As the core component of ozone generation, the ceramic ozone generator tube's design optimization must focus on improving ozone concentration uniformity. This requires a comprehensive approach encompassing multiple dimensions, including material selection, structural innovation, gas source control, electrode design, cooling systems, manufacturing processes, and system integration, to achieve a dual improvement in ozone production and distribution.
Material selection is fundamental to improving ozone concentration uniformity. The ceramic substrate, as the core medium of the ozone generator, must possess characteristics such as high dielectric constant, high temperature resistance, and corrosion resistance. A ceramic substrate employing a honeycomb noble metal discharge design can significantly increase the ozone release area, making the discharge region more uniform, thereby improving both ozone production and distribution uniformity. Furthermore, surface coating moisture-proof technology can prevent moisture from affecting the ceramic substrate's performance, ensuring stable operation even in high-humidity environments, further maintaining ozone concentration uniformity.
Structural innovation is key to optimizing ozone distribution. The design of the ceramic ozone generator tube needs to optimize the gas flow path to ensure uniform distribution of the source gas along the ceramic plate's discharge surface. For example, by using a series gas flow into each ceramic plate, the gas flow rate and flow length are matched to avoid excessively high or low local concentrations. Simultaneously, the design of the ventilation gaps needs precise control to ensure that the gas is close to the discharge surface to increase ozone concentration, while preventing excessively large gaps from causing airflow turbulence and affecting uniformity. Furthermore, the trial use of open-gap discharge devices provides a new approach to uniform discharge in high-humidity environments.
Gas source control directly affects ozone generation efficiency and concentration. Using high-purity oxygen as the gas source can significantly improve ozone generation efficiency, as impurities may absorb discharge energy or react with ozone, reducing concentration. If oxygen cylinders are unavailable, an oxygen generator can provide a stable gas source. In addition, the gas distribution method has a significant impact on ozone production; it is necessary to ensure that the gas is evenly distributed to the surface of each ceramic plate to avoid local concentration differences. Optimizing the gas flow rate and electrode spacing can further improve the uniformity of ozone generation.
Electrode design is the core of improving discharge stability. The material and shape of the discharge electrodes directly affect ozone generation efficiency and uniformity. Employing tungsten sintered electrodes covered with a nano-alumina protective layer enhances their oxidation resistance, reduces material oxidation and migration, and maintains long-term stable discharge. Simultaneously, the electrode shape must match the ceramic substrate to ensure uniform coverage of the discharge area, preventing localized overheating or uneven discharge. Furthermore, precise control of the electrode spacing is crucial for achieving uniform discharge.
The cooling system is vital for maintaining ozone concentration uniformity. If the heat generated during ozone generation is not dissipated promptly, it can lead to localized temperature increases, accelerating ozone decomposition and reducing concentration. Therefore, efficient cooling technologies, such as water cooling or air cooling systems, are necessary to control the operating temperature within a suitable range. For example, a thickened Al-groove design on the back of the ceramic substrate increases the heat dissipation area, improves heat dissipation efficiency, ensures stable equipment operation, and thus maintains ozone concentration uniformity.
Optimizing the manufacturing process is essential for improving product consistency. The manufacturing of the ceramic ozone generator tube requires strict control over wall thickness uniformity and ellipticity to avoid uneven discharge due to structural defects. Simultaneously, impurities such as ammonia nitrate and ammonium sulfate deposited on the ceramic plate surface need to be cleaned regularly to prevent them from affecting discharge and ozone production rate. Introducing automated production lines and precision testing equipment can improve product consistency and reliability, further ensuring the uniformity of ozone concentration.
System integration and intelligent control are the ultimate means to achieve precise regulation. By introducing advanced control systems, parameters such as current, voltage, and temperature can be monitored and adjusted in real time to ensure stable ozone production and concentration. For example, combining automated control systems with high-precision sensors, the output of the ozone generator can be dynamically adjusted based on feedback signals to achieve precise control of ozone concentration. Furthermore, the application of intelligent control algorithms, such as fuzzy control and neural network control, can further improve the accuracy and stability of ozone output, meeting the needs of complex application scenarios.
