III u1111Niuwi11iu111xuuiEir111iumuMIIIIIInNUMi
`
`(19) United States
`(12) Patent Application Publication
`Field
`
`(54) ELECTROLYSIS CELL HAVING
`ELECTRODES WITH
`VARIOUS -SIZED /SHAPED APERTURES
`
`(75)
`
`Inventor:
`
`Bruce F. Field, Golden Valley, MN
`(US)
`
`Correspondence Address:
`WEST_MAN CHAMPLIN & KELLY, P.A.
`SUITE 1400, 900 SECOND AVENUE SOUTH
`MINNEAPOLIS, MN 55402 (US)
`
`(73) Assignee:
`
`Tennant Company, Minneapolis,
`MN (IJS)
`
`(21) Appl. No.:
`
`12/488,333
`
`(22) Filed:
`
`Jun. 19, 2009
`
`Related U.S. Application Data
`
`(60) Provisional application No. 61/074.059, filed on Jun.
`19, 2008, provisional application No. 61/077,001,
`
`(10) Pub. No.: US 2009/03146.54 Al
`Dec. 24, 2009
`(43) Pub. Date:
`
`filed on Jun. 30, 2008, provisional application No.
`61/077,005, filed on Jun. 30, 2008, provisional appli-
`cation No. 61/084,460, filed on Jul. 29, 2008, provi-
`sional application No. 61/092,586, filed on Aug. 28,
`2008, provisional application No. 61/083,046. filed on
`Jul. 23, 2008.
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`C25B 11/03
`
`(52) U.S. Cl.
`
`(2006.01)
`
`205/687: 204/252; 204/242
`
`ABSTRACT
`(57)
`An electrolysis cell is provided, which includes an anode
`electrode and a cathode electrode. At least one of the anode
`electrode or the cathode electrode includes a first plurality of
`apertures having a first size and/or shape and a second plu-
`rality of apertures having a second, different size and/or
`shape.
`
`TC00062664
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 1 of 26
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`US 2009/0314654 Al
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`TC00062665
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 2 of 26
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`US 2009/03146.54 Al
`
`(-74
`
`DISPENSER
`
`LIQUID
`
`52
`
`/58 62
`
`5o
`
`56
`
`FIG. 2
`
`LIQUID
`
`88-)
`
`80--24
`
`FIG. 3
`
`84
`
`86
`
`82
`
`ik-89
`
`TC00062666
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 3 of 26
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`US 2009/0314654 Al
`
`102
`
`106
`
`ñ\/.
`
`100
`
`AiGiM.._..s/ii/////////////M///r.....____..../iiiii
`.////x//n//////////////////////////////////////////n
`A/ ///u///////////////////////////////////////////////I
`H/////N/////////////////////////////////B////////////
`
`//w//®/////////////////////////////o//o/////////////I
`vtn.111//a////////////////////////////////////////////////t
`iiiiiáiiï iiiiii°iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii
`-/////a/-
`1////w///////////////////////////////////////////////
`////a////////////////////////////////////////m ---
`-//®////////////////P -/////////////aOP-
`-//v-
`-®/////////////IP"
`-411/////////.-
`-/////P-
`FIG. 4A
`
`104
`
`106
`
`FIG. 4C
`
`TC00062667
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 4 of 26
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`US 2009/0314654 Al
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`TC00062668
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 5 of 26
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`US 2009/0314654 Al
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`VOLTAGE
`
`ANODE
`
`CATHODE
`
`300
`
`303 JJJ
`
`--0
`
`t0
`
`I
`I
`t1 12
`
`II
`t3 t4
`
`II
`t5 t6
`
`FIG. 6
`
`I
`
`I
`t7 t8
`
`TIME
`
`TC00062669
`
`

`

`Patent Application Publication
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`Dec. 24, 2009 Sheet 6 of 26
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`US 2009/0314654 Al
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`404
`
`fre,--400
`
`(410
`
`I SENSOR
`
`-
`
`406
`
`ELECTROLYSIS
`CELL
`
`402
`
`CONTROL
`ELECTRONICS
`
`--J SENSOR (-
`
`(412
`
`406
`
`PUMP
`
`414
`
`GND
`
`.7416
`
`FIG. 7
`
`TC00062670
`
`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 7 of 26
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`US 2009/0314654 Al
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`TC00062671
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 8 of 26
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`US 2009/0314654 Al
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`TC00062672
`
`

`

`Patent Application Publication
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`Dec. 24, 2009 Sheet 9 of 26
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`US 2009/0314654 Al
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`5E)6
`
`FIG. 8C
`
`TC00062673
`
`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 10 of 26
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`US 2009/0314654 Al
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`TC00062674
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 11 of 26
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`US 2009/0314654 Al
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`TC00062675
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 12 of 26
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`US 2009/0314654 Al
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`TC00062676
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 13 of 26
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`US 2009/0314654 Al
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`TC00062677
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 14 of 26
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`US 2009/0314654 Al
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`510
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`TC00062678
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 15 of 26
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`US 2009/0314654 Al
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`TC00062679
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 16 of 26
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`US 2009/0314654 Al
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`TC00062680
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 17 of 26
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`US 2009/0314654 Al
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`TC00062681
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 18 of 26
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`US 2009/0314654 Al
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`FIG. 13
`
`TC00062682
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 19 of 26
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`US 2009/0314654 Al
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`Ha 14A
`
`Fla 148
`
`580
`
`570
`
`TC00062683
`
`

`

`Patent Application Publication
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`Dec. 24, 2009 Sheet 20 of 26
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`US 2009/0314654 Al
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`584
`
`FIG. 15A
`
`FIG. A 1 58
`
`TC00062684
`
`

`

`Patent Application Publication Dec. 24, 2009 Sheet 21 of 26
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`US 2009/0314654 Al
`
`FIG. 1 6
`
`TC00062685
`
`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 22 of 26
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`US 2009/0314654 Al
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`TC00062686
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`

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`Patent Application Publication
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`Dec. 24, 2009 Sheet 23 of 26
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`US 2009/0314654 Al
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`FIG. 17
`
`TC00062687
`
`

`

`Patent Application Publication
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`Dec. 24, 2009 Sheet 24 of 26
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`US 2009/0314654 Al
`
`r 803
`
`802
`
`-806
`
`,- 804
`
`:
`
`c.
`
`A-7
`
`ELECTROLYSIS
`CELL
`
`CONTROL
`CIRCUIT
`
`SWITCH
`
`L
`
`808
`
`FIG. 18
`
`TC00062688
`
`

`

`Patent Application Publication
`
`Dec. 24, 2009 Sheet 25 of 26
`
`US 2009/0314654 Al
`
`FIG. 19
`
`TC00062689
`
`

`

`552
`
`-550
`
`Electrolysis
`
`Cell
`
`Pump Motor
`
`FIG. 20
`
`596
`
`LEDs
`
`594
`
`(Normal)
`GreenD8
`
`(Fault)
`Red
`
`Motor Driver
`Full Bridge
`
`,-
`
`Regulator DC/DC
`inverting Switching
`
`1004
`
`Power
`Systemn
`5 Volt
`
`1003
`
`570,572
`
`Trigger
`
`Battery Pack
`
`12 Volt
`
`542
`
`V
`
`RSense
`
`p. 1002
`
`Programming I
`
`Header
`
`Sense
`
`Pump Control
`
`Celi Control
`
`Converter Control
`
`tvlicrocontroller
`
`GRNLED_DRVR
`R2
`
`R1
`
`REDLED_DRVR
`
`st()2
`
`D7
`
`D6
`
`D5
`jR4
`+V BAT
`
`Q1
`
`D4
`
`D3
`
`D2
`
`Dl
`R3
`
`+V BAT
`
`

`

`US 2009/0314654 Al
`
`1
`
`Dec. 24, 2009
`
`ELECTROLYSIS CELL HAVING
`ELECTRODES WITH
`VARIOUS- SIZED /SHAPED APERTURES
`
`CROSS -REFERENCE TO RELATED
`APPLICATION
`[0001] The present application is based on and claims the
`benefit of the following applications:
`I) U.S. Provisional Patent Appin. No. 61/074,059,
`[0002]
`filed Jun. 19, 2008, entitled ELECTROLYSIS CELL HAV-
`ING CONDUCTIVE POLYMER ELECTRODES AND
`METHOD OF ELECTROLYSIS;
`[0003] 2) U.S. Provisional Patent Appin. No. 61/077,001,
`filed Jun. 30, 2008, entitled HAND -HELD SPRAY
`BOTTLE ELECTROLYSIS CELL AND DC -DC CON-
`VERTER;
`[0004] 3) U.S. Provisional Patent Appin. No. 61/077,005,
`filed Jun. 30, 2008, entitled ELECTROLYSIS CELL HAV-
`ING ELECTRODES WITH VARIOUS- SIZED /SHAPED
`APERTURES;
`[0005] 4) U.S. Provisional Patent Appin. No. 61/083,046,
`filed Jul. 23, 2008, entitled ELECTROLYSIS DE -SCAL-
`ING METHOD WITH CONSTANT OUTPUT:
`5) U.S. Provisional Patent Appin. No. 61/084,460,
`[00061
`filed Jul. 29, 2008, entitled TUBULAR ELECTROLYSIS
`CELL AND CORRESPONDING METHOD; and
`[0007] 6) U.S. Provisional Patent Appin. No. 61/092,586,
`filed Aug. 28, 2008, entitled APPARATUS HAVING
`ELECTROLYSIS CELL AND INDICATOR LIGHT
`ILLUMINATING THROUGH LIQUID;
`the contents of which are hereby incorporated by
`[0008]
`reference in their entirety.
`
`FIELD OF THE DISCLOSURE
`[0009] The present disclosure relates to electrochemical
`activation of fluids and. more particularly, to electrolysis cells
`and corresponding methods.
`
`BACKGROUND
`100101 Electrolysis cells are used in a variety of different
`applications for changing one or more characteristics of a
`fluid. For example, electrolysis cells have been used in clean -
`ing/sanitizing applications, medical industries, and semicon-
`ductor manufacturing processes. Electrolysis cells have also
`been used in a variety of other applications and have had
`different configurations.
`10011] For cleaning /sanitizing applications, electrolysis
`cells are used to create anolyte electrochemically activated
`(EA) liquid and catholyte EA liquid. Anolyte EA liquids have
`known sanitizing properties, and catholyte EA liquids have
`known cleaning properties. Examples of cleaning and/or
`sanitizing systems are disclosed in Field et al. U.S. Publica-
`tion No. 2007/0186368 Al, published Aug. 16, 2007.
`
`SUMMARY
`[0012] An aspect of the disclosure relates to an electrolysis
`cell, which includes an anode electrode and a cathode elec-
`trode. At least one of the anode electrode or the cathode
`electrode includes a first plurality of apertures having a first
`size and a second plurality of apertures having a second,
`different size.
`[0013] Another aspect of the disclosure relates to an elec-
`trolysis cell, which includes an anode electrode and a cathode
`
`electrode. At least one of the anode electrode or the cathode
`electrode includes a first plurality of apertures having a first
`shape and a second plurality of apertures having a second,
`different shape.
`[0014] Another aspect of the disclosure relates to a method.
`The method includes electrolyzing a liquid using an elec-
`trolysis cell including an anode electrode and a cathode elec-
`trode. At least one of the anode or cathode includes a plurality
`of apertures, wherein at least two of the apertures have dif-
`ferent sizes and/or shapes than one another.
`[0015] This Summary is provided to introduce a selection
`of concepts in a simplified form that are further described
`below in the Detailed Description. This Summary is not
`intended to identify key features or essential features of the
`claimed subject matter, nor is it intended to be used as an aid
`in determining the scope of the claimed subject matter. The
`claimed subject matter is not limited to implementations that
`solve any or all disadvantages noted in the background.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`[0016] FIG. 1 is a simplified, schematic diagram of a hand-
`held spray bottle according to an exemplary aspect of the
`present disclosure.
`[0017] FIG. 2 illustrates an example of an electrolysis cell
`having an ion -selective membrane.
`[0018] FIG. 3 illustrates an electrolysis cell having no ion -
`selective membrane according to a further example of the
`disclosure.
`[0019] FIG. 4A is a fragmentary view of a conductive poly-
`mer electrode having a plurality of rectilinear apertures in a
`regular grid pattern according to an aspect of the disclosure.
`[0020] FIG. 4B is a fragmentary view of a conductive poly-
`mer electrode having a plurality of curvilinear apertures of
`different sizes in a regular grid pattern according to another
`example.
`[0021 ] FIG. 4C is a fragmentary view of a conductive poly-
`mer electrode having a plurality of irregular and regular
`shaped apertures having a variety of different shapes and sizes
`according to another example.
`[0022] FIG. 5 illustrates an example of an electrolysis cell
`having a tubular shape according to one illustrative example.
`[0023] FIG. 6 is a wavefonn diagram illustrating the volt-
`age pattern applied to the anode and cathode according to an
`exemplary aspect of the present disclosure.
`[0024] FIG. 7 is a block diagram of a system having an
`indicator according to an embodiment of the disclosure,
`which can be incorporated into any of the embodiments dis-
`closed herein, for example.
`[0025] FIG. 8A is a perspective view of a spray bottle
`having an indicator light that illuminates through liquid car-
`ried by the bottle.
`[0026] FIG. 8B is a perspective view of a spray bottle
`having an indicator light that illuminates through liquid car-
`ried by the bottle, according to an alternative embodiment of
`the disclosure.
`[0027] FIG. 8C is a rear, perspective view of a head of the
`bottle shown in FIG. 8B.
`[0028] FIGS. 9A and 9B are perspective views of a left -
`hand side housing, and FIG. 9C is a perspective view of a
`right -hand side housing of the bottle shown in FIG. 813.
`[0029] FIG. 10 illustrates various components installed in
`the left -hand side housing.
`[0030] FIGS. 11A and 11B illustrate a liquid container
`carried by the bottle shown in FIG. 8B.
`
`TC00062691
`
`

`

`US 2009/0314654 Al
`
`2
`
`Dec. 24, 2009
`
`[0031] FIG. 12A illustrates a fragmentary, close -up view of
`a pump/ cell assembly installed in a barrel of the housing.
`[0032] FIG. 12B is a perspective view of the pump /cell
`assembly removed from the housing.
`[0033] FIG. 12C is a bottom, perspective view of the pump/
`cell assembly with the trigger removed.
`[0034] FIG. 13 illustrates an exploded, perspective view of
`a mounting bracket of the assembly shown in FIGS. 12A-
`12C.
`[0035] FIGS. 14A and 14B are perspective views of a trig-
`ger of the bottle shown in FIG. 813.
`[0036] FIGS. 15A and 15B are perspective views of a trig-
`ger boot, which overlies the trigger.
`[0037] FIG. 16A illustrates lower compartments of a hous-
`ing half in greater detail.
`[0038] FIG. 16B illustrates a circuit board and batteries
`mounted within the compartments shown in FIG. 16A.
`[0039] FIG. 17 is a perspective view of a mobile cleaning
`machine, which implements an electrolysis cell according to
`an example of the present disclosure.
`[0040] FIG. 18 is a simplified block diagram of an elec-
`trolysis cell that is mounted to a platform according to another
`embodiment.
`[0041] FIG. 19 is a perspective view of an all- surface
`cleaner according to another embodiment of the disclosure.
`[0042] FIG. 20 is a block diagram illustrating a control
`circuit for controlling the various components within the
`band -held spray bottle shown in FIGS. 8 -16 according to an
`illustrating example of the disclosure.
`
`DETAILED DESCRIPTION OF ILLUSTRATIVE
`EMBODIMENTS
`[0043] An aspect of the present disclosure is directed to a
`method and apparatus for electrolyzing liquids.
`
`1. Hand -Held Spray Bottle
`
`[0044] Electrolysis cells can be used ma variety ofdifferent
`applications and housed in a variety of different types of
`apparatus, which can be hand -held, mobile, immobile, wall -
`mounted, motorized or non -motorized cleaning/sanitizing
`vehicle, wheeled, etc, for example. In this example. an elec-
`trolysis cell is incorporated in a hand -held spray bottle.
`[0045] FIG. 1 is a simplified, schematic diagram of a hand-
`held spray bottle 10 according to an exemplary aspect of the
`present disclosure. Spray bottle 10 includes a reservoir 12 for
`containing a liquid to be treated and then dispensed through a
`nozzle 14. In an example, the liquid to be treated includes an
`aqueous composition, such as regular tap water.
`[0046] Spray bottle 10 further includes an inlet filter 16, one
`or more electrolysis cells 18, tubes 20 and 22. pump 24,
`actuator 26. switch 28, circuit board and control electronics
`30 and batteries 32. Although not shown in FIG. 1, tubes 20
`and 22 may be housed within a neck and barrel, respectively
`of bottle 10, for example. A cap 34 seals reservoir 12 around
`the neck of bottle 10. Batteries 32 can include disposable
`batteries and/or rechargeable batteries, for example, and pro-
`vide electrical power to electrolysis cell 18 and pump 24
`when energized by circuit board and control electronics 30.
`In the example shown in FIG. 1, actuator 26 is a
`[0047]
`trigger -style actuator, which actuates momentary switch 28
`between open and closed states. For example, when the user
`"squeezes" the hand trigger to a squeezed state, the trigger
`actuates the switch into the closed state. When the user
`
`releases the hand trigger, trigger actuates the switch into the
`open state. However. actuator 26 can have other styles in
`alternative embodiments and can be eliminated in further
`embodiments. In embodiments that lack a separate actuator,
`switch 28 can he actuated directly by the user. When switch
`28 is in the open, non -conducting state, control electronics 30
`de- energizes electrolysis cell 18 and pump 24. When switch
`28 is in the closed, conducting state, control electronics 30
`energizes electrolysis cell 18 and pump 24. Pump 24 draws
`liquid from reservoir 12 through filter 16. electrolysis cell 18,
`and tube 20 and forces the liquid out tube 22 and nozzle 14.
`Depending on the sprayer, nozzle 14 may or may not be
`adjustable, so as to select between squirting a stream, aero-
`solizing a mist, or dispensing a spray, for example.
`[0048] Switch 28, itself, can have any suitable actuator
`type, such as a push -button switch as shown in FIG. 1, a
`toggle, a rocker, any mechanical linkage, and/or any non -
`mechanical sensor such as capacitive, resistive plastic, ther-
`mal, inductive, etc. Switch 28 can have any suitable contact
`arrangement, such such as momenary, single -pole single
`throw, etc.
`[0049]
`In an alternative embodiment, pump 24 is replaced
`with a mechanical pump, such as a hand -triggered positive
`displacement pump, wherein actuator trigger 26 acts directly
`on the pump by mechanical action. In this embodiment, swich
`28 could be separately actuated from the pump 24, such as a
`power switch, to energize electrolysis cell 18. In a further
`embodiment. batteries 32 are eliminated and power is deliv-
`ered to spray bottle 10 from an external source, such as
`through a power cord, plug, and/or contact terminals.
`[0050] The arrangement shown in FIG. 1 is provided
`merely as a non -limiting example. Spray bottle 10 can have
`any other structural and/or functional arrangement. For
`example, pump 24 can be located downstream of cell 18, as
`shown in FIG. 1, or upstream of cell 18 with respect to the
`direction of fluid flow from reservoir 12 to nozzle 14.
`[0051] As described in more detail below, the spray bottle
`contains a liquid to be sprayed on a surface to be cleaned
`and/or sanitized. In one non -limiting example, electrolysis
`cell 18 converts the liquid to an anolyte EA liquid and a
`catholyte FA liquidpriorto being dispensed from the bottle as
`an output spray. The anolyte and catholyte EA liquids can be
`dispensed as a combined mixture or as separate spray outputs,
`such as through separate tubes and/or nozzles. In the embodi-
`ment shown in FIG. 1, the anolyte and catholyte EA liquids
`are dispensed as a combined mixture. With a small and inter-
`mittent output flow rate provided the spray bottle, electrolysis
`cell 18 can have a small package and be powered by batteries
`carried by the package or spray bottle, for example.
`
`2. Electrolysis Cells
`
`[0052] An electrolysis cell includes any fluid treatment cell
`that is adapted to apply an electric field across the fluid
`between at least one anode electrode and at least one cathode
`electrode. An electrolysis cell can have any suitable number
`of electrodes, any suitable number of chambers for containing
`the fluid, and any suitable number of fluid inputs and fluid
`outputs. The cell can be adapted to treat any fluid (such as a
`liquid or gas -liquid combination). The cell can include one or
`more ion -selective membranes between the anode and cath-
`ode or can be configured without any ion selective mem-
`branes. An electrolysis cell having an ion -selective mem-
`brane is referred to herein as a "functional generator ".
`
`TC00062692
`
`

`

`US 2009/0314654 Al
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`3
`
`Dec. 24, 2009
`
`[0053] Electrolysis cells can be used in a variety of different
`applications and can have a variety of different structures,
`such as but not limited to a spray bottle as discussed with
`reference to FIG. 1, and/or the structures disclosed in Field et
`al. U.S. Patent Publication No. 2007/0186368. published
`Aug. 16, 2007. Thus, although various elements and pro-
`cesses relating to electrolysis are described herein relative to
`the context of a spray bottle, these elements and processes can
`be applied to, and incorporated in, other, non -spray bottle
`applications.
`
`3. Electrolysis Cell Having a Membrane
`3.1 Cell Structure
`
`[0054] FIG. 2 is a schematic diagram illustrating an
`example of an electrolysis cell 50 that can be used in the spray
`bottle shown in FIG. 1, for example. Electrolysis cell 50 and
`which receives liquid to be treated from a liquid source 52.
`Liquid source 52 can include a tank or other solution reser-
`voir, such as reservoir 12 in FIG. 1, or can include a fitting or
`other inlet for receiving a liquid from an external source.
`[0055] Cell 50 has one or more anode chambers 54 and one
`or more cathode chambers 56 (known as reaction chambers),
`which are separated by an ion exchange membrane 58, such
`as a cation or anion exchange membrane. One or more anode
`electrodes 60 and cathode electrodes 62 (one of each elec-
`trode shown) are disposed in each anode chamber 54 and each
`cathode chamber 56, respectively. The anode and cathode
`electrodes 60, 62 can be made from any suitable material,
`such as a conductive polymer, titanitun and /or titanium
`coated with a precious metal, such as platinum, or any other
`suitable electrode material. In one example, at least one of the
`anode or cathode is at least partially or wholly made from a
`conductive polymer. The electrodes and respective chambers
`can have any suitable shape and construction. For example,
`the electrodes can be flat plates, coaxial plates, rods, or a
`combination thereof. Each electrode can have, for example, a
`solid construction or can have one or more apertures. In one
`example, each electrode is formed as a mesh. In addition,
`multiple cells 50 can be coupled in series or in parallel with
`one another, for example.
`[0056] The electrodes 60, 62 are electrically connected to
`opposite terminals of a conventional power supply (not
`shown). Ion exchange membrane 58 is located between elec-
`trodes 60 and 62. The power supply can provide a constant
`DC output voltage, a pulsed or otherwise modulated DC
`output voltage, and/or a pulsed or otherwise modulated AC
`output voltage to the anode and cathode electrodes. The
`power supply can have any suitable output voltage level,
`current level, duty cycle or waveform.
`[0057] For example in one embodiment, the power supply
`applies the voltage supplied to the plates at a relative steady
`state. The power supply (and/or control electronics) includes
`a DC /DC converter that uses a pulse -width modulation
`(PWM) control scheme to control voltage and current output.
`Other types of power supplies can also be used, which can be
`pulsed or not pulsed and at other voltage and power ranges.
`The parameters are application- specific.
`[0058] During operation, feed water (or other liquid to be
`treated) is supplied from source 52 to both anode chamber 54
`and cathode chamber 56. In the case of a cation exchange
`membrane, upon application of a DC voltage potential across
`anode 60 and cathode 62, such as a voltage in a range of about
`5 Volts (V) to about 28V, cations originally present in the
`
`anode chamber 54 move across the ion- exchange membrane
`58 towards cathode 62 while anions in anode chamber 54
`move towards anode 60. However. anions present in cathode
`chamber 56 are not able to pass through the cation -exchange
`membrane, and therefore remain confined within cathode
`chamber 56.
`[0059] As a result, cell 50 electrochemically activates the
`feed water by at least partially utilizing electrolysis and pro-
`duces electrochemically -activated water in the form of an
`acidic anolyte composition 70 and a basic catholyte compo-
`sition 72.
`If desired, the anolyte and catholyte can be gener-
`[0060]
`ated in different ratios to one another through modifications to
`the structure of the electrolysis cell, for example. For
`example, the cell can be configured to produce a greater
`volume of catholyte than anolyte if the primary function of
`the EA water is cleaning. Alternatively, for example, the cell
`can be configured to produce a greater volume of anolyte than
`catholyte if the primary function ofthe EA water is sanitizing.
`Also, the concentrations of reactive species in each can be
`varied.
`[0061] For example, the cell can have a 3:2 ratio of cathode
`plates to anode plates for producing a greater volume of
`catholyte than anolyte. Each cathode plate is separated from
`a respective anode plate by a respective ion exchange mem-
`brane. Thus, there are three cathode chambers for two anode
`chambers. This configuration produces roughly 60%
`catholyte to 40% anolyte. Other ratios can also be used.
`
`3.2 Example Reactions
`
`In addition, water molecules in contact with anode
`[0062]
`60 are electrochemically oxidized to oxygen (02) and hydro-
`gen ions (H *) in the anode chamber 54 while water molecules
`in contact with the cathode 62 are electrochemically reduced
`to hydrogen gas (H,) and hydroxyl ions (OH -) in the cathode
`chamber 56. The hydrogen ions in the anode chamber 54 are
`allowed to pass through the cation -exchange membrane 58
`into the cathode chamber 56 where the hydrogen ions are
`reduced to hydrogen gas while the oxygen gas in the anode
`chamber 54 oxygenates the feed water to form the anolyte 70.
`Furthermore. since regular tap water typically includes
`sodium chloride and/or other chlorides, the anode 60 oxidizes
`the chlorides present to form chlorine gas. As a result, a
`substantial amount of chlorine is produced and the pH of the
`anolyte composition 70 becomes increasingly acidic over
`time.
`[0063] As noted, water molecules in contact with the cath-
`ode 62 are electrochemically reduced to hydrogen gas and
`hydroxyl ions (OH -) while cations in the anode chamber 54
`pass through the cation- exchange membrane 58 into the cath-
`ode chamber 56 when the voltage potential is applied. These
`cations are available to ionically associate with the hydroxyl
`ions produced at the cathode 62, while hydrogen gas bubbles
`form in the liquid. A substantial amount of hydroxyl ions
`accumulates over time in the cathode chamber 56 and reacts
`with cations to form basic hydroxides. In addition, the
`hydroxides remain confined to the cathode chamber 56 since
`the cation -exchange membrane does not allow the negatively
`charged hydroxyl ions pass through the cation- exchange
`membrane. Consequently, a substantial amount of hydrox-
`ides is produced in the cathode chamber 56, and the pH of the
`catholyte composition 72 becomes increasingly alkaline over
`time.
`
`TC00062693
`
`

`

`US 2009/0314654 Al
`
`4
`
`Dec. 24, 2009
`
`[0064] The electrolysis process in the functional generator
`50 allow concentration of reactive species and the formation
`of metastable ions and radicals in the anode chamber 54 and
`cathode chamber 56.
`[0065] The electrochemical activation process typically
`occurs by either electron withdrawal (at anode 60) or electron
`introduction (at cathode 62), which leads to alteration of
`physiochemical (including structural, energetic and catalytic)
`properties of the feed water. It is believed that the feed water
`(anolyte or catholyte) gets activated in the immediate prox-
`imity of the electrode surface where the electric field intensity
`can reach a very high level. This area can be referred to as an
`electric double layer (EDL).
`[0066] While the electrochemical activation process con-
`tinues, the water dipoles generally align with the field. and a
`proportion of the hydrogen bonds of the water molecules
`consequentially break. Furthermore, singly -linked hydrogen
`atoms bind to the metal atoms (e.g., platinum atoms) at cath-
`ode electrode 62, and single -linked oxygen atoms bind to the
`metal atoms (e.g., platinum atoms) at the anode electrode 60.
`These bound atoms diffuse around in two dimensions on the
`surfaces of the respective electrodes until they take part in
`further reactions. Other atoms and polyatomic groups may
`also bind similarly to the surfaces of anode electrode 60 and
`cathode electrode 62, and may also subsequently undergo
`reactions. Molecules such as oxygen (O,) and hydrogen (H,)
`produced at the surfaces may enter small cavities in the liquid
`phase of the water (i.e., bubbles) as gases and/or may become
`solvated by the liquid phase of the water. These gas -phase
`bubbles are thereby dispersed or otherwise suspended
`throughout the liquid phase of the feed water.
`[0067] The sizes of the gas -phase bubbles may vary
`depending on a variety of factors, such as the pressure applied
`to the feed water, the composition of the salts and other
`compounds in the feed water, and the extent of the electro-
`chemical activation. Accordingly, the gas -phase bubbles may
`have a variety of different sizes, including, but not limited to
`macrobubbles, microbubbles, nanobubbles, and mixtures
`thereof. In embodiments including macrobubbles, examples
`of suitable average bubble diameters for the generated
`bubbles include diameters ranging from about 500 microme-
`ters to about one millimeter. In embodiments including
`microbubbles, examples of suitable average bubble diameters
`for the generated bubbles include diameters ranging from
`about one micrometer to less than about 500 micrometers. In
`embodiments including nanobubbles, examples of suitable
`average bubble diameters for the generated bubbles include
`diameters less than about one micrometer, with particularly
`suitable average bubble diameters including diameters less
`than about 500 nanometers, and with even more particularly
`suitable average bubble diameters including diameters less
`than about 100 nanometers.
`[0068] Surlbce tension at a gas -liquid interface is produced
`by the attraction between the molecules being directed away
`from the surfaces of anode electrode 60 and cathode electrode
`62 as the surface molecules are more attracted to the mol-
`ecules within the water than they are to molecules of the gas
`at the electrode surfaces. In contrast, molecules of the bulk of
`the water are equally attracted in all directions. Thus, in order
`to increase the possible interaction energy, surface tension
`causes the molecules at the electrode surfaces to enter the
`bulk of the liquid.
`the
`In
`embodiments
`[0069]
`in which
`gas -phase
`nanobubbles are generated,
`the gas contained
`in the
`
`nanobubbles (i.e., bubbles having diameters of less than about
`one micrometer) are also believed to be stable for substantial
`durations in the feed water, despite their small diameters.
`While not wishing to be bound by theory. it is believed that the
`surface tension of the water, at the gas /liquid interface, drops
`when curved surfaces of the gas bubbles approach molecular
`dimensions. This reduces the natural tendency of the
`nanobubbles to dissipate.
`[0070] Furthermore, nanobubble gas /liquid interface is
`charged due to the voltage potential applied across membrane
`58. The charge introduces an opposing force to the surface
`tension, which also slows or prevents the dissipation of the
`nanobubbles. The presence of like charges at the interface
`reduces the apparent surface tension, with charge repulsion
`acting in the opposite direction to surface minimization due to
`surface tension. Any effect may be increased by the presence
`of additional charged materials that favor the gas /liquid inter-
`face.
`[0071] The natural state of the gas/liquid interfaces appears
`to be negative. Other ions with low surface charge density
`and /or high polarizability (such as Cl -. ClO-, 1 102. and 0z -)
`also favor the gas /liquid interfaces, as do hydrated electrons.
`Aqueous radicals also prefer to reside at such interfaces.
`Thus, it is believed that the nanobubbles present in the
`catholyte (i.e., the water flowing through cathode chamber
`56) are negatively charged, but those in the anolyte (i.e., the
`water flowing through anode chamber 54) will possess little
`charge (the excess cations cancelling out the natural negative
`charge). Accordingly, catholyte nanobubbles are not likely to
`lose their charge on mixing with the anolyte.
`[0072] Additionally, gas molecules may become changed
`within the nanobubbles (such as 0,-), due to the excess
`potential on the cathode, thereby increasing the overall charge
`of the nanobubbles. The surface tension at the gas/liquid
`interface of charged nanobubbles can be reduced relative to
`uncharged nanobubbles, and their sizes stabilized. This can
`be qualitatively appreciated as surface tension causes sur-
`faces to be minimized, whereas charged surfaces tend to
`expand to minimize repulsions between similar charges.
`Raised temperature at the electrode surface, due to the excess
`power loss over that required for the electrolysis, may also
`increase nanobubble formation by reducing local gas solubil-
`ity.
`[0073] As the repulsion force between
`like charges
`increases inversely as the square of their distances apart, there
`is an increasing outwards pressure as a bubble diameter
`decreases. The effect of the charges is to reduce the effect of
`the surface tension, and the surface tension tends to reduce the
`surface whereas the surface charge tends to expand it. Thus,
`equilibrium is reached when thes