis filter can also include a first electrode plate, and a second electrode plate, where the first electrode plate and the second electrode plate each have an electrode plate field parallel length, and where a distance between the first electrode plate and the second electrode plate, when installed in the housing, define an electrode plate field spacing. In some implementations, the electrode plate field spacing multiplied by the parallel length is about equal to an area of the first large aperture or the second large aperture. 
     In some implementations, the electrolysis filter further comprises a first terminal coupled to the first electrode plate, and a second terminal coupled to the second electrode plate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagram of a system view of an example electrolysis filtering system for dielectric fluids in accordance with some implementations. 
         FIG. 2  is a diagram of a back perspective view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 3  is a diagram of a front perspective view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 4  is a diagram of a front cover outside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 5  is a diagram of a front cover inside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 6  is a diagram of a back cover outside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 7  is a diagram of a back cover inside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 8  is a diagram showing a side view of a first electrode plate of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 9  is a diagram showing a side view of a second electrode plate of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 10  is a diagram showing an exploded view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 11  is a diagram showing an exploded view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 12  is a diagram showing a top cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 13  is a diagram showing a top cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 14  is a diagram showing a side cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
         FIG. 15  is a diagram showing a side cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. 
     
    
    
     DETAILED DESCRIPTION 
     Some implementations can include an electrolysis filtering system for dielectric fluids. Electrolysis is a technique that uses a direct electric current (DC) to drive an otherwise non-spontaneous chemical reaction. The voltage that is needed for electrolysis to occur is called the decomposition potential. Electrolysis of water is the decomposition of water into oxygen and hydrogen gas due to the passage of an electric current. It ideally requires a potential difference of 1.23 volts to split water. However, when water is mixed with oil and is in a dissolved state the voltage needed is much greater than of the voltage used in just pure water. Also, the spacing of the electrodes need to be position closer to one another than if they were placed in just pure water. This is due to the dielectric fluids is not conductive by itself and the dissolved water is microscopic. So, without the proper voltage and proper spacing you would only have an electrostatic field there would be no reaction, just the field with no electrolysis taking place. 
       FIG. 1  is a diagram of a system view of an example electrolysis filtering system for dielectric fluids in accordance with some implementations. The electrolysis filtering system  100  includes an electrolysis filter  102 , a control panel  104 , a pump  110 , a high voltage power supply  112 , and a fluid supply tank  120 . 
     The electrolysis filter  102  having a supply inlet line  122 , a relief value  124 , an output line  126 , and a second terminal  128 . 
     The control pane  104  having a power input  106 , a power switch  108 , a first power output  130  and a second power output  132 . 
     The pump  110  having a fluid input coupled to an output line  126  of the electrolysis filter  102  and a fluid output coupled to a fluid return line  118 . The pump  110  also includes a power input connected to the first power output  130  of the control pane 1104 . 
     The high voltage power supply  112  having a power input connected to the second power output  132  of the control pane 1104 , a first electrode  114  and a second electrode  116 , wherein the first electrode  114  of the high voltage power supply  112  is connected to the first electrode plate  802  (not shown in  FIG. 1  see  FIG. 8 ) via a first terminal  302  (not shown in  FIG. 1 , see  FIG. 3 ) of the electrolysis filter  102  , and wherein the second electrode of the high voltage power supply  116  is connected to the second electrode plate  902  (not shown in  FIG. 1  see  FIG. 9 ) via a second terminal  128  of the electrolysis filter  102 . 
       FIG. 2  is a diagram of a back perspective view of an example electrolysis filter  102  for dielectric fluids in accordance with some implementations. The electrolysis filter  102  having a front cover  214 , a back cover  216 , a first large aperture  202 , a second large aperture  204 , a small aperture  206 , a second terminal  128 , a plurality of fasteners  208  connecting the front and back covers together, a plurality of mounting holes  212 . 
       FIG. 3  is a diagram of a front perspective view of an example electrolysis filter  102  for dielectric fluids in accordance with some implementations. The electrolysis filter  102  having a front cover  214 , a back cover  216 , a first terminal  302 , a plurality of fasteners  304  connecting the front and back covers together, a plurality of mounting holes  306 . 
       FIG. 4  is a diagram of a front cover outside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The electrolysis filter portion  214  having a plurality of holes  404 , and a first terminal passage  402 . 
       FIG. 5  is a diagram of a front cover inside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The electrolysis filter portion  214  having a plurality of holes  404 , a small aperture  402 , a first counter bore  510 , a first plane  514 , a second plane  512 , a first set of standoffs  504 , a first small recessed channel  502 , a first large recessed channel  506 , and a second large recessed channel  508 . 
       FIG. 6  is a diagram of a back cover outside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The electrolysis filter portion  214  having a plurality of holes  604 , a first large aperture  202 , a second large aperture  204 , a small aperture  206 , a second terminal passage  602 . 
       FIG. 7  is a diagram of a back cover inside view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The electrolysis filter portion  216  having a plurality of holes  604 , a second terminal passage  602 , a second counter bore  710 , a first plane  714 , a second plane  712 , a second set of standoffs  704 , a first small recessed channel  702 , a third large recessed channel  706 , a fourth large recessed channel  708 , a first large aperture  202 , a second large aperture  204 , a small aperture  206 , a second terminal passage  602 . 
       FIG. 8  is a diagram showing a side view of a first electrode plate of an example electrolysis filter for dielectric fluids in accordance with some implementations. The first electrode plate  802  having a plurality of small apertures  804 , a first terminal connector passage  808 , a first terminal clearance  806 , and a first plate width  810 . 
       FIG. 9  is a diagram showing a side view of a second electrode plate of an example electrolysis filter for dielectric fluids in accordance with some implementations. The second electrode plate  902  having a plurality of small apertures  904 , a second terminal connector passage  908 , a second terminal clearance  906 , and a second plate width  910 . 
       FIG. 10  is a diagram showing an exploded view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The exploded view includes a front cover  214 , a back cover  216 , a first electrode plate  802 , and a second electrode plate  902 . 
       FIG. 11  is a diagram showing an exploded view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The exploded view includes a front cover  214  with a first set of standoffs  504 , a back cover  216  with a second set of standoffs  704 , a first electrode plate  802  having a plurality of small apertures  804 , a second electrode plate  902  having a plurality of small apertures  904 , and an electrode plate field spacing  1102 . 
       FIG. 12  is a diagram showing a top cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The assembled view shows a front cover  214  with a first set of standoffs  504  that protrude through the plurality of small apertures in the first electrode plate  802  and make contact with the second side of the second electrode plate  902 , a back cover  216  with a second set of standoffs  704  that protrude through the plurality of small apertures in the second electrode plate  902  and make contact with the second side of the first electrode plate  802 . The first and second set of standoffs can be spaced apart on the planar surfaces of the first electrode plate  802  and the second electrode plate  902 , provide support for the first electrode plate  802  and the second electrode plate  902 , and create a fixed gap between the first electrode plate  802  and the second electrode plate  902 . This gap is the electrode plate field spacing  1102 . In some implementations, the plates (e.g., the first electrode plate  802  and the second electrode plate  902 ) can be thick enough (e.g., around 0.048 inch thick or other suitable thickness) to remain rigid (or mostly rigid) in order to provide a uniform spacing between the plates when separated by the standoffs. 
     In some implementations, the electrolysis filter can have a plurality of electrode plate field spacings. One electrode plate field spacing exists with two electrode plates but each additional plate added will create an additional electrode plate field spacing. 
       FIG. 13  is a diagram showing a top cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The assembled view shows the front cover  214  with the first set of standoffs  504 , the back cover  216  with the second set of standoffs  704 , the first electrode plate  802 , the second electrode plate  902 , a first plane  1302 , a front cover second plane  1304 , a back cover second plane  1306 , a front cover third plane  1308 , a back cover third plane  1310 , a front cover fourth plane  1312 , a back cover fourth plane  1314 , a first void  1316 , a second void  1318 , and the electrode plate field spacing  1102 . 
     The first large apertures  202  provide a passage for the dielectric fluid to enter the electrolysis filter  102  from the back cover  216  into the first void  1316  between the front cover and the back cover. The dielectric fluid then travels across the first electrode plate  802  and the second electrode plate  902  simultaneously through the electrode plate field spacing  1102 . The dielectric fluid then enters into the second void  1318  and exits the electrolysis filter  102  via the second large apertures  204  on the back cover  216 . The small aperture  206  also provides a passage from the second void  1318  to the outside of the back cover and is connected to the relief value  124 . 
     In some implementations the relief valve  124  can initially be used for burping any air out of the system and can continue venting to release oxygen and hydrogen gas during the electrolysis process. In some implementations the pressure could be released manually by opening the relief valve  124  or with a mechanical pressure relief valve in line before the relief valve  124 . 
     In some implementations the first void  1316  and the second void  1318  can include a filter medium. 
       FIG. 14  is a diagram showing a side cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The view shows the front cover  214 , the back cover  216  with the second set of standoffs  704 , the first electrode plate  802 , the second electrode plate  902 , the first terminal  302 , a first terminal nut  1408 , a second terminal nut  1412 , a first terminal cable, a third terminal nut  1402 , a fourth terminal nut  1406 , a second terminal cable  1404 , the second terminal  128 , the second terminal passage  602 , the first counter bore  510 , an o ring groove  1414 , an o ring  1416 , the second terminal connector passage  908 , and the first terminal clearance  806 . 
     In some implementations the first terminal passage  402  and the second terminal passage  602  could be a drilled aperture. In some implementations the passage could be tapped. 
       FIG. 15  is a diagram showing a side cut through of an assembled view of an example electrolysis filter for dielectric fluids in accordance with some implementations. The view shows the front cover  214 , the back cover  216 , the first electrode plate  802 , the second electrode plate  902 , the electrode plate field spacing  1102 , and an electrode plate field parallel length  1502 . 
     The electrode plate field parallel length  1502  is perpendicular to the electrode plate field spacing  1102 . The electrode plate field spacing  1102  may need to be a narrow path in order for an electrolysis reaction to occur to the dissolved water in the dielectric fluid as it passes through the electrode plate field spacing. To prevent this narrow path from causing a pressure build up the electrode plate field parallel length should be more than or equal to the diameter area in square inches to that of the first large aperture  202  and the second large apertures  204  (e.g., a 1 inch line having an area in square inches of 0.785 inches, an electrode plate field spacing of 0.029 inches would need a parallel length of 27.06 inches of simultaneous travel for the dielectric fluid to flow through the electrode plate field spacing to avoid building up pressure). 
     The first electrode plate width  810  and the second electrode plate width  910 , determines the distance of travel through the electrode plate field spacing. This distance determines the amount of filtering preformed in each pass. The overall dimension of the electrode plates and the gap of the electrode plate field spacing are relative to the voltage (e.g., an electrode plate field spacing of 0.029 inches with an electrode plate width of 12 inch would allow about 800 vdc across the electrode plates. If the electrode plate field spacing is decreased the voltage may need to be decreased or if you increase the electrode plate width the voltage may need to be decreased to prevent arcing). 
     With a DC voltage of about 800 volts across the electrode plates  802 / 902  and an electrode plate field spacing  1102  of about 0.029 inches the decomposition potential is reached. This will start the electrolysis process on the dissolved water in the dielectric fluid and begins to decrease the dissolved water down to a low ppm. The current will increase with the increase of dissolved water in the dielectric fluid and decrease with the removal of the dissolved water. The above voltage and the electrode plate field spacing is one example of a working setting. In another example, the decomposition potential can be reached in a voltage range from around 200 volts to around 1700 volts and an electrode plate field spacing ranging from around a few thousands of an inch to around thirty-five thousandths of an inch. 
     The electrode plate width and electrolysis filter dimension respectively can be increased to provide a longer path of travel for the dielectric fluid or multiple electrolysis filters could be daisy chained together in series to provide more filtering each cycle of travel through the electrolysis filter. 
     While the disclosed example electrolysis filter for dielectric fluids is depicted in a rectangular shape, the electrolysis filter or housing could be other shapes (e.g., round, oval, triangular, etc.). 
     While the disclosed example electrolysis filter for dielectric fluids is described with a control panel  104  only having a simple on/off power switch but it a can include a plurality of sensors and switches (e.g., including, but not be limited to, pressure sensors, temperature sensors, water sensors, relay valves) that can be controlled by a processor configured to execute a sequence of programmed instructions stored on a nontransitory computer readable medium. For example, the processor can include, but not be limited to, a personal computer or workstation or other such computing system that includes a processor, microprocessor, microcontroller device, or is comprised of control logic including integrated circuits such as, for example, an Application Specific Integrated Circuit (ASIC). The instructions can be compiled from source code instructions provided in accordance with a programming language such as Java, C, C++, C#.net, assembly or the like. The instructions can also comprise code and data objects provided in accordance with, for example, the Visual Basic™ language, or another structured or object-oriented programming language. The sequence of programmed instructions, or programmable logic device configuration software, and data associated therewith can be stored in a nontransitory computer-readable medium such as a computer memory or storage device which may be any suitable memory apparatus, such as, but not limited to ROM, PROM, EEPROM, RAM, flash memory, disk drive and the like. The computer can connect to a network such as, but not limited to Bluetooth, Wi-Fi and be controlled or monitored over the web via a computer or mobile app. 
     It is, therefore, apparent that there is provided, in accordance with the various embodiments disclosed herein, electrolysis filtering system for dielectric fluids. 
     While the disclosed subject matter has been described in conjunction with a number of embodiments, it is evident that many alternatives, modifications and variations would be, or are, apparent to those of ordinary skill in the applicable arts. Accordingly, Applicant intends to embrace all such alternatives, modifications, equivalents and variations that are within the spirit and scope of the disclosed subject matter.