Patent Description:
This device uses an electrolysis chemical reaction process to break contaminants into small and stable molecules by using an electric current flowing between parallel electrodes.

<CIT> discloses an apparatus that removes soluble and insoluble contaminants from highly purified and ultra-pure liquids having a bulk resistivity in excess of one megohm-centimeter by establishing laminar flow of the liquid in a cylindrical chamber through an electromagnetic field transverse to the direction of flow, to induce mobility of the constituents.

<CIT> relates to electrolytic cells for producing a sodium hypochlorite solution with active chlorine from brine, said cells comprising a cylindrical metallic cathode with a smaller cylindrical metallic anode disposed within the cathode to define an annular passage through which the electrolyte passes.

In accordance with the present disclosure, an electrode apparatus and method remove a polarized molecule in a fluid. In another aspect, an electric potential is applied to an anode located within the fluid, the fluid flows within a gap between the anode and a surrounding cathode, and a non-uniform electric field is created between the anode and the cathode. A further aspect causes a polarized molecule in a liquid or gaseous fluid to move toward an anode. In another aspect, an electrically conductive porous material is an anode and is circumferentially surrounded by a grounded cathode with a fluid flowing therebetween and a polarized molecule (such as PFAS or other molecules) in the fluid is driven toward the anode, without causing electric current flowing between the anode and cathode and/or without a chemical reaction to the polarized molecule. In a further aspect, an anode is made of a porous metal and/or a porous activated carbon.

Moreover, another disclosure includes a method for manufacturing an anode including making a metallic foil sheet, which may be a porous metal foam, attaching an activated carbon layer to the foil sheet and coiling or bending the foil and activated carbon assembly into a generally cylindrical shape. This method may further include applying an electric field between the foil/carbon anode and a surrounding cathode, flowing a liquid or gaseous fluid between the anode and the cathode, and electrically pulling polarized molecules to the anode without causing an electric current to flow. A further aspect of the present apparatus and method includes a drinking water faucet to which the anode and cathode are attached. Yet another aspect of the present apparatus and method uses the anode and cathode as part of an industrial water fluid treatment piping system. Additional advantages and features will be disclosed in the following description and appended claims, taken in conjunction with the accompanying drawings.

The invention relates to a method for removing a polarized molecule in a fluid, the polarized molecule comprising PFAS, benzene, carbon dioxide, or sulphur dioxide, the method comprising (a) supplying a voltage between an anode and a cathode, wherein the cathode concentrically surrounds the anode, the anode and the cathode being longitudinally elongated and generally cylindrical, said anode being made of porous metal core with a layer of plasma activated carbon or being unitary, uniform and solid with a plasma activated carbon and a binder evenly spread to throughout the entire cross-sectional area from end-to-end, the voltage supplied between the anode and the cathode creating a non-uniform electric field between the anode and the cathode; (b) flowing the fluid within a gap between the cathode and the anode causing the polarized molecule in the fluid to move to the anode with the assistance of step without causing a corresponding electric current flow, wherein the gap is cylindrical and surrounds the anode; and (c) trapping the polarized molecule in the electrically conductive porous material of the anode.

Moreover, the invention relates to an electrode apparatus comprising: (a) an anode, said anode being longitudinally elongated and generally cylindrical, (a) being made of porous metal core with a layer of plasma activated carbon, or (b) being unitary, uniform and solid with a plasma activated carbon and a binder evenly spread to throughout the entire cross-sectional area from end-to-end; (b) a cathode, said cathode being longitudinally elongated and generally cylindrical, and wherein the cathode concentrically surrounds the; (c) a gap between the anode and the cathode; and, wherein the gap is cylindrical and surrounds the anode; and (d) an electrical circuit that electrically connects a direct current power source, the power source being coupled to the anode and the cathode adapted to create at least one of: (i) a non-uniform electric field, or (ii) an electrical potential difference, between the anode and the cathode such that polarized molecules of PFAS, benzene, carbon dioxide, or sulphur dioxide in the fluid move to the anode and are trapped in the electrically conductive porous material of the anode without causing a corresponding electric current flow.

A first preferred embodiment of an electrode apparatus <NUM> used in an industrial water treatment system <NUM> is illustrated in <FIG>. Water treatment system <NUM> includes a contaminated water supply reservoir or tank <NUM>, a decontaminated water receiving or holding reservoir or tank <NUM>, and one or more electrode-based precipitator or treatment units <NUM> and <NUM>. Valves <NUM> of treatment unit <NUM> are turned on to allow flow of contaminated water <NUM> between the tanks while valves <NUM> of treatment unit <NUM> may be optionally turned off to stop fluid flow therein, or vice versa, for example if an anode therein needs to be cleaned and/or replaced. Additionally, water pumps, sensors, pipes and other plumbing components may be employed to flow water <NUM> from tank <NUM>, through treatment units <NUM> and/or <NUM>, and to tank <NUM>.

More specifically, each precipitator and treatment unit <NUM> and <NUM> includes a longitudinally elongated and generally cylindrically shaped cathode electrode <NUM> which concentrically surrounds a generally cylindrically shaped and longitudinally elongated anode electrode <NUM> internally located therein. A cylindrical gap <NUM> concentrically surrounds anode <NUM> between an outer diameter periphery of the anode and an inner diameter surface of cathode <NUM>, such that the cathode and anode are spaced away from each other to allow water <NUM> to longitudinally flow in gap <NUM>. The anode preferably has an outer diameter less than half of the inner diameter of the cathode although such a relationship may be varied for different uses.

Anode <NUM> is preferably a conductive and corrosion resistant rod material <NUM> with porous structures. Anode <NUM> can be a metal, such as copper, stainless steel, nickel or an alloy thereof. Alternatively, anode <NUM> consists of a metal core <NUM> with a layer of activated carbon <NUM> on an outside thereof. Activated carbon <NUM> is preferably treated as is disclosed in <CIT>, and <CIT>. Activated carbon layer <NUM> has a thickness of at least <NUM> micron and a surface area greater than <NUM><NUM>/g is preferred. For PFAS adsorption, it is preferred to employ plasma activated carbon with a relatively positive surface potential. Furthermore, cathode <NUM> is a conductive, corrosion resistant and tubular metallic material, preferably copper but alternately stainless steel, nickel or an alloy thereof.

An electrical circuit <NUM> electrically connects a direct current power source <NUM> to an end <NUM> of anode <NUM> for supplying positive dc voltage thereto. The preferred voltage range is <NUM> - <NUM> volts and more preferably <NUM> - <NUM> volts, however, greater voltage can be used with other fluids. Another electrical circuit <NUM> electrically couples an end of cathode <NUM> to a ground <NUM>. Due to the non-symmetrical nature of the electrodes, for example the fluid-exposed surface area size differences between the smaller outer diameter of anode <NUM> and the larger inner diameter of cathode <NUM>, a non-uniform electric field is created within gap <NUM>. Although there are electrical potential differences between anode <NUM> and cathode <NUM>, however, essentially no electrical current flows between these electrodes since the fresh water within gap <NUM> is a poor electrical conductor and essentially acts as an insulator. There is no current flow corresponding to the transport of PFAS. Thus, there is no electrical current between the electrodes in the water assuming no impurities in the water other than the polarized contaminants to be removed.

As can best be observed in <FIG>, an electrical connector <NUM> retains the associated end <NUM> of anode <NUM> within an end-fitting <NUM>. In the present example, end fitting <NUM> is threadably coupled to a T-pipe junction <NUM>. Furthermore, an intermediate fitting <NUM> threadably couples an associated end <NUM> of cathode <NUM> to pipe junction <NUM>. An additional pipe or contaminated water supply line <NUM> is coupled to pipe junction <NUM> via another fitting <NUM>. A similar arrangement is provided on the opposite end of the treatment unit <NUM>. It should be appreciated that the cathode and anode longitudinal lengths and lateral diameters, as well as the flow through area of the gap therebetween, is sized to match the fluid flow rate, the concentration of the polarized molecule contaminants to be removed, and the adsorption capabilities of the anode employed. Regardless, it is envisioned that the longitudinal length of anode <NUM> will be at least ten times and more preferably at least twenty times an outer diameter thereof.

Referring now to <FIG> and <FIG>, the contaminant to be removed by the present electrode apparatus and method is a polarized molecule <NUM>, preferably a PFAS molecule consisting of at least carbon and fluorine atoms. E denotes the non-uniform electric field between anode <NUM> and cathode <NUM> which drives or pulls the polarized molecule <NUM> toward anode <NUM> which is then adsorbed into the porous anode. It is noteworthy that no chemical reaction or electrolysis is occurring to molecules <NUM> since no or minimal electrical current is flowing between the electrodes. Thus, anode serves to remove the polarized molecule contaminants from the water as the water flows past the anode. No additional filtering or chemical reactions should be necessary to remove these polarized molecules from the flowing drinking water. Periodically, the contaminant-rich anode will be removed and either replaced or cleaned.

It is alternately envisioned that polarized molecules other than PFAS may be removed by use of the present electrode apparatus and method. Moreover, polarized molecules may alternately be removed from other liquid and gaseous fluids, such as within a combustion smokestack or exhaust pipe. Other polarized molecule contaminants include benzene, carbon dioxide, sulphur dioxide and the like.

A residential implementation of an exemplary second preferred embodiment of the present electrode apparatus and method are illustrated in <FIG> and <FIG>. A residential drinking water faucet <NUM> includes an adapter <NUM> adjacent a distal end thereof. Adapter <NUM> employs an anode electrode <NUM> and a concentrically surrounding cathode electrode <NUM>, both of which are longitudinally elongated. A threaded coupling <NUM> removeably couples a proximal end of cathode <NUM> to an outlet pipe <NUM> of faucet <NUM>. Furthermore, a pair of polymeric insulators <NUM> and <NUM> mount and insulate anode <NUM> within cathode while allowing a water flow gap <NUM> between the facing outer and inner surfaces of anode <NUM> and cathode <NUM>, respectively. A polymeric cover plate <NUM> is also provided to secure insulator <NUM> within a stepped recess <NUM> of cathode <NUM>. Cover plate <NUM> may be attached to the inside of the cathode by threads, adhesive or an interference press-fit. Cover plate <NUM> includes multiple longitudinally open holes <NUM>, insulator <NUM> also includes multiple aligned and longitudinally accessible holes <NUM>, and a distal end of cathode <NUM> additionally includes longitudinally accessible holes <NUM>, to allow drinking water to flow therethrough. A battery power supply <NUM> is electrically connected to anode <NUM> and may be retained between insulator <NUM> and cover plate <NUM>, or in a remote different location with a wire or stamped circuit, to supply electrical voltage to an end of anode <NUM>. O-rings <NUM> are also employed to seal the various components. The anode and cathode function essentially the same as with the prior industrial configuration for removing polarized molecule contaminants from the drinking water and adsorbing them onto the anode.

A first method of manufacturing and structure of the present anode <NUM> is shown in <FIG> and <FIG>. Plasma activated carbon <NUM> includes a binder material and is pressed and heated to form a unitary and uniform, solid rod with the activated carbon and binder composition evenly spread throughout the entire cross-sectional area from end-to-end. <FIG> show another manufacturing process and construction of an anode <NUM> wherein a layer of activated carbon <NUM>, intermixed with a binder material, is coated or otherwise affixed to an outer diameter surface <NUM> of a conductive and corrosion resistant metallic rod <NUM>, such as copper, stainless steel, nickel or an alloy thereof, which has a generally circular-cylindrical and longitudinally elongated shape. Preferably, the coated rod assembly of anode <NUM> is only coated at a middle area <NUM> of rod <NUM> such that end sections <NUM> do not have activated carbon <NUM> thereon. This advantageously allows easier and more effective electrical coupling of the uncoated end sections <NUM> to the electrical connector.

A third manufacturing process and configuration for anode <NUM> can be observed in <FIG> and <FIG>. First, a foamed metallic sheet or foil <NUM> is provided. Foamed foil <NUM> is preferably a nickel foam with a surface density of about <NUM>/m<NUM> and a porosity greater than or equal to <NUM> percent, with <NUM>-<NUM> pores per inch (<NUM>-<NUM> pores per cm) and an average hole diameter of about <NUM> mn. One such nickel foam foil can be obtained from MTI Corporation. It should be appreciated, however, that other metallic foam or, less preferably, unfoamed metallic sheets may be employed.

Activated carbon material, preferably intermixed with a binder, is then deposited, coated or otherwise attached to an outer porous surface of metallic foam foil <NUM> in a generally flat state. In one example, activated carbon <NUM> is mixed into a slurry and pressed into the open pores of metallic foam foil <NUM>, which is in a flat state. The assembled activated carbon slurry and foam is then heated at approximately <NUM> - <NUM>° C to dry. An exemplary binder maybe of a cellulose type. Subsequently, the foil and activated carbon assembly is then coiled, rolled or bent into a circular-cylindrical shape with a hollow center <NUM> with an edge seam <NUM> attached together to form a complete cross-sectional circle. Optionally, end caps <NUM> are fastened to both opposite ends of the coiled anode <NUM> to prevent fluid flow through the hollow center <NUM>. Any of these anode configurations <NUM>, <NUM> and <NUM> may be interchangeably used in any of the industrial or residential apparatuses disclosed herein.

Claim 1:
A method for removing a polarized molecule in a fluid, the polarized molecule comprising PFAS, benzene, carbon dioxide, or sulphur dioxide, the method comprising:
(a) supplying a voltage between an anode (<NUM>, <NUM>) and a cathode (<NUM>, <NUM>), wherein the cathode (<NUM>, <NUM>) concentrically surrounds the anode, the anode (<NUM>) and the cathode (<NUM>, <NUM>) being longitudinally elongated and generally cylindrical, said anode (<NUM>, <NUM>) (a) being made of porous metal core with a layer of plasma activated carbon (<NUM>) or (b) being unitary, uniform and solid with a plasma activated carbon and a binder evenly spread to throughout the entire cross-sectional area from end-to-end, the voltage supplied between the anode and the cathode creating a non-uniform electric field between the anode and the cathode;
(b) flowing the fluid within a gap (<NUM>, <NUM>) between the cathode (<NUM>, <NUM>) and the anode (<NUM>, <NUM>) causing the polarized molecule in the fluid to move to the anode with the assistance of step (a) without causing a corresponding electric current flow, wherein the gap (<NUM>, <NUM>) is cylindrical and surrounds the anode (<NUM>, <NUM>); and
(c) trapping the polarized molecule in the electrically conductive porous material of the anode.