Ultraviolet irradiation apparatus

Abstract

An irradiation apparatus having an interior irradiation reactor having an irradiation opening into the reactor in an inlet end, a plurality of inlet liquid ports for entry of liquid into the irradiation reactor, and one or more outlet liquid ports in an opposite outlet end for egress of liquid from the irradiation reactor. One or more ultraviolet (UV)-radiation sources emits UV radiation through the irradiation opening and into the irradiation reactor, with a heatsink surface in heat transfer communication with an underside of the one or more UV-irradiation sources. The irradiation apparatus also has a coolant reservoir in liquid communication between the plurality of inlet liquid ports and a coolant supply port for liquid entry into the coolant reservoir. The heatsink surface is disposed within the coolant reservoir, and a portion of a cooling liquid flowing between the coolant port and the plurality of inlet liquid ports contacts the heatsink surface.

Description

AQSNS.OIOWO PATENTULTRA VIOLET IRRADIATION APPARATUSINCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 713,100, filed October 29, 2024, which is incorporated herein by reference. Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.FIELD

[0002] The present invention relates generally to an apparatus and methods for disinfection of fluids by irradiation. More specifically, the invention relates to an apparatus and methods for disinfection of liquids containing a contaminant or pathogen to be irradiated with a UV radiation source.BACKGROUND

[0003] The use of ultraviolet (UV) radiation for the purpose of disinfection of a fluid, including liquids and gases, is well known. The process of using ultraviolet radiation to inactivate microbial contaminants in fluids is referred to as Ultraviolet Germicidal Irradiation (UVGI). Ultraviolet radiation has also been used for oxidizing organic and inorganic materials in a fluid, termed Advance Oxidation Process (AOP), and many commercial AOP systems are in use today. Systems employing UVGI and AOP methods rely on the ability to transmit UV radiation into the fluid in a predictable manner. The dose of a UVGI system, which has units of J / cm2, can be simply stated as the product of the UV irradiance in units of W / cm2and the exposure time in seconds.

[0004] There are many types of UV radiation sources. Solid state sources such as LEDs create light in a semiconductor material though charge recombination in an active layer where charge injection is applied to an anode and cathode of the semiconductor heterostructure. Solid state radiation sources have maximized outputs at lower ambient temperatures. For example, the output power of a low-pressure mercury lamp may peak at anambient temperature of 40 degrees Celsius while the optical output power of a 265nm light emitting diode (LED) displays a linear relationship with ambient temperature. The slope of the LED curve may vary by the device design, but the trend remains the same with larger optical output powers seen at lower ambient temperatures.

[0005] Many LED manufacturers specify a maximum junction temperature which should not be exceeded. The LED junction temperature is the temperature of the active layer sandwiched between the n-type and p-type semiconductor layers of the LED. Exceeding a maximum rated junction temperature may result in a decrease in the lifetime or other characteristics of the LED. In a simplified model, an LED can be represented as a series of thermal resistances.

[0006] LEDs are unique among most UV sources in that heat is removed through the side of the chip which is electrically connected versus the side which is responsible for most of the UV emission. However, LEDs can be sensitive to electro-static discharge, moisture, and ambient gases like oxygen or nitrogen which can degrade the performance of the LED electrical contacts and the semiconductor. For this reason, a UV-light transmissive window, for example, a quartz window, is often placed on the SMD package of a LED. In UVGI systems where the LED will be protected from the fluid via a window, the window on the SMD becomes superfluous if the above environmental impacts can be mitigated. A single window over a board containing one or more LEDs can be used as the optical window for a fluid disinfection system if the LEDs are sealed between the board and the window such that the window can serve as a portion of the pressure vessel for the disinfection system and to segregate the LEDs from the fluid. Potting compounds like epoxies or silicones can be used between the board and the window to accomplish this. The potting may be undertaken in a low relative humidity environment or even purged with dry air or an inert gas to ensure any voids between the LED and window do not have undesirable moisture or gases inside. This would also increase the output power of the LED since it would pass light through one quartz window versus two. An additional benefit to this type of single window lamp package is that the LED imparts little heating to the window, in contrast to mercury vapor sources which transmit a large amount of heat to the window. Lower window temperatures have been correlated to less fouling of the window. Window fouling lowers the overall UV transmittance of the window, which in turn lowers the performance of UVGI and AOP systems. Thus, a robust productdesign utilizing a UV source will account for the temperature of the UV source during operation by consideration of heat transfer. By such methods the lifetime and output power of the UV source may be better controlled. In addition, methods of assembling the UV source into secondary packaging can be used to enhance the output power and lifetime of the UV source.

[0007] While the UV source is an important component in a UVGI system, it is only one component in the overall system efficiency. The system efficiency can be expressed as the product of the reactor efficiency and the UV source efficiency. It is good practice in the design of a UVGI system to maximize the exposure time, often termed the “residence time”, of the fluid to the UV irradiance thereby maximizing the dose seen by the fluid. The reactor efficiency is a combination of the residence time efficiency and the optical efficiency. The optical efficiency of the reactor is a measure of how effectively the reactor uses photons from the UV source to increase the probability that a microbial contaminant in the fluid will absorb a photon.

[0008] U.S. Patent Application Publications 2012 / 0318749 Al, 2014 / 0161664 Al, and 2014 / 0240695 Al, and U.S. Patent 10,500,295, all incorporated herein by reference, disclose various apparatus, materials and methods useful herein for disinfection of fluids by means of a UV irradiation source that can include UV-emitting light emitting diodes (LEDs).

[0009] Nevertheless, there remains a need for an improved apparatus and method for irradiation that provides good system efficiency, incorporates adequate, and can be used with a variety of housings or flow cells.SUMMARY

[0010] The present invention provides an irradiation apparatus <1> comprising an interior irradiation reactor having a first end and an opposite second end, an irradiation opening into the irradiation reactor in the second end, one or more first liquid ports in the first end for egress from or entry into the irradiation reactor, one or more second liquid ports in the second end for entry into or egress from the irradiation reactor; an ultraviolet (UV) -irradiation device including one or more UV-radiation sources for emitting UV radiation through the irradiation opening and into the irradiation reactor, and a heatsink in heat transfer communication with a heatsink surface opposite the light-emitting surface of the one or more UV-irradiation sources;and a coolant reservoir in liquid communication with the one or more second liquid ports and with the heatsink surface, and having a coolant port for entry into or egress from the coolant reservoir.

[0011] The present invention provides an irradiation apparatus <2> comprising: i) an irradiation body having an interior irradiation reactor with an interior surface, a first end of the irradiation body having a first liquid port for entry into or egress from a first end of the irradiation reactor, a second end of the irradiation body having an irradiation opening into a second end of the irradiation reactor, and a peripheral edge surrounding the irradiation opening and having one or more channels formed through the peripheral edge into the second end of the irradiation reactor, ii) a UV-transparent window having a periphery in contact with the peripheral edge of the irradiation body that forms the one or more channels into one or more second liquid ports into the second end of the irradiation reactor, iii) a ultraviolet (UV)- irradiation device including one or more UV-radiation sources for emitting UV radiation through the UV-transparent window and the irradiation opening, and into the irradiation reactor, and a heatsink surface opposite the light-emitting surface in heat transfer communication with the one or more UV-irradiation sources, and iv) a coolant body having a coolant chamber, the coolant chamber being in liquid communication with the one or more second ports into the second end of the irradiation reactor, and having a liquid transfer port for entry into or egress from the coolant chamber, wherein the heatsink surface is in Liquid communication with the coolant chamber between the one or more second ports and the liquid transfer port.

[0012] The present invention provides an irradiation apparatus <3> comprising: i) a chamber body including an upper end, a lower end, and a peripheral sidewall, and having an irradiation chamber formed into the lower end that includes a lower inner surface with a peripheral edge having one or more tangential channels, and an upper inner surface having a first liquid port extending through the upper end, ii) a UV-transparent window having a periphery in contact with the peripheral edge of the chamber body that forms one or more first tangential liquid ports with the one or more tangential channels, iii) a UV-irradiation device including one or more ultraviolet (UV)-radiation sources for emitting UV radiation through the UV-transparent window and into the irradiation chamber, and a heatsink surface on an underside of the one or more UV-irradiation sources, and iv) a coolant body having a liquidtransfer port that forms a coolant chamber in liquid communication between the one or more tangential ports and the liquid transfer port, and placing the heatsink in liquid contact with the coolant chamber.

[0013] In various embodiments according to any one of <1>, <2> and <3>, wherein the coolant body includes a coolant chamber floor having the liquid transfer port and an upper peripheral sidewall extending axially from an upper side of the coolant chamber floor, the upper peripheral sidewall having a peripheral edge that can be sealed against a peripheral sidewall of the irradiation body.

[0014] In the configuration of the components of the irradiation apparatus, consideration can be given to the size of the apparatus, in both height and breadth, to allow the apparatus to be installed or retrofitted into existing water or liquid supply lines disposed within small spaces. Consideration can be given to the effect of the cooling of the irradiation assembly on the pressure drop of the liquid flow across the apparatus, and consequently to the maximum flow rate of liquid therethrough.

[0015] In various embodiments of one or more of <1>, <2> and <3>, the coolant chamber is configured to provide that only a minority portion of the liquid flowing between the liquid transfer port and the one or more tangential ports passes through a coolant liquid pathway, to engage in thermal energy transfer with the heatsink surface, and a remaining bypass portion of the liquid flows radially outside the UV-irradiation device and out of thermal transfer contact with the heatsink surface.

[0016] In some embodiments, the portion of the liquid that engages in thermal energy transfer with the heatsink surface is the portion of liquid that flows through the flow space beneath the surface of the heatsink. In some embodiments, the portion is the liquid that flows between the surface of the heatsink and the coolant floor of the cooling chamber.

[0017] In some embodiments, the minority portion is at least 10% of the volumetric flow of the liquid flow through the coolant chamber. In other embodiments, the minority portion is up to 25% of the volumetric flow of the liquid into the coolant chamber.

[0018] In various embodiments of one or more of <1>, <2> and <3>, the ratio of the diameter dl of the heatsink surface to the distance hl between the coolant chamber floor and the heatsink surface is 15:1 to 35:1, preferably 19:1 to 25:1.

[0019] In various embodiments of one or more of <1>, <2> and <3>, the liquid transfer port is disposed at a periphery of the coolant chamber floor

[0020] In some embodiments, an electrical port extends through the coolant chamber floor of the coolant body and to the UV-irradiation device.

[0021] In some embodiments, the one or more tangential channels is three tangential channels.

[0022] In various embodiments, the three tangential channels are distributed uniformly along the peripheral edge of the chamber body.

[0023] In various embodiments, a centerline along the one or more tangential channels extends along a chord of a cross section of the irradiation chamber in the lower end of the chamber body.

[0024] In various embodiments, the heatsink surface is a stainless-steel material.

[0025] In various embodiments, the irradiation device further includes a water flow sensor for detecting a flow of liquid through the liquid transfer port.

[0026] In some embodiments, the coolant body further includes a lower peripheral sidewall extending axially from an underside of the coolant chamber floor, and a base cover sealed to the lower peripheral sidewall to form a flow detection chamber, the base cover including an outer liquid flow port, the liquid flow sensor disposed in the flow path between the outer liquid flow port and the liquid transfer port.

[0027] In some embodiments, the flow path through the liquid flow sensor is transverse to the direction of liquid flow through the liquid transfer port. In some embodiments, the flow path through the liquid flow sensor is transverse to and lateral to the direction of liquid flow through the outer liquid flow port. In some embodiments, the liquid flow sensor generates a flowing signal to a controller to deliver power to the one or more UV-irradiation sources when liquid flows through the liquid flow sensor between the outer liquid flow port and the liquid transfer port.

[0028] In some embodiments, the liquid flow sensor includes a paddlewheel placed rotatably within the flow detection chamber to direct liquid flow peripherally through the paddlewheel, [n some embodiments, the peripheral flow path through the paddlewheel traverses a majority of the periphery of the paddlewheel.

[0029] In various embodiments, the irradiation chamber has a spherical or capsule shape.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The invention is illustrated and described herein with reference to the various drawings, in which like reference numbers are used to denote like apparatus components, as appropriate, and in which:

[0031] FIG. 1 is a perspective view of an irradiation apparatus of the invention.

[0032] FIG. 2 is an exploded top-perspective view of the irradiation apparatus.

[0033] FIG. 3 is an exploded bottom-perspective view of the irradiation apparatus.

[0034] FIG. 4 is an exploded top-perspective view of a UV-irradiation assembly for use with.in the irradiation apparatus.

[0035] FIG. 5 is a sectional elevation view of the irradiation apparatus taken along line 5-5 of FIG. 1.

[0036] FIG. 6 is a detailed sectional view of a coolant chamber of the irradiation apparatus shown in FIG. 5.

[0037] FIG. 7 is a view of a chamber body separated from a coolant body and tilted off axis to illustrate how the lower surface of the chamber body confronts the upper surface of the coolant body.

[0038] FIG. 8 illustrates a lower portion of the coolant body separate and tilted off axis from a lower coolant body cover, to illustrate how the liquid flows though the lower portion of the coolant body.

[0039] FIG. 9 illustrates a vertical section taken through the irrational body through line 9-9 of FIG. 2.

[0040] FIG. 10 illustrates a horizontal section taken through the irradiation body through line 10-10 of Figure 5.DETAILED DESCRIPTION

[0041] FIG. 1 shows a perspective view of the irradiation apparatus 1, featuring an irradiation device having an ultraviolet (UV)-irradiation source, a first liquid connection and a second liquid connection.

[0042] FIGS. 2 and 3 show an exploded view of main components and supporting elements of the irradiation apparatus 1, including a reactor body 10 and a coolant body 31, an upper cover body 5, a UV irradiation assembly 60, and a lower cover body 2.Irradiation Chamber

[0043] The irradiation apparatus 1 includes an irradiation chamber 2 having an irradiation reactor 18, a UV irradiation assembly 60, and a coolant body 31. A first liquid connection of the irradiation apparatus 1 provides liquid communication with a first liquid port 28 communicating with the irradiation reactor 18. A second liquid connection of the irradiation apparatus 1 provides liquid communication through the coolant body 31 , communicating with a second liquid port 24 of the irradiation reactor 18.

[0044] As shown in FIG. 5, the irradiation apparatus 1, includes at least two separate bodies - a reactor body 10 and a coolant body 31 - that are positioned and secured together to form a unitary device comprising an interior irradiation reactor 18. The reactor body 10 and the coolant body 31 are also sealed to provide a sealed liquid flow communication between the irradiation reactor 18 and a coolant pool (e.g., reservoir) 38 within the coolant body 31, as described further below.

[0045] The reactor body 10 is the upper body, and the coolant body 31 is the lower body. When describing the apparatus and its bodies, parts, elements, and features, the terms “upper” (or “top”) and “lower” (or “bottom”) are used as a convenience in identifying the relative positions of the bodies, parts, elements and features as illustrated in the drawings. It should be understood that in a normal use, the apparatus can be oriented as illustrated in the drawing, with an “upper” body, part, element or feature oriented vertically upward and a “lower” body, part, element or feature oriented vertically downward; or in the opposite orientation, with an “upper” body, part, element or feature oriented vertically downward and a “lower” body, part, element or feature oriented vertically upward; or in a transverse position, with both the “upper” and “lower” body, part, element or feature oriented horizontally; or in any other omnidirection.

[0046] In some embodiments, the irradiation apparatus 1 also includes a lower cover body 2 that provides a second outer connection 4 in liquid communication with the coolant body 31.

[0047] In some embodiments, the irradiation apparatus 1 also includes an upper cover body 5 that provides a first outer connection 3 in liquid communication with the first liquid port of the irradiation reactor 18. Optionally the upper cover body 5 can assist in securing the coolant body 31 to the reactor body 10.Reactor Body

[0048] A reactor body comprises a cylindrical body having an irradiation reactor having a lower opening, a means for positioning a UV irradiation assembly across the lower opening for emitting UV radiation into the irradiation reactor, a lower liquid pathway into, or out at: the irradiation reactor, disposed adjacent to the lower opening and the UV irradiation assembly, and an upper liquid pathway out of, or into, the irradiation reactor.

[0049] A non-limiting example of a reactor body is illustrated in each of FIGS. 2, 3, 5, 7 and 9.

[0050] As shown in FIG. 9, the reactor body 10 has a domed, hemispherical upper outer surface 13. a sidewall surface 14, and a bottom surface 16. A spherical cavity is formed into the interior the reactor body 10 with an axial centerline 102, forming the irradiation reactor 18 having a lower interior surface 25 and an upper interior surface 26. and a lower opening 27 into the irradiation reactor 18.

[0051] A first liquid port 28 is formed axially through a portion of the upper interior surface 26, and axially opposite the lower opening 27, to provide liquid communication for the irradiation reactor 18 through the upper outer surface 13 of the body 10.

[0052] In some embodiments, a centerline 101 of the first liquid port 28 is parallel to and offset from the axial centerline 102 of the irradiation reactor 18. In some embodiments, the centerline 101 of the first liquid port 28 is coaxial with the centerline 102.

[0053] In some embodiments, the reactor body 10 is formed in two parts: an upper body part 11 and a lower body part 12, divided along a horizontal plane (dashed line 105 of FIG. 9) through a center point of the reactor 18, for easier manufacture. The two parts 11 and 12 are then bonded or secured together to form an integral chamber body.

[0054] In various embodiments the irradiation reactor 18 can be formed having a non-spherical shape, for example, a capsule shape or a stadium-of-revolution shape.

[0055] In various embodiments, the lower opening 27 in the bottom surface 22 is circular in shape.

[0056] The bottom surface 16 comprises a planar surface that peripherally surrounds and extends radially outwardly from the lower opening 27. As illustrated in FIGS. 3 and 7, a plurality (three) of plateaus 20 are positioned surrounding the lower opening 27, and are spaced apart angularly along the inner periphery of the bottom surface 16. preferably angularly uniformly, to provide channels 19 between adjacent plateaus 20.

[0057] In various embodiments, the inner flange 21 of the plateau 20 extends radially inwardly of the edge 17 of the opening 27 and axially away from the bottom surface 16. The inner radial edge of the inner flange 21 is a concave surface, while the outer edge 23 of the plateau 20 extends radially outwardly along the bottom surface 16 toward the side surface 14. As will be seen in the discussion of the cooling chamber, the space between the outer edge 23 of the plateaus 20 and the side surface 14 of the reactor body 10 allows cooling liquid to flow around the outer circumference of the plateaus 20, and along the channels 19 and into the reactor 18. The side edge surfaces of the plateaus 20 are curved and rounded to minimize liquid flow resistance, though they can have any shape.

[0058] In various embodiments, the plateaus 20 are formed integrally with the bottom surface 16 of the reactor body 10.

[0059] In various embodiments, the bottom surface 22 of the plateaus 20 are planar and typically oriented parallel to the bottom surface 16 of reactor body 10. The planar bottom surfaces 22 provide for an improved liquid sealing of the plateaus 20 with a UV radiation device 60, described herein after.UV Irradiation Device

[0060] As shown in FIG. 4, the UV radiation assembly 60 includes a UV irradiation source 74, typically one or more UV light emitting diodes (LEDs), and a UV-light transparent window 68, for example a quartz window . As shown in FIG. 6, the UV-irradiation source 74 and the UV-light transparent window 68 are positioned adjacent and facing the lower opening 27 of the irradiation reactor 18, disposed along the centerline 102.

[0061] The UV radiation assembly 60 is positioned against the bottom edges of the plateaus 20 to form a plurality of second liquid ports 24 (shown in FIGS. 6 and 10), that provide liquid communication between a coolant pool 38 and the irradiation reactor 18.

[0062] The UV irradiation source 74 and other power and control electronic components are fixed upon a PCB 72 and surrounded by a silicone gasket material 73 to form an irradiation device (e.g., LED device) by well known techniques. The silicone gasket material 73 serves as a barrier to protect the peripheral seal 65, which envelopes the peripheral edge 69 of the UV-light transparent window 68. from extreme UV exposure.

[0063] In some embodiments, the UV radiation assembly 60 includes a heatsink shell 70. The heatsink shell 70 includes an electronics seal port 77 extending from the undersurface of a heat transfer plate 76, that seals to an electronics port 43 (shown in FIG. 2) through the floor 37 of the coolant body 31. The electronics port 43 having a sealing member, illustrated as a gasket 94, provides a liquid- sealed pathway for an electronic and control wiring 90 (shown in FIGS. 5 and 6) passing up through a wiring conduit 78, through port 43 in the floor 37 of the coolant body 31, through the electronics seal port 77 and into the UV radiation assembly 60. In some embodiments, the sealing member can be an O-ring.

[0064] A portion of the heatsink shell 70 (e.g., the electronics seal port 77), and the electronics port 43 may form a barrier 98 in the cooling cavity 36. The barrier 98 may be positioned (e.g., disposed) between the coolant port 39 and a centerline of the irradiation reactor 18. The barrier 98 may be configured to prevent direct flow of liquid between the coolant port 39 and the coolant liquid pathway 46. Accordingly, the barrier 98 may be configured to prevent direct flow of liquid between the coolant port 39 and the heat transfer plate 76.

[0065] The wiring conduit 78 has an upper opening that extends from within the UV radiation assembly 60, and through the electronics port 43 and gasket seal 94 of the coolant body 31. The wiring conduit 78 further extends through and exiting from the electronics port 53 of the lower cover body 2. Both the electronics port 43 in the floor 37 of the coolant body 31 and an electronics port 53 (shown in FIGS. 2 and 3) in the lower cover body 2 include a leak-proof seal 95 against the outer surface of the wiring conduit 78, illustrated in FIG. 5 as toroidal O-ring seal disposed within an annular groove 89 formed in the passageways of the electronics ports 43 and 53.

[0066] The bottom surface of the UV irradiation source 74, which generates heat during use, is fixed to the PCB 72 and in thermal transfer communication to an upper surface of a heatsink, illustrated as the heat transfer plate 76 of the heatsink shell 70. The upper surface of the heatsink (e.g., the heat transfer plate 76) may include stainless steel and / or any other suitable material.

[0067] In some embodiments illustrated in FIGS. 4 and 6, the UV radiation assembly includes an upper frame 61 having a planar, annular upper surface 62 and a plurality of clamps 64 positioned on the lower edge of the upper frame 61, to form an inner annular groove 63. The UV-light transparent window 68 is fitted within an annular inner groove 66 of an annular peripheral seal 65 that envelopes the peripheral edge 69 of the UV-light transparent window 68, which is then itself is fitted within the inner annular groove 63 of the upper frame 61. The peripheral seal 65 further includes an annular outer seal surface 67 that is placed into sealing contact with the inner sidewall 71 of the heatsink shell 70. The plurality of clamps 64 positioned on the lower edge of the upper frame 61 can be folded over the outer edge 75 of the heatsink shell 70, thereby securing and sealing the electronics including the UV irradiation source 74 within the UV irradiation assembly 60, beneath the peripheral seal 65 and the UV- light transparent window 68.

[0068] The UV radiation assembly 60 is placed coaxially against the lower opening 27 of the reactor body 10, with the upper surface 62 of the peripheral seal 65 of the irradiation assembly 60 positioned against the lower surfaces 22 of the plateaus 20. The positioning of the UV radiation assembly 60 against the lower surfaces 22 of the plateaus 20 provides a closure of the lower opening 27 of the irradiation reactor 18, and forms the covered channels 19 into a corresponding one or more second liquid ports 24 for liquid flow into or out of the reactor 18.

[0069] The upper exposed surface of the UV-light transparent window 68 and the size of the lower opening 27 provide for a sufficient span for emission of UV radiation to irradiate the entire volume of the irradiation reactor 18, as well as the lower 25 and upper 26 inner surfaces of the irradiation reactor 18.

[0070] In various embodiments, the inner surfaces 25, 26 of the irradiation reactor 18 can be coated with a Uambertian scattering material. In other embodiments, the inner surfaces 25, 26 of the irradiation reactor 18 can be coated with a photocatalytic material capableof destroying adsorbed biological materials in the presence of the generated and reflected radiation.

[0071] In preferred embodiments, the volume and shape of the irradiation reactor 18 is symmetrical about the centerline 102.

[0072] In some embodiments, the side edge surfaces of the plateaus 20 can be angularly shaped to form the one or more second liquid ports 24 along flow centerlines 104 (shown in FIG. 10) that are tangential to the centerline 102 of the irradiation reactor 18. This tangential arrangement of the one or more second liquid ports 24 relative to the centerline 102 induces a circular swirling of liquid with the irradiation reactor 18, whether the liquid is flowing into the irradiation reactor 18 as an entry port, or out of the irradiation reactor 18 as an egress port.Coolant Body

[0073] The function of a coolant body is to guide a liquid into liquid communication with the one or more second liquid ports 24, and into heat transfer contact with the heatsink of the UV radiation devices (typically, light emitting diodes, or LEDs).

[0074] The liquid can be water, including water for consumption. The liquid can be any other liquid, flowing composition in which UV radiation can provide efficacy, including the deactivation and / or destruction of microorganisms.

[0075] As shown in FIGS. 2 and 7, a coolant body 31 includes a sidewall 32 that includes an upper sidewall 33 with an upper rim 34 that boundaries a first end opening 35 into a cooling cavity (e.g., chamber) 36. As shown in FIG. 5, the UV radiation assembly 60 and the lower portion 12 of the reactor body 10 are disposed through the first end opening 35 and into the cooling cavity 36. A floor 37, shown in FIGS. 2 and 7, forms a closed lower end of the cooling cavity 36.

[0076] The inside edge of the upper rim 34 of the upper sidewall 33 is sealed annularly to a lower end of the outer sidewall 14 of the reactor body 10, for example with an O-ring seal 91 retained in an annular groove 15 in the outer sidewall 14 that seals against the inner surface of the upper rim 34 of the coolant body 31, as shown in FIG. 6.

[0077] A resulting sealed coolant pool 38, shown in FIG. 5, is boundaried by the upper sidewall 33 and the floor 37 of the coolant body 31, the bottom surface 16 of the reactorbody 10, and the UV radiation assembly 60, and is in liquid communication between the second liquid port(s) 24 of the irradiation reactor 18 and one or more coolant ports 39 that provides an entry into, or an egress from, the coolant pool 38.

[0078] As shown in FIGS. 2 and 7, the coolant body 31 includes a plurality of supports extending from the floor 37 that support the UV radiation assembly 60 at and along the outer rim edge 75 and at the undersurface of the heat transfer plate 76 of the heatsink shell 70. The supports further can be used to guide the flow of liquid through the coolant pool 38.

[0079] The supports can include a plurality of heatsink positioning guides 40 spaced-apart and positioned outside the periphery of the outer rim edge 75 of the heatsink shell 70, supporting the outer rim edge 75 from lateral movement.

[0080] The supports can also or optionally include a plurality of heatsink supports 41 spaced-apart and positioned along the periphery of the outer rim edge 75 of the heatsink shell 70, supporting the undersurface of the outer rim edge 75.

[0081] The supports can also or optionally include one or more heatsink baffles 42 that are positioned within the periphery of the heat transfer plate 76. The heatsink baffles 42 provide axial positioning of the heatsink shell 70 above the floor 37, and also provide liquid flow baffling and flow restriction for liquid coolant flowing in a coolant liquid pathway 46 (shown in FIG. 6) within the coolant pool 38 between the heat transfer plate 76 and the floor 37.

[0082] In various embodiments, the coolant port 39 is formed within the floor 37 of the coolant body 31. In some embodiments, coolant port 39 is disposed at a periphery of the floor 37. In other embodiments, the coolant port 39 can be formed within the upper sidewall 33 of the coolant body 31.

[0083] In various embodiments, a cross-sectional flow path of the coolant liquid, along a flow pathway between the coolant port 39 and the second liquid ports 24, extends through the coolant liquid pathway 46 in an area beneath the heat transfer plate 76. The coolant liquid pathway 46 has a height dimension between the heat transfer plate 76 and the floor 37, and a lateral dimension across the width of the heat transfer plate 76.

[0084] The cross-sectional flow path of the coolant liquid has a bypass portion 30 that flows through the less-constricted spaces on both sides of the UV radiation assembly 60, boundaried by the bottom surface 16 of the reactor body 10 and the floor 37 of the coolantbody 31 , and extending between the peripheral edges of the UV radiation assembly 60 and the upper sidewall 33.

[0085] In various embodiments, the mass flow of coolant liquid along the coolant liquid pathway 46 (that is, flowing beneath the heat transfer plate 76) is less than the mass flow of coolant liquid flowing through the by-pass portion (that is, flowing outside the sides of the UV radiation assembly 60), resulting primarily from the narrow height dimension of the coolant liquid pathway 46 between the heat transfer plate 76 and the floor 37, and further from the positioning of the one or more heatsink baffles 42 beneath the heat transfer plate 76.

[0086] In various embodiments, a ratio of the diameter dl of the heat transfer plate 76 to a distance hl between the floor 37 and the heat transfer plate 76 is 15:1 to 35:1. In some embodiments, the ratio is 19:1 to 25:1.

[0087] In some embodiments, the coolant mass flow through the coolant liquid pathway 46 is less than 25%, and typically more than 10%, of the total coolant mass flow through the coolant pool 38. In some embodiments, the coolant mass flow through the coolant liquid pathway 46 is a minority of the total coolant mass flow (e.g., less than 50%).

[0088] In some embodiments, an electronics port 77 of the UV radiation assembly 60 is disposed between the floor 37 and the heat transfer plate 76, and is positioned in plan view between the coolant port 39 and center of the heat transfer plate 76.

[0089] In various embodiments, the coolant port 39 is in direct liquid communication with the second outer connection 4 of the irradiation apparatus 1.Liquid Flow Sensor

[0090] In various embodiments, the irradiation apparatus 1 includes a liquid flow sensor assembly 80 that can detect the flow of liquid flowing within a flow-sensor cavity, either to or from the coolant pool 38. When liquid flow is initiated by an outside means (for example, opening of a faucet in a water line upstream or downstream of the irradiation apparatus 1), the liquid flows through the flow-sensor cavity and past or through the liquid flow sensor, which generates a flowing signal. An electronic controller receives the flowing signal and in response thereto delivers electrical power to the LEDs to irradiate the liquid flowing through and within the irradiation reactor 18. When the liquid ceases to flow through the flow-sensor cavity,generation of a flowing signal ceases, and the electronic controller in response ceases delivery of electrical power to the LEDs, ceasing irradiation within the irradiation reactor 18.

[0091] Liquid flow through the flow sensor assembly 80 passes between the second outer connection 4 and the coolant port 39, which provides the liquid flow between the flow sensor 80 assembly and the coolant pool 38.

[0092] In various embodiments, the flow-sensor cavity is formed within a flowsensor chamber that includes several partitions that divide the space into an outer corridor, a sensor space, and an inner corridor. The outer corridor is in liquid communication with the second outer connection 4 on the lower cover body 2. The inner corridor is in liquid communication with the coolant port 39 of the coolant body 31. The sensor space is a cylindrical space partitioned by a cylindrical wall from, and in liquid communication between, the outer corridor and the inner corridor.

[0093] In a preferred embodiment, upper portion of the flow-sensor cavity is formed by the lower end of the coolant body 31, and a lower portion of the flow-sensor cavity is formed by the upper end of a lower cover body 2.

[0094] FIGS. 5 and 8 show the coolant body 31 further including a lower sidewall 44 with a lower rim 45 that forms an upper (first) portion 47a of a flow-sensor cavity 47, and a lower cover body 2 that forms a lower (second) portion 47b of the flow-sensor cavity 47.

[0095] The lower rim 45 of the lower sidewall 44 of the coolant body 31 is sealed annularly, preferably by welding, to an upper rim 57 of the sidewall 56 of the lower cover body 2. Alternatively, sealing can be provided by an O-ring retained in an annular groove or a gasket between surfaces.

[0096] The flow-sensor cavity 47 (47a, 47b) includes several partitions that divide the flow-sensor cavity 47 into an outer corridor 48, a sensor space 49, and an inner corridor 50, shown in FIG. 8. The outer corridor 48 is in liquid communication with the second outer connection 4 on the lower cover body 2. The inner corridor 50 is in liquid communication with the coolant port 39 of the coolant body 31. The sensor space 49 is a cylindrical space partitioned by a sensor wall 58 from, and in liquid communication between, the outer corridor 48 and the inner corridor 50.

[0097] In the illustrated embodiment, the upper portion 47a of the flow-sensor cavity 47 includes an upper peripheral wall formed by the lower sidewall 44 of the coolantbody 31 , an upper portion 58a of the sensor wall 58, and an upper portion 59a of a partition wall 59 that extends radially from the upper portion 58a of the sensor wall 58 to the lower sidewall 44 of the coolant body 31. and separates an upper portion 48a of the outer corridor 48 from an upper portion 50a of the inner corridor 50.

[0098] Correspondingly, a lower portion 47b of the flow-sensor cavity 47 is formed into the upper end of the lower cover body 2, and includes a lower peripheral wall formed by the upper sidewall 56 of the lower cover body 2, a lower portion 58b of the sensor wall 58, and a lower portion 59b of the partition wall 59 that extends from the lower portion 58b of the sensor wall 58 to the sidewall 56 of the lower cover body 2, and separates an lower portion 48b of the outer corridor 48 from an upper portion 50a of the inner corridor 50.

[0099] In various embodiments, a sealant material, such a grease or a thin gasketing material, is optionally placed between the bottom surfaces of the upper sensor wall 58a and an upper partition wall 59a of the upper portion 47a of the flow-sensor cavity 47, and the top surfaces of the lower sensor wall 58b and a lower partition wall 59b of the lower portion 47b of the flow-sensor cavity 47, to prevent leakage between the joined surfaces. In other embodiments, provided that the confronting bottom and top surfaces are smooth and in close contact when assembled, the minor leakage there between is inconsequential.

[0100] The sensor wall 58 further has a pair of flow portals, including an outer flow portal 51 that provides a passageway for liquid into (or out of) the sensor space 49 from the outer corridor 48, and an inner flow portal 52 that provides a passageway for liquid into (or out of) the sensor space 49 from the inner corridor 50. A lower portion 51b of the outer portal 51 and a lower portion 52b of the inner portal 52 are formed into the upper portion 58a of the sensor wall 58, and an upper portion 51a of the outer portal 51 and an upper portion 52a of the inner portal 52 are formed into the lower portion 58b of the sensor wall 58.

[0101] The flow sensor assembly 80 includes a paddlewheel 83 placed rotatable within the cylindrical sensor space 49. In some embodiments, a portion of the sensor wall 58 is formed unitarily with a portion of the inner sidewalls of the flow-sensor cavity 47. The outer flow portal 51 and the inner flow portal 52 are inlet and outlet openings formed into opposite sides of the sensor wall 58, and preferably along a chord path along a unitary wall portion (e.g., formed by the sensor wall 58 and the inner sidewalls of the flow sensor-cavity 47), and through the sensor space 49, such that the chord path traverses a periphery of the paddlewheel 83. Aflow of liquid between the outer and inner flow portals 51 , 52 causes the paddlewheel 83 to rotate in the direction along the chord path. Rotation of the paddlewheel 83 is detected by a rotation sensor, which then generates a flowing signal, described hereinafter.

[0102] The paddlewheel 83 has a multiple vanes 86 extending radially from a hub 85, the hub 85 having an axial bore through which fixedly extends a central shaft 84, so that the shaft 84 rotates with rotation of the paddlewheels 83. The paddlewheel 83 is placed rotatable within the sensor space 49, with a distal end of the shaft 84 extending through the axial bore and into a base 81 on the floor 37 in the center of the sensor space 49. The proximal end of the shaft 84 extends into a sensor housing 88 that converts rotation of the shaft 84 into an electronic flowing signal.

[0103] The upper and lower portions 47a ,47b of the flow-sensor cavity 47 can also include upper and lower portion 53a, 53b of an electronics port 53 that provides a liquid-sealed pathway for an electronic and control cable passing from the port 43 in the floor 37 of the coolant body 31, down through flow-sensor cavity 47 and out through electronics port 53 in the floor 54 of the lower cover body 2, to connect with an electronics conduit.Upper Cover Body

[0104] The irradiation apparatus 1 also includes an upper cover body 5 has an hemispherical interior cavity 8 that covers the upper outer surface 13 of the reactor body 10, a lower rim 7 that attaches to the upper rim of the coolant body 31 to secure the reactor body 10 to the coolant body 31, and provides liquid communication between the first liquid port 28 of the reactor body 10, extending through the upper outer surface 13 of the reactor body, and the first outer connection 3.

[0105] In a preferred embodiment, the upper cover body 5 is “keyed” in only one position rotationally along the device centerline 102 to the reactor body 10. This means that the coolant body 31 is configured to be engaged to the reactor body 10 in only one axially rotational position, whereby elements of the reactor body 10 only properly engage and align with corresponding elements of the upper cover body 5 in one rotational position. As illustrated in FIGS. 2 and 3, a pair of alignment slots 96 are formed into the outer surface of the sidewall 14 of the reactor body 10, oriented axially and peripherally, to engage with a corresponding pair of alignment tabs 97 fanned onto an inner surface of the sidewall 6 of the upper coverbody 5, which register with and are retained in the alignment slots 96 only when the liquid port 9 of the upper cover body 5 aligns with the first liquid port 28 of the reactor body 10.

[0106] In some embodiments, the reactor body 10 can be oriented rotationally in any position relative to the coolant body 31.

[0107] In some embodiments,, the lower cover body 2 is also “keyed” in only one position rotationally along the device centerline 101 to the coolant body 31. This means that the lower cover body 2 is configured to be engaged to the coolant body 31 in only one axially rotational position, whereby elements of the coolant body 31 only properly engage and align with corresponding elements of the lower cover body 2 in one rotational position.

[0108] In some embodiments, the lower cover body 2 is positioned with and fixed to the coolant body 31 in a selected rotational position during the spin welding of the two parts.

[0109] In various embodiments, the irradiation assembly 60 can include a monitoring / detection mechanism and control circuitry for dynamically controlling the delivery of UV radiation to the material to be irradiated based on flow rate, water quality, user input, or other operating conditions. Finally, associated performance data may be stored an onboard or external data storage unit.

[0110] In various embodiments, the UV-LED can be a UV radiation source package containing a single LED die or multiple LED dice arranged in a matrix or array. The LED dice can be selected to provide multiple wavelengths in both the UV and visible radiation spectrum from about 200 nm to about 800 nm. In one exemplary embodiment, the matrix or array includes LED dice emitting wavelengths in the range of about 200-320 nm to saturate the absorption mechanism of nucleocapsids (with peak emission centered at around 280 nm), and at the same time to target the peak absorption of nucleic acid with its peak emission wavelength spanning about 250-280 nm. In another exemplary embodiment, with the intention of mimicking the optical output spectrum of low or medium pressure Hg-based UV lamps used to target various bacteria and viruses, the matrix or array of LED dice utilizes multiple wavelengths, including at least one of about 240-260 nm, about 260-344 nm, about 350-380 nm, about 400-450 nm, or about 500-600 nm. A further exemplary embodiment is a matrix or array of LED dice emitting germicidal wavelengths ranging from about 250 nm to 300 run in conjunction with LED dice emitting wavelengths in the range of about 350 nm to 400 nm to enable photocatalytic oxidation of pathogens or pollutants in water in proximity of crystallinefilms of n-type semiconductors, such as titanium dioxide (TiCL), nickel oxide (NiO), or stannic oxide (S11O2). A still further exemplary embodiment is a modular mounting configuration containing multiple LED dice emitting about 250-320 nm and about 320-400 nm wavelengths arranged in a matrix or array to enable the fluorescence spectra of NADH, and tryptophan, of particles with biological origin. In another exemplary embodiment, a commercially available SETi UV Clean™ LED package is used. Individual LED dice or a single die bonded to a thermally conductive metal core circuit board (MCPCB), such as those available from The Bergquist Company™, may also be used.

[0111] In various embodiments, the LED package may be electrically connected to control and power circuitry, which is included as part of the replaceable module. Circuitry is included within an electronics module to provide telemetric data and track information, such as operating temperature and run time.

[0112] The irradiation assembly 60 and flow sensor assembly 80 are each powered by a separate control board, outside the irradiation apparatus, connected by the wiring 90. One function of the outside control board is to deliver and control electrical power to the UV-LEDs, including the amount of ultraviolet light induced into the irradiation reactor, which in turn produces an amount of heat generated by the UV-LEDs.

[0113] In various embodiments, the modulation of UV-LED power can be accomplished by Pulse Width Modulation (PWM) of the current supplied to the UV-LEDs, whereby the supplied current to the UV-LEDs nominally decreases to zero periodically, or by reduction of the UV-LED, whereby the supplied current to the UV-LEDs is continuous but at a reduced value.

[0114] The amount of power applied to the UV-LEDs can be modulated according to one or more following target signals: a flow rate of the liquid as measured by the flow sensor assembly 80; a temperature detected of the UV-LEDs lamp; a temperature detected of the PCB 72; a signal generated by a UV irradiation sensor; a separately-provided signal that indicates information about the water quality, including but not limited to a ultraviolet transmittance, salinity, conductivity, turbidity, temperature, and acidity; a determined lamp operating duration, such as in hours, whereby the current could increase as the lamp ages to maintain a constant irradiation output; and commands from an outside and independent source, for example, an application of voltage or current to a designated port of the control board and / ortransmission of a digitally encoded signal to the control board. In various embodiments, the control system can provide feedback about the system operation and status to a user or other system via one or more of the following methods: one or more visible indicators that use constant color / brightness or time-changing patterns of color / brightness that can be interpreted by a user; a typical industrial analog signals such as 4-20mA, 0-1 OV or dry-contact signals; and a serialized digital communication.

[0115] The feedback from the control board can contain the following information about one or more of the following conditions: a flow rate of the liquid as measured by the flow sensor assembly; a temperature of the UV-LEDs, irradiation assembly 60, and / or the PCB 72; an UV radiation output from the system as measured by a UV-radiation sensor, either as a raw value or a processed value (a processed UV signal could take into account modulation of the LED power, predicted changes in UV-sensor sensitivity, and water quality); information about the quality of the water or liquid; the cumulative UV-LEDs or irradiation assembly 60 operating hours; a measurement of various onboard sensors or sub-circuits indicating performance of various sub- circuits on the control board; digested system status information that reduces multiple sources of sensors or measurements into simpler Boolean representations; and production information about the device such as a serial number.

[0116] Components for the electrical and / or electronic control of the UV radiation source may optionally be included within a sealed electronics housing assembly, such that they may act upon the UV radiation source while maintaining protection from the external environment through such hermiticity, the use of desiccants, or a combination thereof. Further, the co-location of these components onto the MCPCB, or otherwise, and subsequent thermal union to the heat exchange mechanism may be used to extract heat generated by, for example, power conversion components. Additionally, these electrical and / or electronic components may include sensors by which the operating conditions and status of the UV radiation source may be determined, including but not limited to a photodiode, thermocouple, thermistor, acoustic sensor, hall probe, current probe, etc.

Claims

WHAT IS CLAIMED IS:

1. An irradiation apparatus comprising: an interior irradiation reactor having a first end and an opposite second end, an irradiation opening into the reactor in the second end, one or more first liquid ports in the first end for egress from or entry into the irradiation reactor, one or more second liquid ports in the second end for entry into or egress from the irradiation reactor; an UV irradiation device including one or more UV irradiation sources for emitting UV radiation through the irradiation opening and into the irradiation reactor; a heatsink surface in heat transfer communication with a bottom surface of the one or more UV irradiation sources, and a coolant reservoir in liquid communication with the one or more second liquid ports, and having a coolant port for entry into or egress from the coolant reservoir, wherein the heatsink surface is disposed within the coolant reservoir and in liquid contact with a portion of a cooling liquid flowing between the coolant port and the one or more second liquid ports.

2. The irradiation apparatus according to Claim 1, wherein less than 50% of the cooling liquid flowing between the coolant port and the one or more second liquid ports passes in thermal transfer with the heatsink surface through a coolant liquid pathway.

3. An irradiation apparatus comprising: an irradiation body having an interior irradiation reactor with an interior surface, a first end of the irradiation body having an irradiation opening into a first end of the irradiation body, and a peripheral edge surrounding the irradiation opening and having one or more channels formed through the peripheral edge into the first end of the irradiation body, and a second end of the irradiation body having a second liquid port for entry into or egress from a second end of the irradiation body, a UV-light transparent window having a periphery in contact with the first edge of the irradiation body that forms the one or more channels into one or more first liquid ports into the first end of the irradiation reactor,a UV irradiation device including one or more UV irradiation sources for emitting UV radiation through the UV-light transparent window and the irradiation opening, and into the irradiation body, and a heatsink surface in heat transfer communication with a bottom surface of the one or more UV irradiation sources, and a coolant body including a first end having a cooling reservoir and sealed to the first end of the irradiation body to form a coolant chamber, the coolant chamber being in liquid communication with the one or more first ports into the irradiation reactor, and having a coolant port for entry into or egress from the coolant chamber, wherein the heatsink surface is disposed within the coolant chamber and in liquid communication between the one or more first ports and the coolant port.

4. The irradiation apparatus according to Claim 3, a minority portion of a liquid flowing between the coolant port and the one or more first ports engages in thermal transfer with the heatsink surface through a coolant liquid pathway.

5. The irradiation apparatus according to Claim 4, wherein the coolant liquid pathway is at least 10% and up to 25% of a total liquid flowing into the coolant liquid pathway.

6. The irradiation apparatus according to Claim 4, wherein a bypass portion of the liquid flows radially outside the heatsink surface and the UV irradiation device.

7. The irradiation apparatus according to any of Claims 3-6, wherein the coolant body includes a coolant chamber floor, and a ratio of a diameter of the heatsink surface to a distance between the coolant chamber floor and the heatsink surface is 15:1 to 35:1.

8. The irradiation apparatus according to any of Claim 7, wherein the coolant port is disposed at a periphery of the coolant chamber, and further includes a barrier disposed in the coolant chamber between the coolant port and a centerline of the interior irradiation reactor, to prevent direct liquid flow between the coolant port and the heatsink surface.

9. The irradiation apparatus according to Claim 8, wherein the barrier comprises an electronics port extending through the coolant chamber floor of the coolant body and into the UV irradiation device.

10. The irradiation apparatus according to any one of Claims 3-9, wherein the one or more channels comprises one or more tangential channels, and the one or more first ports comprises one or more tangential first liquid ports.

11. The irradiation apparatus according to Claim 10, wherein the one or more tangential channels are spaced apart uniformly along the peripheral edge at the first end of the irradiation body.

12. The irradiation apparatus according to any one of Claims 3-11, wherein a centerline along the one or more channels extend along a chord of a cross-section of the interior irradiation reactor in the second end of the irradiation body.

13. The irradiation apparatus according to any one of Claims 3-12, wherein the heatsink surface is a stainless steel material.

14. The irradiation apparatus according to any one of Claims 3-13, further including a liquid flow sensor for detecting a flow of liquid through the liquid transfer port.

15. The irradiation apparatus according to Claim 14, wherein the coolant body includes a second end including the liquid flow sensor in liquid communication between the liquid transfer port and an outer liquid port, for entry into or egress from the liquid flow sensor.

16. The irradiation apparatus according to Claim 15, wherein the liquid flow sensor generates a flowing signal to a controller to deliver power to the one or more UV irradiation sources, when liquid flows between the liquid transfer port and the outer liquid port.

17. The irradiation apparatus according to any one of Claims 3-16, wherein the irradiation reactor has a spherical or capsule shape.

18. An irradiation apparatus comprising: a chamber body including an upper end, a lower end, and a peripheral sidewall, and having an irradiation reactor formed into the lower end that includes a lower inner surface with a peripheral edge having two or more tangential channels, and an upper inner surface having a first liquid port extending through the upper end, a UV-light transparent window having a periphery in sealed contact with the peripheral edge of the chamber body that forms two or more first tangential ports with the two or more tangential channels, a UV irradiation device including one or more UV radiation sources for emitting UV radiation through the UV-light transparent window and into the irradiation reactor, and a heatsink surface on a bottom surface of the one or more UV irradiation sources, and a coolant body including a coolant chamber floor having a liquid transfer port and an upper peripheral sidewall extending axially from an upper side of the coolant chamber floor, the upper peripheral sidewall being sealed against the peripheral sidewall of the chamber body that forms a coolant chamber in liquid communication with the two or more first tangential ports and the liquid transfer port, and placing the heatsink surface in liquid contact with the coolant chamber.

19. The irradiation apparatus according to Claim 18, wherein the coolant body further includes a lower peripheral sidewall extending from a bottom surface of the coolant chamber floor, a liquid flow sensor, and a base cover sealed to the lower peripheral sidewall to form a flow detection chamber, the base cover including a second liquid port, wherein the liquid flow sensor is disposed in a liquid flow path between the second liquid port and the liquid transfer port.

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