Patent Document

BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to electrolysis systems, and in particular to an electrolysis chamber. 
     2. Background of the Invention 
     to Electrolysis is a process wherein electric current is passed through an ionic substance dissolved in an appropriate solvent, which results in chemical reactions at the electrodes immersed in the electrolysis chamber solution, and the production of certain desirable output products. 
     The principal components required to bring electrolysis about are a source of electrical energy electrically connected to a pair of electrodes extending into a liquid containing mobile ions (an “electrolyte”), which is contained in an electrolysis chamber. When an electrical potential difference is applied across the electrodes, each electrode attracts ions of the opposite charge: the positive electrode (the “anode”) attracts negatively-charged ions (“anions”), while the negatively-charged electrode (the “cathode”) attracts positively charged ions (“cations”). 
     At the electrodes, electrons are absorbed or released by the atoms and ions. Those atoms that gain or lose electrons to become charged ions pass into the electrolyte. Those ions that gain or lose electrons to become uncharged atoms separate from the electrolyte. The formation of uncharged atoms from ions is called discharging. 
     The electrolysis products are collected at the electrodes. For example where the electrolysis of brine produces hydrogen and chlorine gas, the gas bubbles rise to the surface of the electrolyte for collection. 
     In order to employ electrolysis chambers in a useful manner, it is necessary to provide entry into the electrolysis chamber for the initial products, which may be salt in a water solution and water; and exit from the chamber for the electrolysis products, which may be a chemical A such as hypochlorous acid (HC10) and sodium hydroxide (NAOH), and by-products sich as brine (salt in a water solution). 
     It is common industry practice to install electrolysis electrodes together in series within the same electrolysis chamber, in interest of efficiency. The electrodes are separated by membranes, which also serve to separate the initial products and electrolysis products into appropriate electrolysis sub-chambers. 
       FIG. 3  schematically depicts a four-electrode electrolysis chamber, and  FIG. 4  schematically depicts a three-electrode chamber. It may be appreciated from these figures that routing the correct initial electrolysis products into the appropriate electrolysis sub-chambers is a non-trivial activity. Similarly, extracting electrolysis end products from the appropriate sub-chambers can become complicated, unless a common routing is established for each electrolysis end product. 
     Accordingly, it would be desirable to provide a single inlet port for each electrolysis initial product, and appropriate passaging to distribute each electrolysis initial product from each inlet port to corresponding electrolysis sub-chambers. 
     Similarly, it would be desirable to provide a single outlet port for each electrolysis end product, and appropriate passaging to distribute each electrolysis end product from its corresponding electrolysis sub-chambers to its single outlet port. 
     In addition, it would be desirable to provide a means to set the flow rate of the first initial product into each first initial product sub-chamber, so that input rate and production rate can be set in each first initial product sub-chamber. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the present invention to provide an electrolysis chamber which provides a single inlet port for each electrolysis initial product, and appropriate passaging to distribute each electrolysis initial product from each inlet port to corresponding electrolysis sub-chambers. Design features allowing this object to be accomplished include a first electrolysis product inlet port into a first initial product manifold, and a plurality of first initial product sub-chambers communicating with the first initial product manifold; and a second electrolysis product inlet port into a second initial product manifold, and a plurality of second initial product sub-chambers communicating with the second initial product manifold. Advantages associated with the accomplishment of this object include simplicity of connection and use of the electrolysis chamber, and associated time and cost savings. 
     It is another object of the present invention to provide an electrolysis chamber which provides a single outlet port for each electrolysis end product, and appropriate passaging to distribute each electrolysis end product from its corresponding electrolysis sub-chambers to its single outlet port. Design features allowing this object to be accomplished include a plurality of first initial product sub-chambers adjacent respective positive electrodes communicating with a first end product manifold and a first end product outlet port; a plurality of first initial product sub-chambers adjacent respective negative electrodes communicating with a second end product manifold and a second end product outlet port; and a plurality of second initial product sub-chambers, each disposed between a positive and a negative electrode and separated from these by membranes, which communicate with a third end product manifold and a third end product outlet port. 
     Benefits associated with the accomplishment of this object include simplicity of connection and use of the electrolysis chamber, and associated time and cost savings. 
     It is still another object of this invention to provide an electrolysis chamber which permits flow adjustment into each first initial product sub-chamber. Design features enabling the accomplishment of this object include a flow control valve between a first initial product manifold and each first initial product sub-chamber. Advantages associated with the realization of this object include operator ability to regulate flow of first initial product into each first initial product sub-chamber, increased accuracy of reaction in each first initial product sub-chamber, and associated cost sayings. 
     It is yet another object of this invention to provide an electrolysis chamber which is inexpensive to produce. Design features allowing this object to be achieved include the use of components made of readily available materials. Benefits associated with reaching this objective include reduced cost, and hence increased availability. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention, together with the other objects, features, aspects and advantages thereof will be more clearly understood from the following in conjunction with the accompanying drawings. 
       Five sheets of drawings are provided. Sheet one contains  FIG. 1 . Sheet two contains  FIG. 2 . Sheet three contains  FIG. 3 . Sheet four contains  FIG. 4 . Sheet five contains  FIG. 5 . 
         FIG. 1  is a front quarter elevated isometric view of an electrolysis chamber with inlet and outlet ports. 
         FIG. 2  is a rear quarter upward view of an electrolysis chamber. 
         FIG. 3  is a side cross-sectional schematic view of a four-electrode electrolysis chamber, showing passaging between inlet and outlet ports, and sub-chambers. 
         FIG. 4  is a side cross-sectional schematic view of a three-electrode electrolysis chamber, showing passaging between inlet and outlet ports, and sub-chambers. 
         FIG. 5  is a front cross-sectional view of a flow control valve. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  is a front quarter elevated isometric view of electrolysis chamber  2 .  FIG. 2  is a rear quarter upward view of electrolysis chamber  2 . As may be observed in these figures, electrolysis chamber  2  comprises first initial product inlet port  10  and second initial product inlet port  12  for initial products for the electrolysis process; and first end product outlet port  6 , second end product outlet port  8 , and third end product outlet port  14  for the products resulting from the electrolysis. 
     One example of these products may be water as a first initial product and salt in water solution as a second initial product; and hypochlorous acid as a first end product, sodium hydroxide as a second end product, and brine solution as a third end product. Two important advantages of the instant design are the single inlet ports for each initial product, and the single outlet ports for each end product. 
     In the embodiment depicted in  FIGS. 1 ,  2  and  3 , the electrolysis chamber  2  shown is a four-electrode electrolysis chamber. Accordingly, four electrode contacts  4  are illustrated in  FIG. 1 . 
       FIG. 3  is a side cross-sectional schematic view of a four-electrode electrolysis chamber  2 , showing passaging between inlet and outlet ports, and sub-chambers. 
     The four-electrode electrolysis chamber  2  depicted in  FIGS. 1-3  comprises electrodes, electrolysis sub-chambers, and membranes arrayed side-by-side from electrolysis chamber first side  1  to electrolysis chamber second side  3  in the following order: first initial product sub-chamber  26 , negative electrode  16 , membrane  20 , second initial product sub-chamber  30 , membrane  20 , positive electrode  18 , first initial product sub-chamber  26 , first initial product sub-chamber  26 , negative electrode  16 , membrane  20 , second initial product sub-chamber  30 , membrane  20 , positive electrode  18 , and first initial product sub-chamber  26 . 
     A single first initial product inlet port  10  provides access from the exterior of electrolysis chamber  2  to first initial product manifold  22 . First initial product manifold  22  communicates with a plurality of first initial product sub-chambers  26  through flow control valves  40 . One flow control valve  40  is associated with each first initial product sub-chamber  26 , and sets the flow rate of first initial product  80  into its respective first initial product sub-chamber  26 . 
     A single second initial product inlet port  12  provides access from the exterior of electrolysis chamber  2  to second initial product manifold  28 . Second initial product manifold  28  communicates with a plurality of second initial product sub-chambers  30 . 
     A single first end product outlet port  6  provides exit for first end product  84  from the first initial product sub-chambers  26  which are adjacent positive electrodes  18 , through first end product manifold  50 . A single second end product outlet port  8  provides exit for second end product  86  from the first initial product sub-chambers  26  which are adjacent negative electrodes  16 , through second end product manifold  52 . A single third end product outlet port  14  provides exit for third end product  88  from second initial product sub-chambers  30  through third end product manifold  54  and third end product outlet port  14 . 
     Described in broad brush strokes, initial products enter respective electrolysis sub-chambers, undergo electrolysis, and emerge as end products. In one possible embodiment of this process, second initial product  82  may be salt in water solution, which emerges from second initial product sub-chambers  30  as third end product  88  which may be brine, and thence proceeds to second initial product reservoir  32 , which may be a salt tube. 
     In operation, first initial product  80  is supplied from a source external to electrolysis chamber  2  through first initial product inlet port  10  and first initial product manifold  22  and into first initial product sub-chambers  26  as indicated by arrows  60 . Second initial product  82  is pumped by pump  34  from second initial product reservoir  32  into second initial product manifold  28 , and from thence into second initial product sub-chambers  30  as indicated by arrows  62 . 
     In each electrolysis sub-chamber, the initial products are electrolyzed into end products, and the specific end product flowing from each first initial product sub-chamber  26  depends on the polarity of electrode adjacent the specific first initial product sub-chamber  26 . First initial product  80  passing through first initial product sub-chambers  26  adjacent positive electrodes  18  emerges from electrolysis chamber  2  through first end product outlet port  6  as first end product  84 , as indicated by arrows  64 . First initial product  80  passing through first initial product sub-chambers  26  which are adjacent negative electrodes  16  emerge from electrolysis chamber  2  through second end product outlet port  8  as second end product  86 , as indicated by arrows  66 . 
     Third end product  88  emerges from second initial product sub-chambers  30  into third end product manifold  54 , and thence through third end product outlet port  14  and into second initial product reservoir  32 , as indicated by arrows  68 . 
     Thus, each first initial product sub-chamber  26  adjacent a positive electrode  18  communicates with first end product manifold  50 , which in turn communicates with an exterior of electrolysis chamber  2  through first end product outlet port  6 . Similarly, each first initial product sub-chamber  26  adjacent a negative electrode  16  communicates with second end product manifold  52 , which in turn communicates with an exterior of electrolysis chamber  2  through second end product outlet port  8 . Finally, each second initial product sub-chamber  30  communicates with third end product manifold  54 , which in turn communicates with an exterior of electrolysis chamber  2  through third end product outlet port  14 . 
     As previously mentioned, it is desirable to be able to control the flow rate of first initial product  80  into respective first initial product sub-chambers  26  by means of a flow control valve  40  associated with each first initial product sub-chamber, because this in turn controls the rate of production of first end product  84  and second end product  86 . 
       FIG. 5  is a front cross-sectional view of flow control valve  40 . As may be observed in this figure, flow control valve  40  comprises valve face  44  sized to seat in valve seat  42 , threaded rod  46  attached at one end to valve face  44 , threaded bore  48  in electrolysis chamber  2  sized to mate with threaded rod  64 , and actuator knob  49  attached to an end of threaded rod  48  opposite valve face  44 . 
     In operation, initial product flows into a respective electrolysis sub-chamber as indicated by arrow  90 . Rotation of actuator knob  49  as indicated by arrow  92  causes valve face  44  to translate nearer or farther from valve seat  42 , as indicated by arrow  94 , thus closing or opening valve  40  and setting the flow rate of the initial product into the respective electrolysis sub-chamber. 
       FIG. 4  is a side cross-sectional schematic view of a three-electrode electrolysis chamber, showing passaging between inlet and outlet ports, and sub-chambers. 
     The three-electrode electrolysis chamber  2  depicted in  FIG. 4  comprises electrodes, electrolysis sub-chambers, and membranes arrayed side-by-side from electrolysis chamber first side  1  to electrolysis chamber second side  3  in the following order: first initial product sub-chamber  26 , negative electrode  16 , membrane  20 , second initial product sub-chamber  30 , membrane  20 , positive electrode  18 , first initial product sub-chamber  26 , membrane  20 , second initial product sub-chamber  30 , membrane  20 , negative electrode  16 , and first initial product sub-chamber  26 . 
     A single first initial product inlet port  10  provides access from the exterior of electrolysis chamber  2  to first initial product manifold  22 . First initial product manifold  22  communicates with a plurality of first initial product sub-chambers  26  through flow control valves  40 . One flow control valve  40  is associated with each first initial product sub-chamber  26 , and sets the flow rate of first initial product  80  into its respective first initial product sub-chamber  26 . 
     A single second initial product inlet port  12  provides access from the exterior of electrolysis chamber  2  to second initial product manifold  28 . Second initial product manifold  28  communicates with a plurality of second initial product sub-chambers  30 , so that second initial product  82  may flow through second initial product inlet port  12 , second initial product manifold  28 , and into second initial product sub-chambers  30 . 
     A single first end product outlet port  6  provides exit for first end product  84  from the first initial product sub-chamber  26  which is adjacent positive electrode  18 , through first end product manifold  50 . A single second end product outlet port  8  provides exit for second end product  86  from the first initial product sub-chambers  26  which are adjacent negative electrodes  16 , through second end product manifold  52 . A single third end product outlet port  14  provides exit for third end product  88  from second initial product sub-chambers  30  through third end product manifold  54 . 
     In operation, the three-electrode embodiment depicted in  FIG. 4  is analogous to the operation of the four-electrode embodiment described above. First initial product  80  is supplied from a source external to electrolysis chamber  2  through first initial product inlet port  10  and first initial product manifold  22  and into first initial product sub-chambers  26  as indicated by arrows  100 . Second initial product  82  is pumped by pump  34  from second initial product reservoir  32  into second initial product manifold  28 , and from thence into second initial product sub-chambers  30  as indicated by arrows  102 . 
     In each electrolysis sub-chamber, the initial products are electrolyzed into end products, and the specific end product flowing from each first initial product sub-chamber  26  depends on the polarity of electrode adjacent the specific first initial product sub-chamber  26 . First initial product  80  passing through the first initial product sub-chamber  26  which is adjacent positive electrode  18  emerges from electrolysis chamber  2  through first end product outlet port  6  as first end product  84 , as indicated by arrows  104 . First initial product  80  passing through first initial product sub-chambers  26  which are adjacent negative electrodes  16  emerge from electrolysis chamber  2  through second end product outlet port  8  as second end product  86 , as indicated by arrows  106 . 
     Third end product  88  emerges from second initial product sub-chambers  30  into third end product manifold  54 , and thence through third end product outlet port  14  and into second initial product reservoir  32  as indicated by arrows  108 . 
     While in interest of clarity the schematic depictions of electrolysis chamber  2  in  FIGS. 3 and 4  show boundary lines for sub-chambers  26  and  30 , it is intended to be understood that the actual physical walls of sub-chambers  26 ,  30  are in fact the membranes  30  which border each sub-chamber. 
     The two representative embodiments illustrated in  FIGS. 1-3 , and  4 , respectively, are not intended to be exhaustive. To the contrary, it is intended to fall within the scope of this disclosure that any desired number of first initial product sub-chambers  26 , second initial product sub-chambers  30 , positive electrodes  18 , negative electrodes  16 , and electrolysis membranes  20  be employed. The advantages of providing a single first initial product inlet port  10 , a single second initial product inlet port  12 , a single first end product outlet port  6 , a single second end product outlet port  8 , and a single third end product outlet port  14  are preserved regardless of the number of first initial product sub-chambers  26 , second initial product sub-chambers  30 , positive electrodes  18 , negative electrodes  16 , and electrolysis membranes  20 . 
     In the preferred embodiment, electrolysis chamber  2  was made of acid and corrosion resistant material such as synthetic, nylon, plastic, or other appropriate material. Electrodes  16 ,  18  and membranes  30  were made of conventional commercially available electrolysis materials. Electrode contacts  4  and the inlet and outlet ports were commercially available components. Valve  40  was made of synthetic, nylon, plastic, stainless steel, metal, or other appropriate material. 
     While a preferred embodiment of the invention has been illustrated herein, it is to be understood that changes and variations may be made by those skilled in the art without departing from the spirit of the appending claims. 
     DRAWING ITEM INDEX 
     
         
           1  electrolysis chamber first side 
           2  electrolysis chamber 
           3  electrolysis chamber second side 
           4  electrode contact 
           6  first end product outlet port 
           8  second end product outlet port 
           10  first initial product inlet port 
           12  second initial product inlet port 
           14  third end product outlet port 
           16  negative electrode 
           18  positive electrode 
           20  membrane 
           22  first initial product manifold 
           26  first initial product sub-chamber 
           28  second initial product manifold 
           30  second initial product sub-chamber 
           32  second initial product reservoir 
           34  pump 
           40  flow control valve 
           42  valve seat 
           44  valve face 
           46  threaded rod 
           48  threaded rod 
           49  actuator knob 
           50  first end product manifold 
           52  second end product manifold 
           54  third end product manifold 
           60  arrow 
           62  arrow 
           64  arrow 
           66  arrow 
           68  arrow 
           80  first initial product 
           82  second initial product 
           84  first end product 
           86  second end product 
           88  third end product 
           90  arrow 
           92  arrow 
           94  arrow 
           100  arrow 
           102  arrow 
           104  arrow 
           106  arrow 
           108  arrow

Technology Category: 8