Mesh electrode electrolysis apparatus and method for generating a sanitizing solution

Abstract

The present invention is an apparatus and method of employing an electrolysis cell assembly for producing simultaneously various diluted Hypochlorous Acid solutions and simultaneously a diluted Sodium Hydroxide solution for usage as cleaning and sanitation by electrolysis of an aqueous saline solution. The apparatus comprising a cylindrical three chamber electrolysis cell consisting of an inner chamber, a middle chamber and an outer chamber having two middle mesh-electrodes in the middle chamber wherein ion-selective exchange membranes are sealed around or on the inside of the middle mesh-electrodes to separate the middle chamber from the inner and outer chamber. The method allows production of different concentrations of Sodium Hydroxide and Hypochlorous Acid solutions isolating a Sodium Hydroxide solution having a negative redox potential ranging from −600 to −1200 mV and isolating a diluted Hypochlorous Acid solution having a positive redox potential ranging from +700 to +1200 mV.

Description

REFERENCE TO RELATED APPLICATIONS

In accordance with 37 C.F.R. 1.76, a claim of priority is included in an Application Data Sheet filed concurrently herewith. Accordingly, under 35 U.S.C. §119(e), 120, 121, and/or 365(c) the present invention claims priority, as a continuation-in-part of U.S. patent application Ser. No. 13/324,714, filed Dec. 13, 2011, entitled “DUAL DIAPHRAGMELECTROLYSIS CELL ASSEMBLY AND METHOD FOR GENERATING A CLEANING SOLUTION WITHOUT ANY SALT RESIDUES AND SIMULTANEOUSLY GENERATING A SANITIZING SOLUTION HAVING A PREDETERMINED LEVEL OF AVAILABLE FREE CHLORINE AND pH”; and is related to co-pending U.S. patent application Ser. No. ______, filed ______ and entitled “APPARATUS AND METHOD FOR GENERATING A STABILIZED SANITIZING SOLUTION”; the contents of the above referenced applications are incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to the field of producing Hypochlorous Acid solutions and more specifically to the use of an apparatus and method to form a hypochlorous acid solution for use as a wound care product or usage as a hospital sanitizing solution, wherein the solution has a different pH, free-available-chlorine content, osmolality and shelf life for usage.

BACKGROUND OF THE INVENTION

Cylindrical electrolysis cells are known for use in the production of diluted Hypochlorous Acid solutions. The basic feature of these cells is two concentrically disposed cylindrical electrodes with a ceramic porous diaphragm separating a space between the two electrodes to define anode and cathode compartments. An electrolyte such as brine is passed through the anode and cathode compartments, separately or successively. When brine is electrolyzed in this way, under suitable conditions, it can produce a diluted Hypochlorous Acid solution.

Typically when an electrolyte solution passes through a single electrolyses cell having a porous ceramic diaphragm to separate the anode and cathode chambers, the diaphragm permits the diffusion of electrolytes between the anode and cathode. However, porous ceramic diaphragms are not ion specific and therefore at any time when negative ions are attracted to the positive anode and positive ions are attracted to the negative cathode, ions will move without limitations over the ceramic diaphragm.

While the primary function of such a ceramic diaphragm is to allow ions to move freely over the diaphragm, the ceramic diaphragm's secondary function is to retard the migration of electrolysis products at the anode and cathode from diffusing to each other. When utilizing a porous ceramic diaphragm, the effectiveness of preventing undesired side products moving over the diaphragm depends greatly on a pressure differential between both chambers. In various flow patterns, the flow of Hypochlorous Acid and Sodium Hydroxide is not equal in volume and pressure, as in most cases more Hypochlorous Acid than Sodium Hydroxide is required. Therefore the volume of Sodium Hydroxide is mostly reduced to a minimum resulting in pressure differences between the anode and cathode chamber which significantly increases leakage of undesired products through the porous ceramic diaphragm.

Several cylindrical electrolysis cells exist to produce a diluted Hypochlorous Acid solution utilizing two concentrically disposed cylindrical electrodes with a porous ceramic diaphragm separating the space between the two electrodes to define the anode and cathode chambers. The efficiency of these cylindrical electrolysis cells depend on supply more electrical current into the cylindrical electrolysis cell.

Generally, there are a few methods to supply more electric currents into cylindrical electrolysis cells. So can the voltage applied on the electrodes increased, the distances between the electrodes reduced, the surface area of the electrodes enlarged and the number of electrodes increased.

Spacing between anode and cathode in a cylindrical electrolysis cell requires electrical current to follow a current pathway through chambers from anode to cathode and where resistance to current can be relatively high depending on conductivity and salinity of the fluids passing through the chambers. Generally, wider distances between anode and cathode require that a more voltage be applied to the cell to effect the desired electrochemical reaction. This elevated voltage requirement adds to electrical power consumption in operating the cell, adding to costs of cell operation.

Recent development is focused upon reducing the anode cathode spacing within a cell, and thereby reducing power consumption associated with cell operation. Reduced anode cathode spacing can be achieved by replacing ceramic diaphragms with ion-selective exchange membranes, as the thickness of ion-selective membrane varies between 0.025 mm and 0.5 mm compared to a thickness of ceramic membrane varies between 1 mm and 2 mm, whereas it should be mentioned that the ion-selective membrane is likely supported around or inside a perforated porous tube with a thickness of 0.025 mm to 0.5 mm to give it strength.

The perforated porous tube used to support the ion-selective exchange membrane is preferable 10.5 mm thick to give the ion-exchange membrane sufficient strength. The spacing between anode and cathode in cylindrical electrolysis cells can be even more reduced if the ion-selective exchange membranes are in contact with the mesh-electrodes and utilizing the mesh-electrode as support tube. The present invention provides a cylindrical electrolysis cell wherein two ion-selective exchange membranes separate the cylindrical electrolysis cell into an inner, a middle and an outer chamber. Two cylindrical mesh-electrodes are in direct contact with the ion-selective exchange membranes, as the ion-selective exchange membranes are mounted on the inside or around the cylindrical mesh-electrodes.

Further, as solid electrodes have no way to organize or channel the current being delivered, solid electrodes have an inconsistent saturation of electrons. Electrons move across the solid electrode finding the path of the least resistance. Generally, this would result in an inconsistent delivery of power and less efficient and effective electrolysis results. This concept is especially crucial to redox potential performance.

Mesh electrodes force the current to be organized by providing more “channeling” to direct the electron flow. The applied current or power very evenly saturates the mesh-electrode, which increases the amount of surface area that is receiving the electrical current that is used for electrolysis. The present invention increases the electrode surface area significantly not only by introducing two middle mesh-electrodes, but also by facilitating an optional mesh-electrode on the inside of the outer electrode tube and an optional mesh-electrode on the outside of the inner electrode tube.

Thus the instant invention improves cell performance as it uses multiple mesh-electrodes instead of one solid anode and one solid cathode. Next to increased surface area, the distance between the electrodes is significantly reduced using ion-selective membranes in direct contact with the middle mesh-electrodes.

SUMMARY OF THE INVENTION

The present invention is an optimized Electrolysis cell assembly which can efficiently produce dilute Hypochlorous Acid (HOCL) solutions with excellent sanitizing properties having a shelf life of over 24 months when bottled and stored. The cylindrical electrolysis cell of the present invention consist of two insulating end pieces for a cylindrical electrolysis cell comprising at least two cylindrical ion-selective exchange membranes with two cylindrical mesh-electrodes arranged co-axially between them. The method of producing different ph and concentrations of diluted Hypochlorous Acid solutions comprises passing an aqueous sodium chloride or potassium chloride solution into the middle chamber of a cylindrical electrolytic cell and feeding the electrolysis product of the middle chamber into the inner and outer chambers of the cylindrical electrolysis cell. The two cylindrical ion-selective exchange membranes consist of a polymer or a perfluorinated ion-exchange material that separates the middle chamber from the inner and outer chambers. The two ion-selective exchange membranes are sealed inside or around the two middle mesh-electrodes on which tube-ends a conductive bushing is mounted. One of the ion-selective exchange membranes is made of a cation-selective material and the other ion-selective ion-exchange membrane is made of an anion-selective material. The four sections of the end pieces facilitate the assembly of the cylindrical electrolysis cell.

The invention is directed to a cylindrical electrolysis cell assembly comprising two ion-selective exchange membranes mounted on the inside or around two mesh-electrodes, providing a middle chamber, an inner chamber and an outer chamber wherein optionally a mesh-electrode is tacked to the inside of the outer electrode tube and wherein optionally a mesh-electrode is tacked on the outside of the inner electrode tube. The present invention provides an insulating end piece for a cylindrical electrolysis cell of the type comprising at least two cylindrical electrodes arranged coaxially one within the other with two middle mesh-electrodes arranged coaxially between two cylindrical ion-selective exchange membranes.

The usages of two ion-selective exchange membranes in direct contact with multiple mesh-electrodes and the introduction of a mesh-electrode in the outer chamber and the introduction of a mesh-electrode in the inner chamber, improves the electrochemical reaction within the cylindrical electrolysis cell making this cylindrical electrolysis more efficient than existing cylindrical electrolysis cells.

An objective of the instant invention is to disclose a mesh electrode Electrolysis cell assembly and method for generating a sanitizing solution having a predetermined level of available free chlorine and pH.

Another objective of the invention is to disclose an apparatus and method of improving the stability and shelf life of on-site produced Hypochlorous Acid solutions.

Still another objective of the invention is to disclose the use of a three chamber cylindrical electrolysis cell constructed and arranged to provide a more stable Hypochlorous Acid solution suitable for bottling and storage up to 24 months.

Yet still another objective of the invention is to disclose how a three chamber cylindrical electrolysis cell may replace the usage of two cylindrical two chamber electrolysis cells resulting in various savings such as less material usages, less assembly costs and less energy costs.

Still another objective of the invention is to disclose how produced Hypochlorous Acid solutions can be used for wound care and hospital sanitation. The Hypochlorous Acid solutions are effective for sanitizing equipment, tools and surfaces, in particular after equipment, tools and surfaces have been cleaned with the generated Sodium Hydroxide solutions.

Another objective of the invention is to disclose Hypochlorous Acid and Sodium Hydroxide solutions having a long shelf life and a low salt residue which is in contrast with most generated Hypochlorous Acid and Sodium Hydroxide solutions produced by electrolysis of a brine solution in a single cell utilizing a ceramic diaphragm as separator between the anode and cathode.

Still another objective of the invention is to disclose various different sanitizing solutions can be produced utilizing the cylindrical electrolysis cells of the present invention, depending on the various flow patterns through the cells e.g. a neutral Hypochlorous Acid solution with a pH between 6 to 7.5 and a long shelf life can be generated by dividing the diluted brine solution in a Product-flow (Hypochlorous Acid) and a Waste-flow (Sodium Hydroxide).

Yet still another objective of the invention is to disclose a diluted Sodium Hydroxide as cleaning solution suitable for cleaning all surfaces, including textiles, fabrics and carpets.

Still another objective of the invention is to disclose a diluted Hypochlorous Acid as sanitizing solution suitable for wound care, hospital sanitation, water disinfection, but also suitable for sanitizing hands, food, (food contact) surfaces, air and fabrics.

Yet another objective of the invention is to disclose a generated cleaning and sanitizing solutions that contains limited salt residues due to the fact that the diluted brine solution passes two of more cells with ion-selective membranes whereas almost all sodium chloride or potassium chloride is efficiently converted into Hypochlorous Acid or Sodium Hydroxide.

Other objectives and further advantages and benefits associated with this invention will be apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plane view a cylindrical three chamber electrolysis cell of the instant invention;

FIG. 2 is a cross sectional view of a cylindrical three chamber electrolysis cell cut in a plane on the center axis between the port to one electrode compartment in one end cap and the port to the other electrode compartment in the other end cap;

FIG. 3 is a cross sectional view of the optional mesh-electrode tacked to the inside of the outer electrode tube;

FIG. 4 is a cross sectional view of the optional mesh-electrode tacked to the outside of the inner electrode tube;

FIG. 5 is a partial cross sectional view of a multiple section end piece from the side into which the tubes of a three chamber electrolysis cell would be inserted;

FIG. 6 an end view of a multiple section end piece from the top of a three chamber electrolysis cell;

FIG. 7 is a view of the construction of an ion-selective exchange membrane mounted around a mesh-electrode;

FIG. 8 is a view of the construction of an ion-selective exchange membrane mounted on the inside of a mesh-electrode;

FIG. 9 is a flow pattern (prior art) used to produce various diluted Hypochlorous Acid solutions using two cylindrical dual chamber electrolysis cells; and

FIG. 10 is a flow patterns to produce a diluted Hypochlorous Acid solution using a single cylindrical three chamber electrolysis cell.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a method of producing a stable Hypochlorous Acid solution suitable for bottling and storage utilizing an optimized cylindrical three chamber electrolysis cell having multiple mesh-electrodes and two ion-selective exchange membranes to separate the electrolysis cell into a middle chamber, an inner chamber and an outer chamber wherein the surface areas of the electrodes have been increased, the distance between the anodes and cathodes have been reduced and wherein the generated Hypochlorous Acid solution is used for wound care, hospital sanitation and sanitation of hands, food, food contact surfaces, equipment, tools and other surfaces.

Now referring in general to FIGS. 1-8, set forth is an improved three chamber electrolysis cell where an inner cylindrical electrode tube [1] is positioned within an inner cylindrical ion-selective exchange membrane [2] which mounted within an inner cylindrical mesh-electrode [3] that is positioned within an outer cylindrical mesh-electrode [4] where an outer ion-selective exchange membrane [5] is mounted around the outer cylindrical mesh-electrode [4], and where the outer cylindrical ion-selective exchange membrane [5] is positioned within an outer cylindrical electrode tube [6] by the use of two end pieces which consist of an tube cap [7], port C cap [8], port B cap [9] and port A cap [10].

The design of the four sections of the end piece permits the orientation and sealing of the entire assembly. Tube cap [7] seals the outer electrode [6] with the end piece using an O-ring [11]. The tube cap [7] is clamped on the outer electrode tube [6] using a stainless steel clip [12] that locks the outer electrode [6] in a groove [13] that is manufactured on both tube ends of the outer electrode tube [6]. Two holes [14] are manufactured in the tube cap [7] to allow the stainless clip [11] to pass through the tube cap [7] to lock the outer electrode tube [6] in the groove [13] manufactured on the tube-ends of the outer electrode tube [6].

Port C cap [8] features port C for direction of the flow of a diluted brine solution through port bending in fittings [17] into the chamber C defined by the spaces between the outer electrode tube [6] and the outer ion-selective exchange membrane [5] and out of chamber C through port C ending in fittings [17] of the opposite port C cap [8].

Port B cap [9] features port B for direction of the flow of a diluted brine solution through port B ending in fittings [17] into chamber B defined by the spaces between the inner ion-selective membrane [2] and the outer ion-selective membrane [5] and out of chamber B through port B ending in fittings [17] of the opposite port B cap [9].

Port A cap [10] features port A for direction of the flow of a diluted brine solution through port A ending in fittings [17] into chamber A defined by the spaces between the inner electrode tube [1] and the inner ion-selective exchange membrane [2] and out of chamber A through port A ending in fittings [17] of the opposite port A cap [10]. The four sections of the end piece are compressed on each other using O-rings [15] to seal the section on each other.

The tube cap [7] is clamped on the outer electrode [6] by pushing a clip [12] through two holes [14] in the tube cap [7] locking the outer electrode tube [6] in a groove [13] manufactured on both tube ends of the outer electrode tube [6]. Port C cap [8] is pressed on the tube cap [7] whereas the tube cap [7] facilitated a groove for an O-ring [15] and whereas port C cap [8] is pressed on the tube cap [7]. Port B cap [9] is pressed on port C cap [8] whereas the port C cap [8] facilitated a groove for an O-ring [15] and whereas the Port B cap [9] is pressed on port C cap [8]. Port A cap [10] is pressed on port B cap [9] whereas port B cap [9] facilitated a groove for an O-ring [15] and whereas port A cap [10] is pressed on port B cap [9].

The tube cap [7], port A cap [10], port B cap [9] and port C cap [8] are bolted together using four stainless steel bolts [18], washers [19] and nuts [20]. In each section of the end piece, there are four holes [21] to facilitate the stainless steel bolts [18], washers [19] and nuts [20]. The seal between each section of the end piece is achieved by compressing the sections of the end piece onto each other, in a manner such that the compressive force can be applied slowly and smoothly without the introduction of torque.

The electrode tubes [1] and [6] preferably act as the anode with the middle mesh-electrodes [3] and [4] acting as the cathode. Alternatively, the electrode tubes [1] and [6] can act as the cathode with the middle mesh-electrodes [3] and [4] acting as the anode. The choice can be made by considerations of the ease of manufacture or requirements of the nature of the electrolysis process to be performed which can favor the anode or cathode chamber preferentially being the middle chamber. These considerations include the desired spacing between the electrode tubes [1] and [6] and the ion-selective exchange membranes [3] and [4], the desired space between the ion-selective exchange membranes [2] and [5] and the relative volume requirements for the balance of flows in chamber A, chamber B and Chamber C. Optionally, an outer mesh-electrode [26] is tacked to the inside of the outer electrode tube [6] as can be seen in FIG. 3 and an inner mesh-electrode [25] is tacked to the outside of the inner electrode tube [1] as can be seen in FIG. 4 to reduce the distance between the anode and cathode as well to increase the surface area of the electrode tubes [1] and [6].

The inner electrode tube [1], outer electrode tube [6], the middle mesh-electrode tubes [3] and [4], the optional inner mesh-electrode [25] and the optional outer mesh-electrode [26] are constructed of an electrically conductive metal, preferably titanium or stainless steel. The metal electrode tubes [1] and [6] are preferably coated with a mixed metal oxide on the face of the tube directed toward the ion-selective exchange membranes [2] and [5]. The metal of the two middle mesh-electrodes [3] and [4] are preferably titanium. All metal tubes can be coated with a mixed metal oxide, wherein the cathodes can be an uncoated metal, but the anodes have to be a mixed metal oxide coated metal. A preferred arrangement has the outside electrode tubes [1] and [6] as the anodes coated with a mixed metal oxide and the middle mesh-electrodes [3] and [4] as the cathodes and not coated.

The outer electrode tube [6] has an electrical connector [23] welded to the outside of the outer electrode tube [6]. The inner electrode tube [1] has an electrical connector [24] on its end that is part of the inner electrode tube [1] and extends out of the outside of the upper end piece. Although not necessary for the function of the assembly, the outside of the outer electrode tube [6] is insulated by a rubber sleeve [16] that is heat-shrinked over the outer electrode tube [6] and cut to length.

The anodes and cathodes are separated by either two cation-selective exchange membranes [2] and [3] or by one cation-selective exchange membrane and one anion-selective exchange membrane. The inner ion-selective exchange membrane [2] can be either a cation- or an anion exchange membrane whereas the outer ion-selective exchange membrane [5] can be either an anion or a cation exchange membrane. The thickness of the ion-selective exchange membranes can vary between 0.025 mm and 0.5 mm depending on the application the electrolysis cell assembly is to be used.

The relative diameter of the outer electrode tube [6], the inner electrode tube [1], the inner ion-selective exchange membrane [2] mounted within an inner cylindrical mesh-electrode [3], the outer ion-selective exchange membrane [5] mounted around an outer cylindrical mesh-electrode [4] can vary within the single requirement that outer electrode tube [6] must be of greater diameter than the outer ion-selective membrane [5], the diameter of the outer ion-selective membrane [5] greater than the outer mesh-electrode [4], the diameter of the outer mesh-electrode [4] greater than the inner mesh-electrode [3], the diameter of the inner mesh-electrode [3] greater than the inner ion-selective exchange membrane [2] and the diameter of the inner ion-selective exchange membrane [2] greater than the inner electrode tube [1]. The actual diameters can vary depending upon the desired features of the electrolysis cell assembly. To this end the diameters can be varied to optimize the rate of electrolysis, rate of flow through the cell assembly, and the need of facilitating the optional inner mesh-electrode [25] and outer mesh-electrode [26]. Likewise, the relative length of the electrodes tubes [1] and [6], the ion-selective exchange membranes [2] and [5] and the middle mesh-electrode tubes [3] and [4] can vary within the single requirement of this embodiment that the outer electrode tube [6] must be shorter than the outer ion-selective exchange membrane [5] together with the outer mesh-electrode [4], outer ion-selective exchange membrane [5] together with the outer mesh-electrode [4] shorter than the inner ion-selective exchange membrane [2] together with the inner mesh-electrode [3] and the inner ion-selective exchange membrane [2] together with the inner mesh-electrode [3] shorter than inner electrode tube [1]. The lengths of the electrode tubes [1] and [6], the length of the combined inner ion-selective membrane [2] mounted inside the inner mesh-electrode [3], and the length of the combine outer ion-selective exchange membrane [5] mounted around the outer mesh-electrode [4] can be determined by factors such as ease of construction and geometries to optimize the performance of the electrolysis cell assembly in the system it which it is to perform.

The upper and lower end pieces are interchangeable and constructed of an insulating material, preferably Polyvinyl Chloride. Each end piece consist of four sections, the tube cap [6], Port A cap [10], Port B cap [9] and port C cap [8].

The four sections of the end piece can be formed by molding or machining. Ports [17] are for introduction or exit of a diluted brine solution to chamber B and for introducing or exit of Chamber B electrolysis product to Chamber A and to Chamber C. Port [17] is for the introduction and exit of electrolyte to chamber B and Chamber C. All sections of the end piece consists four or more holes to accept three or more stainless steel bolts [18], washers [19] and nuts [20] by which the four sections of the end piece [99] are compressed together. Three sections [7], [8] and [9] of the end piece have a groove to facilitate O-ring [15] to form the seals between the end piece sections. When the tube cap [7] is clamped on the outer electrode tube [6] pushing clip [12] through holes [14] in groove [13] and stainless steel bolts [18], washers [19] and nuts [20] are used, then the four bolts provide the structural integrity of the assembly.

Two holes [22] with female thread are made in the tube cap [7] at both opposite sides. This allows mounting the assembly on a plate or bracket. This plate or bracket may be a plastic or stainless steel as long as the metal is insulated from one or both of the electrodes. A preferred fabrication of a mounting plate or bracket is a machined sheet of Polyvinyl Chloride, which is commercially available as PVC.

One critical feature of the end piece is that the inside diameter of all sections of the end piece closely match the outside diameters of the four tubes [1], [6], [3] and [4] so that when pressing the sections of the end piece [99] on each other, a good seal can be achieved. When clamping the tube cap [7] on the outer electrode tube [6] using clip [12] and groove [13] and when the other sections of the end piece are compressed on each other, it is important that the O-ring [11], [27], [28] and [29] forms a good seal between the electrode tubes [1] and [6], the bushings of the mesh-electrode tube [3] and [4] and the four end caps [7], [8], [9] and [10] as well a good seal between the four sections themselves using O-ring [15]. The ion-selective exchange membranes [2] and [5] require the use of heat to form a seal between the inner ion-selective membrane [2] and the inner mesh electrodes [3] and to form a seal between the outer ion-selective membrane [5] and the outer mesh electrodes [4] such that a leak free seal is made. It is necessary that upon assembly the length of the cell assembly is defined by the length imposed by the outer electrode tube [6]. The inner ion-selective exchange membrane [2] must be long enough to reach and seal on the bushing [31] tacked with a clip [31a] on to the tube-ends of the mesh-electrodes [3]. The outer ion-selective exchange membrane [5] must be long enough to reach and seal on the bushing [30] tacked with a clip [30a] on to the tube-ends of the mesh-electrodes [4]. The bushings [30] on the tube end of outer mesh electrode [4] are pressed into O-ring [27]. The bushing [31] on the tube ends of the inner mesh electrode [3] are pressed into O-ring [28]. The inner electrode tube [1] is pressed into O-ring [29] on each side of the end piece. The end piece is defined as four stackable sections having complimentary topography with at least one seal between adjacent sections. Each seal forming feature is a compressible ridge, a gasket, or an O-ring. The end pieces are formed from Polyvinyl Chloride (PVC). The gaskets and O-rings are formed from Ethylene Propylene (EPDM), Nitrile (BUNA-N), Fluorocarbon (FKM) or any combination of a plastic and a rubber.

A second critical feature of the end caps is the presence of three ports. Port A begins at fitting [17] on an outside surface of Port A cap [10] permits the flow of a diluted brine solution through chamber A defined by the inside of the inner ion-selective membrane [2] and the outside of the inner electrode tube [1]. Port B begins at fitting [17] on an outside surface of Port C cap [9] and permits the flow of a diluted brine solution though chamber B defined by the inside of the outer ion-selective exchange membrane [5] and the outside of the inner ion-selective exchange membrane [2] as illustrated in. Port A begins at the fitting [17] on an outside surface of port A cap [8] and permits the flow of a diluted brine solution through chamber A defined by the inside of the outer electrode tube [6] and the and the outside of the outer ion-selective exchange membrane [5]. The outside of port A, port B and port C is a fitting [17] which accepts a tube for introduction or exit of a fluid to the cell assembly.

These fittings [17] can be a compression fitting or it can be a hose barb or some other coupling which is appropriate for the system within which the electrolysis cell assembly is to function. The orientation of the ports is necessarily to promote a tight spiral flow around the inner electrode tube [1], middle mesh-electrodes [3] and [4], inside the outer electrode tube [6] and between the spaces in chamber A, chamber B and chamber C.

The end pieces can have other configurations as long as the configuration permits for the sealing of the assembly where the compressive force is imposed upon the outer electrode tube [6] and no significant compressive force is imposed on the ion-selective membranes [2] and [5]. The different types of end pieces can be combined in any combination as long as the appropriate lengths of tubing are chosen and as long as the sections of the end piece [99] can be sealed together by compression. While the preferred end piece [99] has been illustrated and described, it will be clear that the invention is not so limited. Modifications, changes, variations, substitutions and equivalents will occur to those skilled in the art without departing from the spirit and scope of the present invention as described in the claims.

Another critical feature of this invention is the construction of the two cylindrical ion-selective exchange membranes on a mesh-electrode tube using two bushings [30] and [31], a clip [30a] and [31a] and mesh-electrode connectors [38] and [39] that a screwed in one end of an end piece [99] to press against the bushings [30] and [31] of the mesh-electrode tubes [3] and [4] to establish a connection suitable to apply a voltage on the mesh-electrodes [3] and [4].

The generated diluted Sodium Hydroxide as cleaning solution is suitable for cleaning all surfaces, including textiles, fabrics and carpets. The generated diluted Hypochlorous Acid as sanitizing solution can be used for wound care, hospital sanitation as well is suitable for sanitizing all hard surfaces including glass, mirrors, plastics, wood, ceramic, granite, metals and laminate.

A typical flow pattern as seen in FIG. 9 employs a pre-filter [41] that is used in combination with ion exchange water softener [42] and/or reverse osmosis unit [43]. The diluted brine makeup water is placed into a brine tank [45]. A pressure reducing valve [44] and a mixing chamber [47] are fluidly communicated with control valve [37]. A pressure reducing valve [44] and product control valve [48] are fluidly communicated with the brine tank [45]. The brine tank [45] and brine pump [46] are fluidly communicated with the mixing chamber [47]. Saturated brine is added to softened water using a brine pump [46] where the saturated brine is mixed with softened water in the mixing chamber [47]. Diluted brine is directed through the product valve [37] before directing 100% of the diluted brine solution to pass chamber C and 70% to 100% of the volume from the outlet of chamber C is re-directed successively through chamber A of cell 1 and then through chamber A of cell 2. Eventually the electrolysis product-flow flows into a product storage tank [36]. The volume of diluted brine solution that passes chamber A can be restricted by closing product valve [37] that is mounted prior to the inlet of chamber C and by opening drain valve [33] that is mounted after degassing chamber [32]. The volume of Chamber's A electrolysis product solution that is redirected can be regulated with drain valve [33] that is mounted after degassing chamber [32]. A vent [34] is mounted on top of the degassing chamber to vent hydrogen or chlorine gases. The surplus of Chamber's C electrolysis product flows as waste-flow into a waste storage tank [35]. The re-directed volume flows either first through Chamber A of cell I and then to Chamber A of cell II or first to Chamber A of cell II and then to Chamber A of cell I. Eventually the electrolysis product-flow flows into a product storage tank [36]. The volume of diluted brine solution that passes Chamber A can be restricted by closing product valve [37] and opening drain valve [33] which is mounted prior to the inlet of Chamber C and that is mounted after degassing chamber [32].

Referring now to FIG. 10, the three chamber cylindrical electrolysis cell can be used with different flow patterns allowing changing the pH, free available chlorine content, redox-potential, osmolorarity and conductivity of the diluted Hypochlorous Acid solution. Flow pattern example employs a pre-filter [51] that is used in combination with ion exchange water softener [52] and/or reverse osmosis unit [53]. The diluted brine makeup water is placed into a brine tank [55]. A pressure reducing valve [54] and a mixing chamber [57] are fluidly communicated with control valve [67]. A pressure reducing valve [54] and product control valve [58] are fluidly communicated with the brine tank [45]. The brine tank [45] and brine pump [46] are fluidly communicated with the mixing chamber [77]. Saturated brine is added to softened water using a brine pump [56] where the saturated brine is mixed with softened water in the mixing chamber [57]. Diluted brine is directed through the product valve [67] before directing 100% of the diluted brine solution to pass chamber one [71] with a portion directed to waste storage [79] and the remainder directed to chamber two [72], effluent from chamber two [72] is directed to chamber 3 [73]. Diluted brine is directed through a mixing chamber [57] and product control valve [67] before directing 100% of the diluted brine solution to pass Chamber one [71] with a portion directed to waste storage [79] and the remainder directed to Chamber two [72], effluent from Chamber two is directed to Chamber three [73]. The volume of Chamber's electrolysis product solution that is redirected can be regulated with drain valve [33] that is mounted after degassing chamber [62]. A vent [64] is mounted on top of the degassing chamber to vent hydrogen or chlorine gases. The surplus of Chamber's electrolysis product flows as waste-flow into a waste storage tank [66]. Eventually the electrolysis product-flow flows into a product storage tank [66]. The volume of diluted brine solution that passes to the Chamber can be restricted by closing product valve [67] which is mounted prior to the inlet of Chamber one [71]. The apparatus and method allow for the Isolating of a Sodium Hydroxide solution having a negative redox potential ranging from −600 to −1200 mV; and the isolating of a diluted Hypochlorous Acid solution having a positive redox potential ranging from +700 to +1200 mV. The pH, the free available chlorine content, conductivity and osmolality is regulated by altering the voltage, volume of the dilute brine solution passing through the middle, inner and outer chamber, brine concentration and whereas the current across the electrodes is at least 20 amps.

One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objectives and obtain the ends and advantages mentioned, as well as those inherent therein. The embodiments, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.

Claims

1. An apparatus for generating a stabilized sanitizing solution comprising:

an outer cylindrical electrode tube separated from two middle cylindrical mesh-electrodes by an outer cylindrical ion-selective exchange membrane; an inner cylindrical electrode tube separated from said two middle mesh-electrodes by an inner cylindrical ion-selective exchange membrane, said two middle cylindrical mesh-electrodes separated from the inner and outer electrode tubes by two ion-selective exchange membranes arranged coaxially one within the other to create an middle chamber having two mesh-electrodes; an inner chamber with an inner electrode tube and an outer chamber with an outer electrode tube; a pair of end pieces where a space between the inner cylindrical electrode-tube and the inner cylindrical ion-selective exchange membrane and a space between the outer cylindrical ion-selective exchange membrane and the outer electrode tube defines anode and cathode chambers, a space between said two ion-selective exchange membranes defines cathode or anode chambers and said two middle mesh-electrode functions as a cathode or anode and the inner and outer electrode tubes function as a anode or cathode; one of said end pieces having a lateral inlet through an outer wall thereof, said inlet being provided with a fitting for tangential feeding of the liquid to the inside of the end piece, and three pairs of ports for entrance or exit of fluid are situated in the upper and lower end piece each comprising an external fitting for attachment of a hose or pipe; wherein said first pair of ports at opposite ends of said assembly internally addresses a space between said outer electrode tube and said outer ion-selective membrane and said second pair of ports at opposite ends of said assembly internally addresses a space between said outer ion-selective membrane and said inner ion-selective membrane and said third pair of ports at opposite ends of said assembly internally addresses a space between said inner electrode tube and said inner ion-selective membrane, whereby a diluted brine solution is passed through the middle chamber of the electrolysis cell and distributing the electrolysis product of the middle chamber separately or successively to both the inner and outer chamber of the electrolysis cell.

2. The apparatus according to claim 1 wherein said outer mesh-electrode is constructed from titanium wire screen securable to an inside surface of said outer electrode tube, said outer electrode tube constructed from titanium to form a screen along the inside of the outer electrode tube, wherein the screen and the electrode tube may be coated with a mixed metal oxide coating for use as an anode.

3. The apparatus according to claim 1 wherein said an inner mesh-electrode is constructed from titanium wire screen securable to an outside surface of said inner electrode tube, said inner electrode tube constructed from titanium for form a screen along the outside of the inner electrode tube, wherein the screen and the electrode tube may be coated with a mixed metal oxide coating for use as an anode.

4. The apparatus of claim 1 wherein the two middle mesh-electrodes is constructed from titanium wire screen placed in a cylindrical shape, said middle mesh electrodes having a titanium bushing securable thereto, wherein the two cylindrical mesh-electrodes and bushings are coated with a mixed metal oxide for use as an anode.

5. The apparatus according to claim 1 wherein the anode and cathode, or both, comprise a titanium base activated with a mixed metal oxide coating structure consisting of a mixture of ruthenium, iridium, titanium, tantalum and rhodium.

6. The apparatus according to claim 1 wherein a connector is secured to an outside surface of the outer electrode tube for use in applying voltage on the outer electrode tube and on the outer mesh-electrode tacked on the inside of the outer electrode tube.

7. The apparatus according to claim 1 wherein a connector is secured to one of the tube edges of the inner electrode allowing for the application of voltage to the inner electrode tube and the inner mesh-electrode on the outside of the inner electrode tube.

8. The apparatus according to claim 1 wherein connector-bolts are threaded to the end piece of the electrolysis cell, said connector bolts having a length to make contact with a titanium bushing placed over the tube-ends of the mesh-electrodes whereby the connector-bolts make contact with the bushing on one tube-end of each middle mesh-electrode to apply a voltage on both middle mesh-electrodes.

9. The apparatus according to claim 1 wherein the middle mesh-electrodes function as a cathode and the inner and outer electrode-tubes functions as an anode.

10. The apparatus according to claim 1 wherein the middle mesh-electrodes function as an anode and the inner and outer electrode-tubes function as a cathode.

11. The apparatus according to claim 1 wherein the ion-selective membranes are construed from a polymer or a perfluorinated sheet and the inner ion-selective membrane is sealed inside the inner mesh-electrode and the outer ion-selective membrane is sealed around the outer mesh-electrode.

12. The apparatus according to claim 1 wherein said end piece is further defined as four stackable sections having complimentary topography with at least one seal between adjacent sections

13. The apparatus according to claim 1 wherein the end pieces are formed from Polyvinyl Chloride (PVC).

14. The apparatus according to claim 1 wherein the outer chamber comprises an inlet fitting connected to a tube that passes tangentially through a specific section of the lower end piece to communicate with the outer chamber through an aperture and wherein the inner chamber comprises an inlet fitting connected to a tube that passes tangentially through a specific section of the lower end piece to communicate with the inner chamber through an aperture and wherein a specific section of the lower end piece comprises an inlet fitting connected to a pipe that passes through the specific section of the lower end piece to communicate with the middle chamber through an aperture.

15. The apparatus according to claim 1 wherein the outer chamber comprises an outlet fitting connected to a tube that passes tangentially through a specific section of the upper end piece to communicate with the outer chamber through an aperture and wherein the inner chamber comprises an outlet fitting connected to a tube that passes tangentially through a specific section of the upper end piece to communicate with the inner chamber through an aperture and wherein a specific section of the upper end piece comprises an outlet fitting connected to a pipe that passes through the specific section of the upper end piece to communicate with the middle chamber through an aperture.

16. The apparatus according to claim 1 wherein ports address spaces through said end pieces or through said electrode tubes adjacent to the site of insertion of said electrode tubes into said end pieces.

17. The apparatus according to claim 1 wherein entrance ports direct fluid flow at an angle between 0 to 15 degrees relative to the plane of the seats of the end pieces.

18. A method of generating a stabilized sanitizing solution comprising the steps of:

preparing a diluted brine solution;

injecting a liquid through a three chamber cylindrical electrolysis cell in a predetermined flow pattern;

venting gases from said chambers;

isolating of a Sodium Hydroxide solution having a negative redox potential ranging from −600 to −1200 mV; and

isolating of a diluted Hypochlorous Acid solution having a positive redox potential ranging from +700 to +1200 mV.

19. The method according to claim 18 including the step of modifying the flow pattern to said chambers to change pH, free available chlorine content, redox-potential, osmolorarity and conductivity of the diluted Sodium Hydroxide solution.

20. The method according to claim 18 including the step of modifying the flow pattern to said chambers to change pH, free available chlorine content, redox-potential, osmolorarity and conductivity of the diluted Hypochlorous Acid solution.

21. The method according to claim 18 wherein said three chamber cylindrical electrolysis cell is further defined as a mesh based electrode electrolysis apparatus comprising an outer cylindrical electrode tube separated from two middle cylindrical mesh-electrodes by an outer cylindrical ion-selective exchange membrane; an inner cylindrical electrode tube separated from said two middle mesh-electrodes by an inner cylindrical ion-selective exchange membrane, said two middle cylindrical mesh-electrodes separated from the inner and outer electrode tubes by two ion-selective exchange membranes arranged coaxially one within the other to create an middle chamber having two mesh-electrodes; an inner chamber with an inner electrode tube and an outer chamber with an outer electrode tube; a pair of end pieces where a space between the inner cylindrical electrode-tube and the inner cylindrical ion-selective exchange membrane and a space between the outer cylindrical ion-selective exchange membrane and the outer electrode tube defines anode and cathode chambers, a space between said two ion-selective exchange membranes defines cathode or anode chambers and said two middle mesh-electrode functions as a cathode or anode and the inner and outer electrode tubes function as a anode or cathode; one of said end pieces having a lateral inlet through an outer wall thereof, said inlet being provided with a fitting for tangential feeding of the liquid to the inside of the end piece, and wherein three pairs of ports for entrance or exit of fluid are situated in the upper and lower end piece, each comprising an external fitting for attachment of a hose or pipe, said first pair of ports at opposite ends of said assembly internally addresses a space between said outer electrode tube and said outer ion-selective membrane and said second pair of ports at opposite ends of said assembly internally addresses a space between said outer ion-selective membrane and said inner ion-selective membrane and said third pair of ports at opposite ends of said assembly internally addresses a space between said inner electrode tube and said inner ion-selective membrane.

22. The method according to claim 21 wherein a diluted brine solution passes through the middle chamber and wherein the electrolysis product of the middle chamber is partly or in total separately or successively re-distributed to the inner and outer chamber of the cylindrical electrolysis cell.

23. The method according to claim 21 wherein the middle chamber functions preferably as cathode chamber and wherein the inner and outer chambers preferably function as anode chambers.

24. The method according to claim 21, wherein the two middle mesh-electrodes preferably function as cathode and the inner and outer electrode tubes preferably function as anode.

25. The method of claim 18, wherein the liquid is brine and the method further comprises, isolating a Sodium Hydroxide solution having a negative redox potential ranging from −600 to −1200 mV.

26. The method of claim 18, wherein the liquid is brine and the method further comprises, isolating a diluted Hypochlorous Acid solution having a positive redox potential ranging from +700 to +1200 mV.

27. The method of claim 18, wherein a portion of the liquid exiting the middle chamber is fed into the inner and outer chambers and another portion collected in a storage tank or drained.

28. The method of claim 18, wherein a part of the diluted Sodium Hydroxide solution (NAOH) is fed separately or successively through the anode chambers to produce a more neutral pH Hypochlorous Acid solution (HOCL).

29. The method of claim 18, wherein the pH of the sanitizing solution is regulated by re-directing a volume of Sodium Hydroxide (NAOH) exiting the cathode chamber through the anode chambers.

30. The method of claim 21, wherein the electrolysis product of the middle chamber is supplied separately or successively to the inner chamber and outer chamber at a lower end piece of the electrolysis cell and cleaning solutions (NAOH) and sanitizing solutions (HOCL) are obtained from an upper end piece of the cell.

31. The method of claim 21, wherein a spiral feed of a diluted brine solution is fed to the middle chamber and the electrolysis product of the middle chamber fed into the inner chamber and outer chamber using tangential inlet and outlet ports.

32. The method of claim 21, wherein the current is a direct current is applied across the anodes and cathodes and wherein the middle mesh-electrodes are wired together and wherein the outer electrode-tube and inner electrode-tube are wired together and a voltage is applied across the two middle-mesh electrodes and the inner electrode tube plus outer electrode tubes.

33. The method of claim 21, wherein pH, the free available chlorine content, conductivity and osmolality is regulated by altering the voltage, volume of the dilute brine solution passing through the middle, inner and outer chamber, brine concentration and whereas the current across the electrodes is at least 20 amps.