UV Lamp Braid Attachment for Heat-Stable Electrical Contact
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Solution Overview
Problem
Existing UV light sanitizing systems face challenges such as prolonged microbial killing times, microbial resistance to UVC light, human safety risks due to direct UV exposure, and unreliable electrical connections to UV lamps due to heat-generated issues.
Innovation Solution
A system and method for maintaining a reliable electrical connection between a UV lamp and an electrical coupling, involving a braid attachment with a compressive wrap, such as fiberglass, and a conductive layer secured with a clamp or tape, designed to withstand high temperatures and ensure consistent electrical contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a low temperature solder joint is used to attach an electrical braid to the UV lamp, then the manufacturing process is simplified, but the electrical connection reliability deteriorates at high operating temperatures
Solution Approach 1:
The patent changes the attachment method from low-temperature soldering to high-temperature capable alternatives such as brazing, welding, or mechanical clamps. This parameter change in the joining process enables the electrical connection to withstand the high operating temperatures of UV lamps without failing, thereby improving reliability while maintaining ease of manufacture through standardized high-temperature joining processes.
Solution Approach 2:
The patent employs composite construction for the electrical braid attachment, using materials such as copper braids with heat-resistant coatings or combinations of metal clamps with insulating materials. This composite approach allows the electrical connection to simultaneously handle high electrical conductivity and high-temperature resistance, resolving the contradiction between ease of manufacture and reliability at operating temperatures.
2Reliability
If tape is disposed over the braid attachment to secure it, then the electrical connection is initially stable, but the connection reliability deteriorates when the tape is removed due to grid line detachment
Solution Approach 1:
The patent segments the electrical connection system into distinct functional components: a permanent high-temperature attachment method (brazing, welding, or clamping) for the electrical braid to the lamp, and a separate removable insulation or protection layer. This segmentation allows the electrical connection to maintain reliability through the permanent attachment while enabling easy repair by simply removing the protective layer without damaging the grid lines or connection points.
Solution Approach 2:
The patent applies beforehand cushioning by using a protective coating or heat-resistant insulation that is applied during manufacturing but does not interfere with the electrical connection integrity. This protective layer cushions the connection during operation but can be removed without causing damage, preventing the grid line detachment problem that occurs with tape removal while maintaining ease of repair.
3Reliability
If the UV lamp operates at high temperatures to maintain electrical connection, then the electrical connection stability is improved, but harmful factors increase due to heat generation
Solution Approach 1:
The patent introduces an intermediary thermal management system between the UV lamp and the electrical connection components. This intermediary system includes heat sinks, thermal barriers, or heat-dissipating clamps that conduct heat away from the electrical connection points while allowing the lamp to operate at its required temperature. This mediator enables electrical connection stability without transferring excessive heat to surrounding components, thereby reducing harmful thermal effects.
Solution Approach 2:
The patent extracts the heat generation function from the electrical connection system by separating the lamp's operational temperature requirements from the connection stability requirements. The lamp operates at high temperature for UV generation, while the electrical connection system uses heat-resistant materials or active cooling to maintain stability without being subjected to the full thermal load, thereby reducing harmful heat generation in the connection areas.
Data Source
AI summary
A system for connecting an ultraviolet (UV) lamp with an electrical coupling includes a braid attachment coupled to the UV lamp, and one or both of a compressive wrap secured around at least a portion of the braid attachment, or a clamp secured around at least a portion of the braid attachment.