CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application No. 62/807,797, filed February 20, 2019. The entire disclosure of the above application is incorporated herein by reference.

GOVERNMENT RIGHTS

[0002] This invention was made with government support under 1700785, 1700787, and 1724941 awarded by the National Science Foundation. The government has certain rights in the invention.

BACKGROUND AND SUMMARY

[0003] Per-and-polyfluoroalkyl substances (“PFAS”) are a group of man-made chemicals that are very persistent in the environment and human body, which can lead to adverse human health effects. PFAS molecules have been commonly used as stain repellants and fire-fighting foams which were emitted into the air and water by industrial processes used to manufacture fluoro chemicals. PFAS molecules have also entered the ground and surface water through disposal of waste and sewage sludge, and as a result of fire-fighting use.

[0004] U.S. Patent Publication No. 2018/0222781 is entitled“Water Purification using Porous Carbon Electrode” which published to Liu et al. on August 9, 2018. This patent publication is incorporated by reference herein. This device uses an electrolysis chemic8al reaction process to break contaminants into small and stable molecules by using an electric current flowing between parallel electrodes.

[0005] In accordance with the present invention, an electrode apparatus and method remove a polarized molecule in a fluid. In another aspect, an electric potential is applied to an anode located within the fluid, the fluid flows within a gap between the anode and a surrounding cathode, and a non-uniform electric field is created between the anode and the cathode. A further aspect causes a polarized molecule in a liquid or gaseous fluid to move toward an anode. In another aspect, an electrically conductive porous material is an anode and is circumferentially surrounded by a grounded cathode with a fluid flowing therebetween and a polarized molecule (such as PFAS or other molecules) in the fluid is driven toward the anode, without causing electric current flowing between the anode and cathode and/or without a chemical reaction to the polarized molecule. In a further aspect, an anode is made of a porous metal and/or a porous activated carbon.

[0006] Moreover, another aspect includes a method for manufacturing an anode including making a metallic foil sheet, which may be a porous metal foam, attaching an activated carbon layer to the foil sheet and coiling or bending the foil and activated carbon assembly into a generally cylindrical shape. This method may further include applying an electric field between the foil/carbon anode and a surrounding cathode, flowing a liquid or gaseous fluid between the anode and the cathode, and electrically pulling polarized molecules to the anode without causing an electric current to flow. A further aspect of the present apparatus and method includes a drinking water faucet to which the anode and cathode are attached. Yet another aspect of the present apparatus and method uses the anode and cathode as part of an industrial water fluid treatment piping system. Additional advantages and features will be disclosed in the following description and appended claims, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a diagrammatic view showing an industrial water treatment apparatus employing the present electrode apparatus;

[0008] Figure 2 is a longitudinal-sectional view, taken along line 2 - 2 of Figure 1 , showing the present electrode apparatus;

[0009] Figure 3 is a diagrammatic view showing the present electrode apparatus of Figure 2;

[0010] Figure 4 is a cross-sectional view, taken along line 4 - 4 of Figure 3, showing the present electrode apparatus;

[0011] Figure 5 is a model of a polarized PFAS molecule employed with the present electrode apparatus;

[0012] Figure 6 is a perspective view showing a drinking water faucet apparatus employing the present electrode apparatus;

[0013] Figure 7 is a longitudinal-sectional view, taken along line 7 - 7 of Figure 6, showing the present electrode apparatus; [0014] Figure 8 is a series of perspective views showing a first manufacturing process to make an anode used in the present electrode apparatus;

[0015] Figure 9 is a cross-sectional view, taken along line 9 - 9 of Figure 8, showing the anode used in the present electrode apparatus;

[0016] Figure 10 is a series of perspective views showing a second manufacturing process to make the anode of the present electrode apparatus;

[0017] Figure 1 1 is a cross-sectional view, taken along line 1 1 - 1 1 of Figure 10, showing the anode of the present electrode apparatus;

[0018] Figure 12 is a series of perspective views showing a third manufacturing process to make the anode of the present electrode apparatus;

[0019] Figure 13 is a cross-sectional view, taken along line 13 - 13 of Figure 12, showing the anode of the present electrode apparatus; and

[0020] Figure 14 is a graph showing a Zeta potential of biochar used in the anode of the present electrode apparatus.

DETAILED DESCRIPTION

[0021] A first preferred embodiment of an electrode apparatus 21 used in an industrial water treatment system 23 is illustrated in Figures 1 - 4. Water treatment system 23 includes a contaminated water supply reservoir or tank 25, a decontaminated water receiving or holding reservoir or tank 27, and one or more electrode-based precipitator or treatment units 31 and 33. Valves 37 of treatment unit 31 are turned on to allow flow of contaminated water 35 between the tanks while valves 39 of treatment unit 33 may be optionally turned off to stop fluid flow therein, or vice versa, for example if an anode therein needs to be cleaned and/or replaced. Additionally, water pumps, sensors, pipes and other plumbing components may be employed to flow water 35 from tank 25, through treatment units 31 and/or 33, and to tank 27.

[0022] More specifically, each precipitator and treatment unit 31 and 33 includes a longitudinally elongated and generally cylindrically shaped cathode electrode 41 which concentrically surrounds a generally cylindrically shaped and longitudinally elongated anode electrode 43 internally located therein. A cylindrical gap 45 concentrically surrounds anode 43 between an outer diameter periphery of the anode and an inner diameter surface of cathode 41 , such that the cathode and anode are spaced away from each other to allow water 35 to longitudinally flow in gap 45. The anode preferably has an outer diameter less than half of the inner diameter of the cathode although such a relationship may be varied for different uses.

[0023] Anode 43 is preferably a conductive and corrosion resistant rod material 47 with porous structures. Anode 43 can be a metal, such as copper, stainless steel, nickel or an alloy thereof. Alternatively, anode 43 consists of a metal core 47 with a layer of activated carbon 49 on an outside thereof. Activated carbon 49 is preferably treated as is disclosed in PCT International Patent Publication No. WO 2018/136502 entitled“Magnetic Field Enhanced Plasma for Materials Processing” which published to one of the present co-inventors Qi Hua Fan, on July 26, 2018, and U.S. Patent No. 9,754,733 entitled“Method for Plasma Activation of Biochar Material” which also issued to co-inventor Qi Flua Fan, on September 5, 2017, both of which are incorporated by reference herein. Activated carbon layer 49 has a thickness of at least 1 micron and a surface area greater than 600 m ² /g is preferred. For PFAS adsorption, it is preferred to employ plasma activated carbon with a relatively positive surface potential. Furthermore, cathode 41 is a conductive, corrosion resistant and tubular metallic material, preferably copper but alternately stainless steel, nickel or an alloy thereof.

[0024] An electrical circuit 51 electrically connects a direct current power source 53 to an end 55 of anode 43 for supplying positive dc voltage thereto. The preferred voltage range is 1 - 100 volts and more preferably 3 - 40 volts, however, greater voltage can be used with other fluids. Another electrical circuit 57 electrically couples an end of cathode 41 to a ground 59. Due to the non-symmetrical nature of the electrodes, for example the fluid-exposed surface area size differences between the smaller outer diameter of anode 43 and the larger inner diameter of cathode 41 , a non-uniform electric field is created within gap 45. Although there are electrical potential differences between anode 43 and cathode 41 , however, essentially no electrical current flows between these electrodes since the fresh water within gap 45 is a poor electrical conductor and essentially acts as an insulator. There is no current flow corresponding to the transport of PFAS. Thus, there is no electrical current between the electrodes in the water assuming no impurities in the water other than the polarized contaminants to be removed.

[0025] As can best be observed in Figure 2, an electrical connector 71 retains the associated end 55 of anode 43 within an end-fitting 73. In the present example, end fitting 73 is threadably coupled to a T-pipe junction 75. Furthermore, an intermediate fitting 77 threadably couples an associated end 79 of cathode 41 to pipe junction 75. An additional pipe or contaminated water supply line 81 is coupled to pipe junction 75 via another fitting 83. A similar arrangement is provided on the opposite end of the treatment unit 31 . It should be appreciated that the cathode and anode longitudinal lengths and lateral diameters, as well as the flow through area of the gap therebetween, is sized to match the fluid flow rate, the concentration of the polarized molecule contaminants to be removed, and the adsorption capabilities of the anode employed. Regardless, it is envisioned that the longitudinal length of anode 43 will be at least ten times and more preferably at least twenty times an outer diameter thereof.

[0026] Referring now to Figures 4 and 5, the contaminant to be removed by the present electrode apparatus and method is a polarized molecule 91 , preferably a PFAS molecule consisting of at least carbon and fluorine atoms. E denotes the non-uniform electric field between anode 43 and cathode 41 which drives or pulls the polarized molecule 91 toward anode 43 which is then adsorbed into the porous anode. It is noteworthy that no chemical reaction or electrolysis is occurring to molecules 91 since no or minimal electrical current is flowing between the electrodes. Thus, anode serves to remove the polarized molecule contaminants from the water as the water flows past the anode. No additional filtering or chemical reactions should be necessary to remove these polarized molecules from the flowing drinking water. Periodically, the contaminant-rich anode will be removed and either replaced or cleaned.

[0027] It is alternately envisioned that polarized molecules other than PFAS may be removed by use of the present electrode apparatus and method. Moreover, polarized molecules may alternately be removed from other liquid and gaseous fluids, such as within a combustion smokestack or exhaust pipe. Other polarized molecule contaminants include benzene, carbon dioxide, sulphur dioxide and the like.

[0028] A residential implementation of an exemplary second preferred embodiment of the present electrode apparatus and method are illustrated in Figures 6 and 7. A residential drinking water faucet 101 includes an adapter 103 adjacent a distal end thereof. Adapter 103 employs an anode electrode 105 and a concentrically surrounding cathode electrode 107, both of which are longitudinally elongated. A threaded coupling 109 removeably couples a proximal end of cathode 107 to an outlet pipe 1 1 1 of faucet 101 . Furthermore, a pair of polymeric insulators 131 and 133 mount and insulate anode 105 within cathode while allowing a water flow gap 135 between the facing outer and inner surfaces of anode 105 and cathode 107, respectively. A polymeric cover plate 137 is also provided to secure insulator 131 within a stepped recess 139 of cathode 107. Cover plate 137 may be attached to the inside of the cathode by threads, adhesive or an interference press-fit. Cover plate 137 includes multiple longitudinally open holes 141 , insulator 131 also includes multiple aligned and longitudinally accessible holes 143, and a distal end of cathode 107 additionally includes longitudinally accessible holes 145, to allow drinking water to flow therethrough. A battery power supply 147 is electrically connected to anode 105 and may be retained between insulator 131 and cover plate 137, or in a remote different location with a wire or stamped circuit, to supply electrical voltage to an end of anode 105. O-rings 149 are also employed to seal the various components. The anode and cathode function essentially the same as with the prior industrial configuration for removing polarized molecule contaminants from the drinking water and adsorbing them onto the anode.

[0029] A first method of manufacturing and structure of the present anode 43 is shown in Figures 8 and 9. Plasma activated carbon 49 includes a binder material and is pressed and heated to form a unitary and uniform, solid rod with the activated carbon and binder composition evenly spread throughout the entire cross-sectional area from end-to-end. Figures 10 and 1 1 show another manufacturing process and construction of an anode 143 wherein a layer of activated carbon 49, intermixed with a binder material, is coated or otherwise affixed to an outer diameter surface 151 of a conductive and corrosion resistant metallic rod 153, such as copper, stainless steel, nickel or an alloy thereof, which has a generally circular-cylindrical and longitudinally elongated shape. Preferably, the coated rod assembly of anode 143 is only coated at a middle area 155 of rod 151 such that end sections 157 do not have activated carbon 49 thereon. This advantageously allows easier and more effective electrical coupling of the uncoated end sections 157 to the electrical connector.

[0030] A third manufacturing process and configuration for anode 243 can be observed in Figures 12 and 13. First, a foamed metallic sheet or foil 171 is provided. Foamed foil 171 is preferably a nickel foam with a surface density of about 346 g/m ² and a porosity greater than or equal to 95 percent, with 80-1 10 pores per inch and an average hole diameter of about 0.25 mn. One such nickel foam foil can be obtained from MTI Corporation. It should be appreciated, however, that other metallic foam or, less preferably, unfoamed metallic sheets may be employed.

[0031] Activated carbon material, preferably intermixed with a binder, is then deposited, coated or otherwise attached to an outer porous surface of metallic foam foil 171 in a generally flat state. In one example, activated carbon 49 is mixed into a slurry and pressed into the open pores of metallic foam foil 171 , which is in a flat state. The assembled activated carbon slurry and foam is then heated at approximately 60 - 100 ^° C to dry. An exemplary binder maybe of a cellulose type. Subsequently, the foil and activated carbon assembly is then coiled, rolled or bent into a circular-cylindrical shape with a hollow center 173 with an edge seam 175 attached together to form a complete cross-sectional circle. Optionally, end caps 177 are fastened to both opposite ends of the coiled anode 243 to prevent fluid flow through the hollow center 173. Any of these anode configurations 43, 143 and 243 may be interchangeably used in any of the industrial or residential apparatuses disclosed herein.

[0032] Figure 14 illustrates a zeta potential of the activated carbon. Use of different plasma gas precursors such as CFU, O2H2 and N2 may be employed in the plasma activation of the carbon to efficiently modulate the surface electropotential of the activated carbon and facilitate contaminant molecule absorption. This allows for tuning or shifting of the surface area potential of the activated carbon so it can be tailored for specific contaminant materials to be absorbed most effectively. In the present example, the use of H2 during the plasma activation is best suited for PFAS adsorption into the anode in the present apparatus.

[0033] While various embodiments have been disclosed, it should be appreciated that additional variations of the electrode apparatus and method are also envisioned. For example, additional or different hardware components may be used although certain of the present advantages may not be fully realized. An anode made of porous metals or other electrically conductive materials can be also used. While certain electrode and pipe shapes have been disclosed it should be appreciated that alternate shapes may be used (for example, octagonal, oval or other cross-sectional shapes that create a non-uniform electric field) although all of the present advantages may not be fully achieved. It is also noteworthy that any of the preceding features may be interchanged and intermixed with any of the others. Accordingly, any and/or all of the dependent claims may depend from all of their preceding claims and may be combined together in any combination. Variations are not to be regarded as a departure from the present disclosure, and all such modifications are entitled to be included within the scope and sprit of the present invention.