Ozone generator having a conductor with projections extending through an inner electrode and associated fabrication method

• US 5,433,927 A
• Filed: 04/16/1993
• Issued: 07/18/1995
• Est. Priority Date: 02/10/1992
• Status: Expired due to Fees

• Current Assignee: Aerogenix, L.L.C.
• Original Assignee: Figge International Incorporated
• Inventors: McEachern, Dennis H., Mausgrover, Robert H.
• Primary Examiner(s): Walsh, Donald P.
• Assistant Examiner(s): JENKINS, DANIEL J
• Application Number:
  US08/048,487
• Time in Patent Office: 823 Days
• Field of Search: 422/186.07, 422/186.18, 422/907
• US Class Current: 422/186.07
• CPC Class Codes: C01B 13/11 by electric discharge
• CPC Class Codes: C01B 2201/14 Concentric/tubular dischargers
• CPC Class Codes: C01B 2201/22 Constructional details of the electrodes
• CPC Class Codes: C02F 1/32 with ultraviolet light
• CPC Class Codes: C02F 1/40 Devices for separating or removing fatty or oily substances or similar floating material cleaning or keeping clear the surface of open water from oil or like materials E02B15/04; devices in sewers for separating liquid or solid substances from sewage E03F5/14, e.g. for use in drains leading to the sewer E03F5/16
• CPC Class Codes: C02F 1/78 with ozone C02F1/4672 takes precedence
• CPC Class Codes: C02F 2201/008 Mobile apparatus and plants, e.g. mounted on a vehicle for biological treatment C02F2203/008
• CPC Class Codes: C02F 2201/782 Ozone generators
• CPC Class Codes: Y02P 20/129 Energy recovery, e.g. by cogeneration, H2recovery or pressure recovery turbines
• CPC Class Codes: Y10S 422/907 Corona or glow discharge means

Abstract

An ozone generator includes an inner electrode formed of a mass of helical windings through which an elongate electrical conductor extends. The elongate conductor is preferably a metal strip having opposing rows of sawtooth projections extending outwardly from opposing side edges of the strip. The metal strip also preferably has a generally sinuous shape in longitudinal cross-section. An outer electrode is separated from the inner electrode by a dielectric tube. The inner and outer electrodes produce ozone gas using an electrical corona discharge in the presence of an oxygen containing gas. A second tube surrounds the first dielectric tube to capture ozone generated at the outer electrode. A pair of endcaps directs gas flow adjacent the outer conductor and through the inner conductor.

Claims

1. An apparatus for generating ozone from an oxygen containing gas using an electrical corona, said apparatus comprising:

a first dielectric tube;

an outer electrode overlying a portion of said first dielectric tube;

an inner electrode positioned in an interior of said first dielectric tube and underlying said outer electrode for creating an electrical corona and thereby producing ozone from an oxygen containing gas passing through said inner electrode; and

an elongate electrical conductor positioned in the interior of said first dielectric tube, said elongate electrical conductor having a plurality of outwardly extending projections in electrical contact with adjacent portions of said inner electrode wherein said inner electrode is formed of a mass of helical windings of electrically conductive material, and wherein said helical windings have a series of curved surfaces thereon for creating the electrical corona therefrom.

2. An apparatus according to claim 1 wherein said elongate electrical conductor comprises an electrically conductive strip, and wherein said plurality of outwardly extending projections comprise opposing rows of sawtooth-shaped projections extending outwardly from opposing side edges of said strip.

3. An apparatus according to claim 2 wherein said strip has a generally sinuous longitudinal cross-section defined by a series of spaced apart alternating bends.

4. An apparatus according to claim 2 wherein said strip has enlarged opposite end portions for securing the mass of helical windings therebetween.

5. An apparatus according to claim 1 wherein said mass of helical windings substantially fills an interior cross-section of said first dielectric tube.

6. An apparatus according to claim 1 wherein said mass of helical windings comprises a plurality of milled sponges, wherein each milled sponge has a plurality of layers of at least one continuous helical winding extending in a generally spiral direction about a central axis of said milled sponge, and wherein each milled sponge is maintained in an axially compacted condition by engagement with said plurality of outwardly extending projections of said elongate electrical conductor.

7. An apparatus according to claim 1 wherein the radius of curvature of each of said helical windings is not more than about one quarter of an inch.

8. An apparatus according to claim 1 further comprising:

a second tube surrounding and in spaced apart relation from said first dielectric tube thereby defining a passageway between the first and said second tubes for capturing ozone generated at the outer electrode; and

endcap means connected to said first and second tubes for permitting the inflow of an oxygen containing gas into the passageway between the first and second tubes, for permitting the flow of gas from the passageway between the first and second tubes to the interior of said first dielectric tube, and for permitting the outflow of gas from the interior of said first dielectric tube.

9. An apparatus according to claim 1 wherein said first dielectric tube comprises borosilicate glass.

10. An apparatus according to claim 1 wherein said outer electrode has an open lattice structure.

11. An apparatus for generating ozone from an oxygen containing gas using an electrical corona, said apparatus comprising:

a first dielectric tube;

an outer electrode overlying a portion of said first dielectric tube;

an inner electrode positioned in an interior of said first dielectric tube and underlying said outer electrode, said inner electrode being formed of a mass of helical windings of electrically conductive material substantially filling an interior cross-section of said first dielectric tube, said helical windings having a series of curved surfaces thereon for creating the electrical corona therefrom and being permeable to a flow of gas to thereby produce ozone from an oxygen containing gas passing through said helical windings; and

an elongate electrical conductor positioned in the interior of said first dielectric tube and extending through said mass of helical windings, said elongate electrical conductor having a plurality of outwardly extending projections in electrical contact with adjacent portions of said mass of helical windings.

12. An apparatus according to claim 11 wherein said elongate electrical conductor comprises an electrically conductive strip, wherein said plurality of outwardly extending projections comprise opposing rows of sawtooth-shaped projections extending outwardly from opposing side edges of said strip.

13. An apparatus according to claim 12 wherein said strip has a generally sinuous longitudinal cross-section defined by a series of spaced apart alternating bends.

14. An apparatus according to claim 12 wherein said strip has enlarged opposite end portions for securing the mass of helical windings therebetween.

15. An apparatus according to claim 11 wherein said mass of helical windings comprises a plurality of milled sponges, wherein each milled sponge has a plurality of layers of at least one continuous helical winding extending in a generally spiral direction about a central axis of said milled sponge, and wherein each milled sponge is maintained in an axially compacted condition by engagement with said plurality of outwardly extending projections of said elongate electrical conductor.

16. An apparatus according to claim 11 wherein the radius of curvature of each of said helical windings is not more than about one quarter of an inch.

17. An apparatus according to claim 11 further comprising:

a second tube surrounding and in spaced apart relation from said first dielectric tube thereby defining a passageway between the first and said second tubes for capturing ozone generated at the outer electrode; and

endcap means connected to said first and second tubes for permitting the inflow of an oxygen containing gas into the passageway between the first and second tubes, for permitting the flow of gas from the passageway between the first and second tubes to the interior of said first dielectric tube, and for permitting the outflow of gas from the interior of said first dielectric tube.

18. An apparatus according to claim 11 wherein said first dielectric tube comprises borosilicate glass.

19. An apparatus according to claim 11 wherein said outer electrode has an open lattice structure.

20. An apparatus for generating ozone from an oxygen containing gas using an electrical corona, said apparatus comprising:

a housing;

a first dielectric tube positioned within said housing;

an outer electrode overlying a portion of said first dielectric tube;

an inner electrode positioned in an interior of said first dielectric tube and underlying said outer electrode for creating an electrical corona and thereby producing ozone from an oxygen containing gas passing through said inner electrode;

an elongate electrical conductor positioned in the interior of said first dielectric tube, said elongate electrical conductor having a plurality of outwardly extending projections in electrical contact with adjacent portions of said inner electrode;

a second tube surrounding and in spaced apart relation from said first dielectric tube thereby defining a passageway between the first and said second tubes for capturing ozone generated at the outer electrode; and

endcap means connected to said first and second tubes for permitting the inflow of an oxygen containing gas into the passageway between the first and second tubes, for permitting the flow of gas from the passageway between the first and second tubes to the interior of said first dielectric tube, and for permitting the outflow of gas from the interior of said first dielectric tube, said endcap means further comprising plunger means at one end of said first and second tubes for removably positioning said first and second tubes within said housing wherein said inner electrode is formed of a mass of helical windings of electrically conductive material, and wherein said helical windings have a series of curved surfaces thereon for creating the electrical corona therefrom.

23. An apparatus according to claim 20 wherein said strip has enlarged opposite end portions for securing the mass of helical windings therebetween.

24. An apparatus according to claim 20 wherein said mass of helical windings substantially fills an interior cross-section of said first dielectric tube.

25. An apparatus according to claim 20 wherein said mass of helical windings comprises a plurality of milled sponges, wherein each milled sponge has a plurality of layers of at least one continuous helical winding extending in a generally spiral direction about a central axis of said milled sponge, and wherein each milled sponge is maintained in an axially compacted condition by engagement with said plurality of outwardly extending projections of said elongate electrical conductor.

26. An apparatus according to claim 20 wherein the radius of curvature of each of said helical windings is not more than about one quarter of an inch.

21. An apparatus according to claim 21 wherein said elongate electrical conductor comprises an electrically conductive strip, and wherein said plurality of outwardly extending projections comprise opposing rows of sawtooth-shaped projections extending outwardly from opposing side edges of said strip.

22. An apparatus according to claim 21 wherein said strip has a generally sinuous longitudinal cross-section defined by a series of spaced apart alternating bends.

27. A method for making an ozone generator comprising the steps of:

providing a plurality of milled sponges, each having a plurality of layers of at least one continuous helical winding extending in a generally spiral direction about a central axis of the milled sponge;

providing an elongate electrical conductor having a plurality of outwardly extending projections thereon; and

successively positioning each of the plurality of milled sponges onto the elongate electrical conductor about the central axis of each sponge.

28. A method according to claim 27 wherein the step of successively positioning each milled sponge onto the elongate electrical conductor comprises positioning each with respect to adjacent projections so that each sponge is positioned having a predetermined degree of axial compaction.

29. A method according to claim 27 further comprising the steps of:

providing a dielectric tube; and

positioning the elongate electrical conductor carrying the plurality of milled sponges into an interior of the dielectric tube.

30. A method according to claim 29 further comprising the steps of providing an outer electrode and positioning the outer electrode overlying a portion of the dielectric tube.

31. A method according to claim 30 further comprising the steps of providing and positioning a second tube surrounding said the outer electrode for capturing ozone produced thereby.

32. A method according to claim 27 wherein the step of providing the elongate electrical conductor comprises providing a strip having opposing rows of sawtooth-shaped projections extending outwardly from opposing side edges of the strip, and wherein the strip has a generally sinuous longitudinal cross-section defined by a series of alternating bends.