Photoreactor Lighting with Conformal Cooling and Segmented LEDs
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Solution Overview
Problem
Current photoreactors face challenges with complex designs, limited control over energy input, and inefficient light utilization, particularly in terms of sealing, power supply, and cooling, which complicates targeted reaction control and light absorption in photoreactions.
Innovation Solution
A photoreactor design featuring a tubular housing with conformal cooling passages for efficient heat management and lightweight construction, utilizing individual LEDs mounted on the inner surface with flexible light distribution and control, and a reaction chamber with tubular flow channels made of transmissive materials to optimize light absorption and reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If medium-pressure mercury lamps are used to generate high light density, then illumination intensity is improved, but luminous efficacy deteriorates (5% to 20% electrical power consumption)
Solution Approach 1:
The patent segments the single high-power mercury lamp into multiple individual LED light sources distributed around the reaction chamber. Each LED operates independently at lower power consumption while collectively providing sufficient illumination intensity for photoreactions, thereby improving overall luminous efficacy.
Solution Approach 2:
The patent changes the light source parameter from mercury lamp to LED, which fundamentally alters the luminous efficacy parameter. LEDs inherently convert electrical energy to light more efficiently than mercury lamps, achieving 10% to 60% luminous efficacy while maintaining the required illumination intensity for photoreactions.
2Illumination intensity
If medium-pressure mercury lamps are used, then illumination intensity is improved, but service life deteriorates (around one year)
Solution Approach 1:
By using multiple individual LED modules instead of a single mercury lamp, the system distributes the operational stress across multiple units. LEDs inherently have longer operational lifespans than mercury lamps, and the modular design allows individual modules to be replaced without replacing the entire lighting system, effectively extending the overall service life.
3Illumination intensity
If mercury lamps are used, then light generation is improved, but harmful factors deteriorate (toxic heavy metal mercury requiring recovery)
Solution Approach 1:
The patent replaces the mercury-containing lamp with LED modules that do not contain toxic heavy metals. While LEDs have finite lifespans, they can be replaced without environmental contamination concerns, eliminating the need for mercury recovery processes and eliminating toxic harmful factors entirely.
4Productivity
If complex photoreactor designs are used to improve light utilization, then reaction efficiency is improved, but device complexity deteriorates (sealing, power supply, cooling)
Solution Approach 1:
The LED modules are designed to perform multiple functions simultaneously: they provide illumination for photoreactions, serve as self-contained heat generation points for localized cooling, and include integrated mounting structures for secure positioning. The reaction chamber structure serves both as a containment vessel and as a light-transmissive window, eliminating the need for separate complex sealing and lighting systems.
Solution Approach 2:
The LED modules are designed to be self-contained units that require minimal external infrastructure. Each module includes its own mounting structure and can be independently positioned and secured, eliminating the need for complex power supply routing and sealing systems that would be required for traditional lamp-based systems.
5Ease of manufacture
If conventional photoreactor designs are used, then construction is simplified, but targeted reaction control deteriorates (limited energy input control)
Solution Approach 1:
The lighting system is segmented into multiple independently controllable LED modules distributed around the reaction chamber. This allows selective activation and independent intensity control of individual modules, enabling precise spatial and temporal control over energy input to the reaction medium while maintaining relatively simple construction through modular assembly.
Solution Approach 2:
The system incorporates dynamic control capabilities where individual LED modules can be activated or deactivated independently based on reaction requirements. The intensity of each module can be dynamically adjusted to match the specific photoreaction needs, providing versatile reaction control while maintaining ease of manufacture through standardized modular components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables full reaction control, efficient cooling, and flexible energy input, enhancing the photoreactor's performance by improving light absorption and maintaining a stable temperature profile, thus increasing the efficacy of photoreactions.
Implementation Method 1
the housing comprises flow channels for a heat transfer fluid, the flow channels being arranged at the back side of the inner surface of the housing behind the individual light sources forming a conformal cooling passage for the individual light sources
Implementation Method 2
the channel wall being made of a material transmissive to the light emitted by the light sources
Implementation Method 3
Photoreactors are reactors that permit conducting photoreactions, e.g. photocatalytic reactions or photo-initiated reactions
Data Source
AI summary
The invention relates to a lighting device for a photoreactor comprising a tubular housing (40) having a longitudinal axis (41) and a plurality of individual light sources (30) mounted on the inner surface of the housing (40), wherein the housing (40) comprises flow channels (46) for a heat transfer fluid, the flow channels (46) being arranged at the back side of the inner surface of the housing (40) behind the individual light sources forming a conformal cooling passage for the individual light sources. The invention further relates to a photoreactor comprising a lighting device and a reaction chamber with at least one tubular flow channel, the reaction chamber being arranged inside the lighting device and the channel wall being made of a material transmissive to the light emitted by the light sources.