Patent Description:
Various chlorine generating devices have been constructed in the past, for example, such as the drop-in chlorinator disclosed in <CIT>. Further, relevant documents are <CIT>, <CIT>, <CIT>, <CIT>.

Illustrative embodiments provide a chlorine generator installed in a spa and having a disposable and consumer replaceable electrode cartridge. The invention is defined in independent apparatus claim <NUM>. Further preferred embodiments are described in dependent claims <NUM>-<NUM>.

According to the invention, there is disclosed, a chlorine generator apparatus comprises a housing adapted to be mounted in a user-accessible exterior surface of a spa and a chlorine generating electrode cartridge mounted in the housing and carrying first and second electrodes wherein the electrode cartridge is configured to be replaceable by a user.

There is disclosed, a housing is provided for receiving an electrode cartridge comprising a wall fitting mounted to a consumer accessible surface of a spa and a cap removably attachable to the wall fitting by a user to provide user access to the electrode cartridge. In one embodiment, the housing may further comprise a lower housing section attached to a lower end of the wall fitting. The lower housing section may provide an electrode chamber wherein electrodes of the electrode cartridge may be disposed to generate chlorine for sanitizing the spa water.

There is disclosed, an electrode cartridge adapted to be installed into a housing by a user of a spa is provided comprising a handle component grippable by the user to insert the electrode cartridge into the housing and to pull the electrode cartridge out of the housing for replacement. In one embodiment, first and second electrodes are mounted beneath the handle for generating chlorine from spa water, and first and second electrical contacts are positioned to come into electrical contact with first and second electrical contacts located on an interior surface of the housing when the electrode cartridge is in an installed position in the housing.

There is disclosed, an electrode cartridge is provided comprising first and second electrodes each of which include a vertical portion which forms into a horizontal base portion from which extends an outwardly curved spring arm electrical contact. According to another aspect, the horizontal base portions of each of the first and second electrodes respectively fit into a respective mating opening in an electrode cup. In one embodiment, each horizontal base portion may be held in place by a bottom surface of a handle component of the electrode cartridge.

There is disclosed, a chlorine generator apparatus is provided wherein a housing comprises first and second internal electrical contact terminals formed on an inner surface thereof and wherein spring arm portions of the first and second electrodes of an electrode cartridge form electrical contact surfaces which are positioned to make electrical contact with the first and second internal electrical contact terminals when the electrode cartridge is fully inserted into the housing.

There is disclosed, a chlorine generator apparatus is provided comprising a groove formed in an inner wall of an electrode cartridge housing and first and second locking bars having first and second projections on respective outer ends thereof and mounted to slide laterally in an electrode cartridge such that the first and second projections can come into engagement with the groove in the housing inner wall in order to lock the electrode cartridge in position. A spring loaded plunger mounted in the electrode cartridge is shaped and positioned to cause the first and second locking bars to move laterally such that the first and second projections come into engagement with the groove.

A chlorine generator system according to an illustrative embodiment is shown in <FIG>. The illustrative system includes an electrical controller <NUM> and a chlorine generator <NUM> mounted in a bar top <NUM> of a spa <NUM>. As may be appreciated, the bar top <NUM> is an example of a user accessible surface of the spa <NUM> where a user may be, for example, a user or owner of the spa <NUM>. In one embodiment, the spa <NUM> may be a portable spa.

The chlorine generator <NUM> comprises an electrode cartridge housing <NUM> and an electrode cartridge <NUM>. In the illustrative embodiment, the electrode cartridge <NUM> carries a pair of electrodes <NUM>, <NUM>, and is removably installed in the electrode cartridge housing <NUM>. In one embodiment, the housing <NUM> is keyed to the electrode cartridge <NUM> to ensure that the cartridge <NUM> may only be installed in the housing <NUM> in a proper manner. In an illustrative embodiment, water from the spa circulation path is routed up to the housing <NUM>, through the electrodes <NUM>, <NUM> and back out of the housing <NUM> to the spa <NUM>.

In an illustrative embodiment, the electrical controller <NUM> controls generation of chlorine by the electrode cartridge <NUM>. In one embodiment, the electrical controller <NUM> is relatively small in size, powered through the spa control system <NUM>, and fully integrated into the spa <NUM>. In one embodiment, the electrical controller <NUM> utilizes an RS485 communication protocol to transmit data and communicate with the spa control system <NUM>. In one embodiment, the spa control system <NUM> may be accessed through and driven by a spa control panel <NUM>. In another embodiment, a closed loop control system may be employed which includes a sensor which measures, for example, one or more of: chlorine, bromine, ozone, ORP, pH, conductivity, alkalinity, cyanuric acid, water hardness and/or temperature. The sensor then feeds parameters to an electronic controller which then automatically causes generation of the appropriate amount of chlorine via the chlorine generator <NUM>.

In the illustrative embodiment, operation of the chlorine generator <NUM> is controlled by user settings for chlorine output made at the spa control panel <NUM>. In an illustrative embodiment, the electrical controller <NUM> drives the electrodes of the chlorine generator <NUM> in a constant current mode to enable an optimal or desired chlorine generation rate. This mode of operation also allows the system to be driven at different specific current levels to control the generation rate of chlorine per hour depending on the user settings.

In one embodiment, the spa water is salted, for example, by adding sodium chloride to achieve a concentration of, for example, <NUM> ppm. Such an embodiment may be characterized as a salt water chlorinator system.

As shown in <FIG>, in an illustrative embodiment, the electrode cartridge housing <NUM> comprises a wall fitting <NUM>, which has circular groove <NUM>, which receives an edge, e.g. <NUM> (<FIG>), of the spa bar top <NUM>. The wall fitting <NUM> mounts to the bar top <NUM> via a centering ring <NUM> and a nut <NUM>. A cap <NUM> is screwed to the wall fitting <NUM> on the user side of the system to provide access to the electrode cartridge <NUM>. An internal web portion <NUM> of the cap <NUM> also positions and holds the electrode cartridge <NUM> in place during operation.

In an illustrative embodiment, an upper portion <NUM> of a lower housing section <NUM> glues into or otherwise attaches to the wall fitting <NUM> to form a watertight attachment. An O-ring <NUM> mounts in a receptacle in the wall fitting <NUM> and provides a watertight seal between the wall fitting <NUM> and the cap <NUM>. In illustrative embodiments, the wall fitting <NUM>, cap <NUM>, and lower housing section <NUM>, may all be a suitable molded plastic material, such as, for example PVC or ABS plastic.

In the illustrative embodiment, the electrical connection of the electrode cartridge <NUM> to the controller <NUM> via electrical leads <NUM>, <NUM> (<FIG>) is completed through a pair of titanium electrical contacts <NUM>, <NUM>, which are molded into the housing <NUM> in watertight fashion. The contacts <NUM>, <NUM> have flat vertical terminals <NUM>, <NUM> adjacent an inside surface of the housing <NUM>, as well as quick disconnect terminals <NUM>, <NUM> on the outside of the housing <NUM>. The electrical contacts <NUM>, <NUM> thus enable dry electrical connections to the chlorine generator <NUM> and ease of service of the system.

Below the electrical contacts <NUM>, <NUM> is a drain port <NUM>. This port <NUM> allows for removal of any water that may have entered the dry portion of the housing <NUM> during removal and replacement of the electrode cartridge <NUM>. A water inlet port <NUM> on the bottom <NUM> of the housing <NUM> allows spa water to enter the housing <NUM> and flow through the wet electrode chamber <NUM>. At the top of the wet electrode chamber <NUM> is an outlet port <NUM> through which the chlorinated spa water flows into the spa <NUM>. The vertical water flow through the housing <NUM> ensures efficient flushing of the housing <NUM> and removal of all liquids and gases generated in the housing <NUM> during operation of the chlorinator I1.

As shown in <FIG>, in an illustrative embodiment, the electrode cartridge <NUM> comprises a tee handle <NUM> and pair of mixed metal oxide titanium electrodes <NUM>, <NUM>. In illustrative embodiments, the electrodes <NUM>, <NUM> may comprise, for example, titanium or niobium base metal with a suitable oxide coating, such as, for example, ruthenium oxide, iridium oxide, or platinum oxide. In other embodiments, the electrodes could be boron/nitrogen doped diamond.

In the illustrative embodiment, the electrodes <NUM>, <NUM> are each formed as a single piece and each includes a respective rectangular vertical portion <NUM>, <NUM>, which forms into a respective horizontal base portion <NUM>, <NUM>, from which extends respective outwardly curved spring arm electrical contact <NUM>, <NUM>. The electrodes <NUM>, <NUM> could of course be formed of multiple parts in other embodiments, for example, with separate wet electrode and spring contact components.

The horizontal base portions <NUM>, <NUM> of each of the electrodes <NUM>, <NUM> each fit into a respective mating opening <NUM>, <NUM> in an electrode cup <NUM> and are held in place by a bottom surface <NUM> of the tee handle <NUM>. An O-ring <NUM> provides a watertight seal between the housing <NUM> and the electrode cup <NUM>.

First and second slots, e. <NUM>, are defined in the electrode cup <NUM> on either side of horizontal projections <NUM>, <NUM>, through which a respective one of the electrodes <NUM>, <NUM> are inserted. Potting material is applied to seal openings around the electrodes <NUM>, <NUM>. A cap <NUM> covers the opening in the electrode cup <NUM> and prevents potting material from leaking up through the opening. In an illustrative embodiment, the tee handle <NUM> and electrode cup <NUM> may be molded plastic components formed, for example, of PVC or ABS plastic.

In an illustrative embodiment, the design and shape of the electrodes <NUM>, <NUM> provide a single piece component extending from the wetted electrode blade portions <NUM>, <NUM> to the dry spring arm electrical contacts <NUM>, <NUM>. The wetted blade portions <NUM>, <NUM> of the electrodes <NUM>, <NUM> are equally spaced apart down the length of the cartridge <NUM>, and a spacer <NUM> is mounted at the end of the cartridge <NUM> to ensure that the electrodes <NUM>, <NUM> are held in proper position. The dry spring arm portions <NUM>, <NUM> of the electrodes <NUM>, <NUM> form electrical contact surfaces which are spring-biased into electrical contact with the flat vertical electrical contact terminals <NUM>, <NUM>, located on the interior of the electrode housing <NUM>.

As noted above, in one embodiment, the geometry of the electrode cartridge <NUM> permits installation of the electrode cartridge <NUM> into the housing <NUM> in only one direction and orientation, insuring proper electrical contact. In particular, in the illustrative embodiment, the outer vertical edges of the rectangular plastic guards, <NUM>, <NUM> around each of the electrode contact arms <NUM>, <NUM> extend outwardly and are shaped to mate with respective channels <NUM> defined by vertical guides <NUM>, <NUM> formed on the inner wall of the electrode housing <NUM>, as shown in <FIG>. The electrode cartridge <NUM> is thereby keyed to the housing <NUM>, permitting the cartridge <NUM> to be inserted in only one orientation.

In one illustrative embodiment, a locking mechanism is used to secure the cartridge <NUM> in place within the housing <NUM> independent of the cap <NUM>. In particular, as shown in <FIG> and <FIG>, a spring loaded plunger is slidably mounted in an internal opening in the tee handle <NUM> and comprises a bottom shaft <NUM>, a spring <NUM> and a plunger cap <NUM>. Respective locking bars <NUM>, <NUM> with ball-shaped end surfaces <NUM>, <NUM> are positioned to move laterally in respective channels <NUM>, <NUM> (<FIG>) formed in the lower end of the tee handle <NUM>. Oblong slots <NUM>, <NUM>, (<FIG>) are formed in each of the locking bars <NUM>, <NUM> to permit the locking bars <NUM>, <NUM> to move laterally left and right with respect to the attachment screws <NUM>, which attach the tee handle <NUM> to the electrode cup <NUM>.

As a result of this construction, the cartridge <NUM> cannot be installed in the housing <NUM> without first pushing the plunger down by depressing the plunger cap <NUM> to retract the balls <NUM>, <NUM> to a position within the respective channels <NUM>, <NUM> in the lower end of the handle <NUM>, as illustrated in <FIG>. Once the balls <NUM>, <NUM>, are positioned adjacent the channel <NUM> in the housing <NUM>, as shown in <FIG>, the plunger can be pulled upward to the position shown in <FIG> so as to force lateral movement of the locking bars <NUM>, <NUM>, thereby causing the balls <NUM>, <NUM> to enter the locking position shown in <FIG>. If the cartridge <NUM> is not fully inserted into its proper position in the housing <NUM>, the dimensioning of the cap <NUM> will cause the cap <NUM> to push the cartridge <NUM> into the locked position of <FIG> when the cap <NUM> is installed. If the cap <NUM> is thereafter removed, the cartridge <NUM> remains in its proper place.

To remove the cartridge <NUM>, the tee handle <NUM> may be grasped with two fingers and the plunger cap <NUM> depressed with the thumb, thereby releasing the locking balls <NUM>, <NUM> and allowing them to slide back. The cartridge <NUM> may then be lifted out of the housing <NUM>.

Illustrative embodiments provide numerous advantages and improvements and in particular a low cost, disposable, consumer replaceable electrode cartridge, which is removable from the top side of a spa. Illustrative embodiments enable dry removal of the electrode cartridge, avoiding the risk of electrical shock. Spa-side control and operation of the system is also provided.

Significantly lower water maintenance requirements are also achieved by illustrative embodiments because the electrode cartridge is designed to last a short life and to be disposable. Hence, the necessity to control spa water parameters in order to maintain chlorine generator electrodes in operating condition is minimized or eliminated. For example, softening the spa water can help to minimize the need to clean the electrodes. The illustrative embodiments eliminate the need to clean the electrodes and hence the need to control spa water parameters in order to maintain the electrodes. Thus, when the electrode cartridge is spent (no longer operating in spec) the system instructs the owner to change it out.

Claim 1:
A chlorine generator apparatus comprising:
a housing (<NUM>) adapted to be mounted in and through an opening in an exterior, user-accessible surface (<NUM>) of a spa (<NUM>) and
a user replaceable electrode cartridge (<NUM>) configured to be installable by a user into said housing (<NUM>) and to thereafter be pulled out of the housing (<NUM>) by the user and replaced;
wherein the electrode cartridge (<NUM>) comprises a handle (<NUM>) grippable by the user to pull the electrode cartridge (<NUM>) out of the housing (<NUM>) and first and second electrodes (<NUM>, <NUM>) positioned to extend into said housing (<NUM>); and
wherein the housing (<NUM>) comprises:
a wall fitting (<NUM>) adapted to be installed into the opening in said user-accessible surface (<NUM>); and
a cap (<NUM>) removably attachable to the wall fitting (<NUM>) by a user to provide user access to the installed electrode cartridge (<NUM>).