Patent Abstract:
Apparatus and methods for purifying the water in spas or hot tubs are provided. Such apparatus include an ozone generator sized and adapted to purify the water in a spa or jetted tub, the ozone generator including a chip electrode assembly adapted to produce ozone from air using an electric discharge, a power supply assembly, and a transfer assembly cooperating with said ozone generator to pass ozone produced by the ozone generator to the water in the spa or jetted tub. The chip electrode assembly is removably secured to and separately enclosed from the power supply assembly and is adapted to be easily, manually replaceable.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 09/257,745, filed Feb. 25, 1999, now U.S. Pat. No. 6,129,850 which claims the benefit of U.S. Provisional Application No. 60/090,771, filed Jun. 26, 1998. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to systems of purifying waters used in spas and jetted tubs. More particularly, the invention relates to apparatus and methods specifically configured and adapted for the treatment, for example, for the purification, of waters used in spas and jetted tubs. 
     Spas, jetted (hot) tubs and the like are often treated with active compounds to maintain the water therein in a purified or sanitized condition. Compounds, such as chlorine and ozone, have been used to sanitize the relatively large volumes, for example, hundreds or thousands of gallons, of water in such spas, tubs, etc. As used herein, the terms “spa” and “jetted tub” refer to systems which hold or contain a body of liquid aqueous medium, hereinafter referred to as water, which is often heated, in a reservoir which is smaller than a swimming pool, but is sufficiently large so that an adult human being can be completely submerged or immersed in the water contained in the reservoir. 
     Spas are often used by submerging all or a major portion of one&#39;s body in the water in the reservoir for recreation and/or relaxation. Additional, separate purifying or sanitizing components are also included in spa waters to control bacteria, algae, etc., which are known to contaminate such waters. Very low concentrations of these active materials are used in order to avoid harming sensitive parts of the body—since such spas, tubs, etc. are sized so that the entire body can be immersed in the water and to minimize costs, because of the relatively large volume of water to be treated. For example, the normal (that is the typical, non-acute contamination) concentration of ozone used to purify or sanitize the water in a spa or tub is often in the range of about 0.005 to about 0.05 parts per million (ppm) based on weight of ozone per volume of water (w/v). 
     Typically, ozone is generated on site for use in purifying spa/tub waters. Conventional ozone generators used for such service include a sealed ultraviolet (UV) light lamp which is known to produce ozone in the desired amounts. Such conventional ozone generators are generally effective. However, these generators do have certain drawbacks. For example, the UV light lamp is relatively bulky, can burn out (often requiring system disassembly and lamp replacement) and are relatively inefficient in producing the desired amounts of ozone. 
     Therefore, it would be advantageous to provide new systems for purifying waters used in spas and jetted tubs. 
     SUMMARY OF THE INVENTION 
     New systems, for example, apparatus and methods, for purifying the waters in spas and jetted tubs have been discovered. The new systems employ ozone as the purifying/sanitizing component. The ozone is generated using an assembly which is compact, durable, convenient, reliable, requires little or no maintenance and generates ozone efficiently, for example, more efficiently than a conventional UV light lamp ozone generator. Such an ozone generator is particularly effective in producing purifying amounts of ozone for spas and jetted tubs used for recreation and/or relaxation. The owners of such spas and jetted tubs want to use these items when desired, want the water to be effectively purified/sanitized, but do not want to spend large amounts of time/money on maintenance. The systems of this invention meet these requirements. 
     In one broad aspect, the present apparatus for purifying the water in a spa or jetted tub comprise an ozone generator and a transfer assembly. The ozone generator is sized and adapted to purify the water in a spa or jetted tube, and includes a chip electrode assembly adapted to produce ozone from air using an electric discharge. The transfer assembly cooperates with the ozone generator to pass ozone produced by the ozone generator to the water in the spa or jetted tub. 
     Preferably, the ozone generator is effective to produce sufficient ozone to purify (sanitize) the water in a spa or jetted tub containing about 50 or about 200 to about 1000 or about 5000 gallons of water. The concentration of ozone in the water in the spa/jetted tub is generally as noted elsewhere herein. Two or more ozone generators in accordance with the present invention can be utilized together if larger volumes of water are to be treated. 
     In one particularly useful embodiment, the chip electrode assembly is adapted to produce ozone from air using a corona discharge. The ozone generator preferably further includes a transformer (an electrical transformer) sized, adapted and located to control the electric power (voltage) provided to the chip electrode assembly. Often, the ozone generator operates on conventional line voltage. For example, the transformer may be adapted to function by being provided with (to be inputted with) supply (e.g., line) A.C. electric power of about 100 to about 130 volts. 
     Alternatively, a 12 volt D.C. system may be employed to supply electric power. 
     One specific ozone generator useful in the present invention is the generator sold by Del Industries under the trademark ZO-CDS or CDS16. The specifications for the CDS16 ozone generator include power: 110-120 VAC, 50/60 Hz, 90 mA and 11 W; flow: 3 SCFH or 1415 cc/min; and weight: 12 oz or 340 g. 
     Any suitable transfer assembly may be utilized provided that it functions to cooperate with the ozone generator to pass ozone produced by the ozone generator to the water in the spa or jetted tub. 
     The transfer assembly preferably includes a water pump, an adductor assembly and a transfer conduit. The adductor (or venturi) assembly has an inlet and an outlet. The transfer conduit is adapted to provide a passage for ozone-containing gases between the ozone generator and the adductor assembly. The water pump is positioned to pump water from the spa or jetted tub through the adductor assembly. The transfer conduit is positioned so that the passage of water through the adductor assembly causes ozone-containing gases from the ozone generator to pass through the transfer conduit into and through the adductor assembly. 
     The water pump can be, and preferably is, the spa/jetted tub water pump, that is the pump used to circulate water in the spa/jetted tub. In one useful embodiment, the adductor assembly is located in a bypass conduit and a minor amount, that is less than about 50%, of the water being pumped by the water pump is passed through the bypass line. 
     The transfer assembly preferably includes a water transfer line which circulates water from and to the spa or jetted tub, a filter located upstream of the adductor assembly in fluid communication with the water transfer line and adapted to remove solid or particulate matter from the water passing through the water transfer line. The transfer assembly preferably further includes a heater adapted to heat the water flowing through the water transfer line upstream of the adductor assembly. 
     In one embodiment, the ozone transfer conduit is configured to reduce the probability of water passing from the adductor assembly to the ozone generator. This feature is designed to avoid detrimentally affecting the ozone generator. For example, the ozone transfer conduit may include a water trap. The ozone transfer conduit may include a loop (for example, a water trap loop), preferably located above the adductor assembly, to reduce the risk of water contacting the ozone generator. The ozone generator preferably is located above the water level in the spa/jetted tub. The present apparatus may include a check valve, for example, of conventional design, located in the ozone transfer conduit and adapted to prevent fluid flow in the ozone transfer conduit toward the ozone generator. 
     In another embodiment of the present invention, a water purifying apparatus for a spa or jetted tub is provided which comprises a removable, replaceable chip electrode. Preferably, an ozone generator in accordance with this embodiment, generally comprises a power supply assembly housed in a main housing or enclosure, and a chip electrode assembly, separately enclosed from, and removably coupled to, the power supply assembly. 
     More particularly, the chip electrode assembly includes a corona discharge chip electrode housed in a separate housing or enclosure having a body portion and a cover portion. The chip electrode assembly is removably coupled to the main enclosure which houses the power supply. 
     Importantly, electrical connectors providing electrical connection between the power supply and the chip electrode, are adapted to be easily disengaged, thus facilitating removal of the chip electrode assembly for replacement. 
     For example, each electrical connector comprises a electrical contact integrated with, or mounted on, the main enclosure and a cooperating electrical contact integrated with, or mounted on, the chip electrode enclosure. In the preferred embodiment, the electrical contact on the main enclosure may comprise one or more receptacles or pins, electrically wired to the transformer or power supply, and the electrical contact on the chip electrode enclosure may comprise one or more cooperating or complementary pins or receptacles electrically wired to the chip electrode. Contact surfaces of the integrated receptacles and pins may be made of copper or other suitable conductive material. 
     In addition, a manually manipulable fastener, such as a thumb screw or the like, may be provided for securing attachment of the chip electrode assembly to the main enclosure and securing electrical contact between the integrated pins and receptacles. Structure may be included for enabling the chip electrode assembly to be snapped in place. 
     The chip electrode will eventually become worn and less effective in producing ozone over time and through repeated use. With this specific embodiment hereinabove briefly described, the worn chip electrode assembly may safely and easily be removed and replaced with a new chip electrode assembly without need for a user/consumer to open the power supply enclosure or remove the ozone generator from its location. Replacement chip electrode assemblies in accordance with this embodiment may be made available at relatively low cost. 
     Methods for purifying/sanitizing waters located in spas and jetted tubs are included within the scope of the present invention. Preferably, these methods comprise employing the present apparatus to provide a purifying/sanitizing amount of ozone to the water located in the spa/jetted tub. 
     Any combination of two or more features described herein are included within the scope of the present invention provided that the features in each such combination are not mutually inconsistent. 
     These and other aspects and advantages of the present invention are apparent in the following detailed description and claims, particularly when considered in conjunction with the accompanying drawings in which like parts bear like reference numerals. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a generally schematic illustration showing an embodiment of the present invention in use in purifying the water in a spa. 
     FIG. 2 is a plan view of the ozone generator used in the embodiment shown in FIG. 1 with the housing cover removed. 
     FIG. 3 is a plan view of the inner surface of the housing cover of the ozone generator used in the embodiment shown in FIG.  1 . 
     FIG. 4 is a top plan view of the ozone generator used in the embodiment in FIG.  1 . 
     FIG. 5 is a side plan view of the ozone generator used in the embodiment in FIG.  1 . 
     FIG. 6 is a partially cut away plan view of another embodiment of the present invention that includes a removable/replaceable flow cell. 
     FIG. 7 is a rear plan view of the embodiment shown in FIG.  6 . 
     FIG. 8 is an exploded view of the embodiment shown in FIG.  6 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, the present purification apparatus, shown generally at  10 , includes an ozone generator, shown generally at  12 , and a transfer assembly, shown generally at  14 . Ozone generator  12  includes a housing body  16  and a housing cover  18  which is adapted to be joined or connected to the housing body by coupling threaded inserts  20  through complimentary cover holes  22  with threaded screws (not shown). 
     With housing cover  18  secured to housing body  18 , ozone generator  12  is in the form of a compact, closed unit. Located within the space  24  between the housing body  16  and housing cover  18  is an ozone-producing corona discharge chip electrode  26 . Ozone-containing gases produced from air, which enters housing body  16  through air inlet  27  in the housing, by chip electrode  26  exit the housing through housing outlet  28 , which can be an integral part of the housing body  16 . The air inlet may, and preferably does, include a particulate filter, for example, of conventional construction. Both the housing body  16  and housing cover  18  can be made from any suitable material or materials of construction. Preferably, these components are made of polymeric material. The ozone generator  12  typically has a length in a range of about 4 inches to about 10 inches, a width in a range of about 1 inch to about 6 inches and a thickness of about 0.5 inch to about 4 inches. 
     An electrical transformer  30 , of conventional design, is included within space  24 . Electrical transformer  30  processes line power, e.g., 120V, from source  32  through power cord  33  into power suitable for use by chip electrode  26 . Transformer  30  is a “step up” transformer in that the chip electrode  26  uses power having a voltage in the range of about 3000 to about 5000 volts and a frequency in the range of about 18 KHz to about 20 KHz. A series of electrical connectors  33   a,    34  and  36  are included within space  24  and are adapted to connect electric wires so as to provide electric power from source  32  ultimately to chip electrode  26 . These connectors are adapted to be easily removed to allow maintenance of generator  12 . A variable potentiometer  37  is provided and is used to control or adjust the ozone output of generator  12 . 
     The top  38  of housing cover  18  includes a transparent window  40  through which the spa owner can visually observe chip electrode  26 , which glows when ozone is being produced. This glow diminishes over time as the chip electrode  26  becomes less effective in producing ozone. Thus, the spa owner, by observing chip electrode  26 , is provided with an indication as to when ozone generator  12  should be replaced. Atmospheric air from air inlet  27  is directed to come in contact with the chip electrode  26  to produce an ozone-containing gas which passes through housing outlet  28 . 
     In addition, the housing cover  18  includes two end tabs  44  and  46 , each of which includes a through hole  48  through which screws can be passed to secure the ozone generator  12  in place in a suitable stationary position. 
     Ozone generator  12  operates as shown in FIG.  1 . Spa  50  includes a quantity of heated and circulating water  52 , for example, about 500 to 1000 gallons in volume. The spa  50  is equipped with a water circulating system in which water from the spa passes through spa outlet  54  into conduit  56  through spa pump  58 , spa filter  60  and spa heater  62 . Eventually the pumped, filtered and heated water is passed back to the spa  50  through return lines  64  and  66 . 
     In the present invention, piping segment  70  (a part of conduit  56 ), downstream of heater  62  is divided to provide a bypass line, shown generally at  72 . Bypass line  72  includes a venturi assembly  74 , of generally conventional construction, which acts as an ozone adductor to suction ozone-containing gases from ozone generator  12  into bypass line  72 . The combined ozone-containing gases and water is returned to the main water conduit  56 , as shown in FIG. 1. A valve  78 , of conventional design, is located in water conduit  79  and can be adjusted to control the amount of water passed through bypass line  72 . The ozone-containing gases from ozone generator  12  are passed through housing outlet  28  and through ozone conduit  80  into the water flowing through bypass line  72 . The suction created by venturi assembly  74  causes ozone to flow through ozone conduit  80 . 
     Ozone conduit  80  includes a water trap loop  82  located above venturi assembly  74 . This water trap loop  82  acts to protect the ozone generator from being exposed to water in line  56  and bypass line  72 . In addition, ozone conduit  80  includes a check valve  84 , of conventional construction, which effectively prevents fluid flow in the ozone conduit back to the ozone generator  12 . This feature inhibits, or even substantially prevents, any water from line  56  and bypass line  72  from entering ozone generator  12 . 
     Apparatus  10  functions as follows. When it is desired to purify/sanitize the water  52  in spa  50 , operation of the pump  58  and ozone generator  12  is initiated. This causes water  52  to flow from spa  50  through line  56  into pump  58 , filter  60 , heater  62  into piping segment  70 . At this point, a minor amount, that is less than about 50%, of the total water passing through segment  70  is caused to flow through bypass line  72  and venturi assembly  74 . This causes ozone-containing gases being generated by ozone generator  12  to pass through ozone conduit  80  into the water in bypass line  72 , which is ultimately returned to the spa via return line  64  and  66 . 
     Sufficient ozone is produced in accordance with the present invention to purify/sanitize the water  52  in spa  50  and/or to maintain such water in the desired purified/sanitized state. 
     Another advantageous embodiment of the present invention is shown in FIGS. 6,  7  and  8 . In this embodiment, the ozone generator  12  of the spa purifying apparatus  10  shown generally in FIG. 1, may be replaced with the ozone generator shown generally at  112 . 
     The ozone generator  112  comprises a chip electrode assembly  114  that is adapted to be removably coupled to a power supply assembly  116 . 
     More specifically, the power supply assembly  116  includes a power supply  120  housed and contained within a main housing or enclosure  122  comprising a main enclosure base  126  and a main enclosure cover  128 . The power supply  120  includes electrical transformer such as described hereinabove, which processes electrical power from a power source (line power of 110-120 V, or high voltage power e.g. 220-240 V) through molded plug  132  and power cord  133 . 
     Advantageously, the chip electrode assembly  114  is adapted to be removably coupled to the power supply assembly  116 . More specifically, the chip electrode assembly includes a chip electrode  142 , for example a corona discharge chip, shown in FIG. 8, separately enclosed from, and removably coupled to, the power supply assembly  116 . Preferably, the chip electrode  142  is housed in a separate housing or enclosure  146 , hereinafter referred to as a chip electrode enclosure, that includes a body portion  152  and a cover portion  154 . Both the main enclosure  122  and the chip electrode enclosure  146  may be made from any suitable material or materials of construction. The chip electrode enclosure portions  152  and  154  may be soldered together such that when the replacement chip electrode assembly  114  is provided to a customer/consumer, the chip electrode  142  itself is inaccessible. 
     Importantly, electrical connectors  160 , adapted to provide electrical connection between the power supply  120  and the chip electrode  142  are provided which are structured to be easily disengaged, thus facilitating removal of the chip electrode assembly  114 . 
     For example, each electrical connector  160  comprises an electrical contact, for example a receptacle  164  and cooperating pin  166 , integrated with, or mounted on, the main enclosure  122  and the chip electrode enclosure  146  respectively. Electrical wires  170  and  172  provide electrical connection from power supply  120  and chip electrode  142  to receptacles  164  and pins  166 , respectively, as shown. Contact surfaces of the integrated receptacles  164  and pins  166  may be made of copper or other suitable conductive material. 
     Turning now specifically to FIGS. 6 and 7, an example of electrical connections between the cell electrode assembly  114  and the power supply assembly  116  is shown. More specifically, FIG. 7 shows a diagrammatical example of the electrical wires  170  from the power supply  120  to four sets of connectors  160  (i.e. coupled pins and receptacles). The electrical wires  170  may more specifically comprise two 120V wires  173 , and two (optional) high voltage wires  174 . 
     Means for securing mechanical and electrical attachment between the power supply assembly  116  and the chip electrode assembly  114  is preferably provided. This may be achieved by a thumb screw  178  for example, adapted enable easy manual coupling and uncoupling of the assemblies  114 ,  116 . As shown in FIGS. 6 and 8, apertures  180  are provided in both the body portion  152  and cover portion  154  of chip electrode enclosure  146 . Similarly, threaded receptacle  182  is provided in the cover portion  128  of the main enclosure  122 , wherein the apertures  180  and threaded receptacle  182  are adapted to receive the thumb screw  178  when the assemblies  114 ,  116  are properly aligned. It can be appreciated that the thumb screw  178  provides means for securing mechanical attachment of the chip electrode assembly to the main enclosure as well as securing electrical contact between the integrated pins  166  and receptacles  164 . It should also be appreciated that other suitable means of securing the assemblies  114 ,  116  may alternatively be provided. For example, suitable structure (not shown) may be included for enabling the chip electrode assembly  114  to be “snap fitted” onto the power supply assembly  116 . 
     Preferably, the chip electrode enclosure  146  includes indented, grip relief surfaces  184  for facilitating the manual removal of the chip electrode assembly  114 . Similar to as described hereinabove, with respect to the ozone generator embodiment shown in FIGS. 2-5, the chip electrode assembly  114  includes ozone supply outlet  190  to be connected to ozone conduit/supply tubing  80  (see FIG.  1 ). The ozone supply outlet  190  preferably comprises a barb member designed and structured to accommodate two different, standard tubing sizes (e.g. ¼ inch diameter and ⅜ inch diameter). 
     The embodiment shown in FIGS. 6,  7  and  8  is designed to enable a user (e.g. spa owner) to easily remove and replace a worn chip electrode with a new chip electrode without the need to open the power supply assembly thereby exposing the power supply/transformer. Instead, when the chip electrode becomes worn or spent, which may be evidenced, for example, by a visually observable loss of glow through a clear view window  194 , the spa owner will need perform the following simple procedure. After disconnecting cord  133  from power source, the user will (1) disconnect ozone supply tubing  80  (FIG.  1 ), (2) unscrew the thumbscrew  178 , (3) remove the old chip electrode assembly  114 , (4) install a new chip electrode assembly by aligning and connecting pins  166  with receptacles  164 , (5) secure the assemblies  114 ,  116  by means of the thumbscrew  178 , and (6) reconnect ozone supply tubing  80 . Preferably, the assemblies  114 ,  116  are structured accordingly to prevent misalignment between the pins  166  and receptacles  164 . In the embodiment shown, the pins  166  and receptacles  164  can not be misaligned. 
     Thus, it should be appreciated that a worn chip electrode assembly may safely and easily be removed and replaced with a new chip electrode assembly without need for a user/consumer to either open the power supply enclosure or remove the ozone generator from its location. Replacement chip electrode assemblies in accordance with this embodiment may be made available at relatively low cost. 
     The present ozone generator provides a very compact structure which: is easily and conveniently mounted for use in a spa/jetted tub application; requires relatively reduced amounts of maintenance; is cost effective to produce and use; and effectively and efficiently produces ozone in sufficient quantities to perform the desired spa/jetted tub purification/sanitation service. 
     While this invention has been described with respect to various specific examples and embodiments, it is to be understood that the invention is not limited thereto and that it can be variously practiced within the scope of the following claims.

Technology Classification (CPC): 2