WO2025032419A1

WO2025032419A1 - Uv fluid treatment system with laterally removable led light source assembly

Info

Publication number: WO2025032419A1
Application number: PCT/IB2024/057364
Authority: WO
Inventors: Ana-Maria Bogatan; John VAREKA
Original assignee: Trojan Technologies Group ULC
Current assignee: Trojan Technologies Group ULC
Priority date: 2023-08-09
Filing date: 2024-07-30
Publication date: 2025-02-13
Anticipated expiration: 2026-02-09

Abstract

A fluid treatment system for treating a fluid with ultraviolet (UV) radiation. The system includes a reactor vessel including a treatment chamber that includes an inlet where the fluid enters the treatment chamber and an outlet where the fluid exits the treatment chamber. Fluid flows within the treatment chamber from the inlet to the outlet generally along a longitudinal axis of the treatment chamber. The system further includes at least one light source assembly that is removably coupled to the reactor vessel so that the light source assembly can be inserted into the treatment chamber in a direction transverse to the longitudinal axis. The at least one light source assembly includes a light source unit including an array of light-emitting diodes (LEDs) for emitting UV radiation into the treatment chamber to treat the fluid.

Description

UV FLUID TREATMENT SYSTEM WITH LATERALLY REMOVABLE LED LIGHT SOURCE ASSEMBLY

CROSS-REFERENCE TO RELATED APPLICATIONS

[0000] This application claims the benefit of U.S. Provisional Application No. 63/531,647, filed August 9, 2023.

BACKGROUND

[0001] Disinfection of water is critical to ensure water quality. Water sources can be contaminated with pathogens, such as bacteria, viruses, fungi, algae, molds, and yeasts, making the water unsafe for consumption by humans and animals. One way of disinfecting water is by ultraviolet (UV) radiation treatment, in which water is irradiated with UV light. UV radiation damages the DNA, RNA, and protein in pathogens, and inactivates them, making the water safe for use and consumption. UV radiation treatment can be used in residential, municipal, commercial, and industrial water systems. Conventional UV radiation treatment systems vary depending on the application. For example, large industrial and commercial systems, such as a municipal water treatment facility, may include a large reactor including multiple UV lamps, such as mercury lamps, for effectively disinfecting a large volume of water. However, in a mercury lamp-based system, there is a risk that the water being treated could be contaminated with mercury if the lamp is broken, for example, during removal of the UV lamps for maintenance and cleaning.

[0002] Residential systems, on the other hand, may be designed for a smaller volume of water used in a home and may use UV light-emitting diodes (LEDs), which do not include hazardous materials, making them safer for use than mercury lamps. UV LEDs also have a longer operating lifetime and lower voltage and power requirements than mercury lamps. However, UV LEDs are lower power, and thus, multiple LEDs may be necessary for sufficient disinfection even in residential systems. In known systems, a UV LED assembly is arranged inside a chamber of a reactor vessel along a primary axis of the reactor vessel and includes an array of UV LEDs provided along the primary axis of the chamber so that the fluid can be irradiated with UV light as it passes through the chamber.

[0003] Residential systems may be arranged in-line in existing household piping, for example, at a point of entry of water into the household piping. However, there may be limited space around the existing household piping, and the reactor vessel is often arranged in tight spaces. This can make it difficult to remove the UV LED assembly for cleaning to remove fouling materials and other maintenance without disturbing the piping connection. Additionally, in use, the UV LED assembly and related electrical components can generate considerable heat, especially on the back side of the UV LED array, and it can be difficult to effectively cool the UV LED assemblies. Excessive heating of the LEDs may decrease radiation output and decrease the useful lifetime of the LEDs.

SUMMARY

[0004] The present disclosure provides a fluid treatment system for treating a fluid with UV radiation that can overcome the above drawbacks. For example, the fluid treatment system disclosed herein may include a light source assembly that can be easily removed for cleaning and other servicing, even in tight spaces, without disturbing the piping connection. The light source assembly in the present fluid treatment system may also be effectively cooled to avoid overheating.

[0005] The fluid treatment system includes a reactor vessel including a treatment chamber that includes an inlet where the fluid enters the treatment chamber and an outlet where the fluid exits the treatment chamber. Fluid flows within the treatment chamber from the inlet to the outlet generally along a longitudinal axis of the treatment chamber. The system further includes at least one light source assembly that is removably coupled to the reactor vessel so that the light source assembly can be inserted into the treatment chamber in a direction transverse to the longitudinal axis. The at least one light source assembly includes a light source unit including an array of LEDs for emitting UV radiation into the treatment chamber to treat the fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 shows a perspective view of a fluid treatment system.

[0007] FIG. 2 is a cross-sectional view of the fluid treatment system taken along line A-A in FIG. 1.

[0008] FIGS. 3 A and 3B are partial cross-sectional views of a light source assembly detached from the reactor vessel and attached to the reactor vessel, respectively.

[0009] FIG. 4 shows a perspective view of a reactor vessel.

[0010] FIGS. 5A and 5B are perspective views illustrating a light source assembly.

[0011] FIG. 6 is a perspective view illustrating a light source unit.

[0012] FIG. 7 is an exploded perspective view illustrating the light source unit.

[0013] FIG. 8 is a perspective view illustrating a fluid treatment system.

DETAILED DESCRIPTION OF EMBODIMENTS

[0014] In the following description, numerous details are set forth to provide an understanding of the present disclosure. However, it may be understood by those skilled in the art that the systems and methods of the present disclosure may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

[0015] Embodiments of the present disclosure provide a fluid treatment system including at least one light source assembly including an array of UV LEDs for irradiating a fluid flowing through a treatment chamber of a reactor vessel with UV radiation for disinfection, purification, sterilization, or the like. The light source assembly is removably inserted into the treatment chamber of the reactor vessel in a direction transverse to the longitudinal axis of the treatment chamber. The light source assembly may be inserted into the treatment chamber through a lateral opening formed in an outer wall of the reactor vessel. For example, the light source assembly may be inserted into the treatment chamber in a direction transverse or orthogonal to the longitudinal axis of the treatment chamber, such as in a radial direction of the reactor vessel. By this arrangement, the light source assembly can be laterally removed from the treatment chamber in a direction transverse to the longitudinal axis for servicing, cleaning, and the like. Therefore, even in tight spaces, the light source assembly can be easily removed from and inserted into the treatment chamber without disturbing the piping connection.

[0016] The light source unit is arranged in the treatment chamber so as to be immersed in the fluid being treated. The light source unit can therefore be continuously cooled by the fluid flowing through the chamber, which impinges on and flows around the light source unit. By this arrangement, the fluid being treated will contact not only the front of the light source unit, through which the UV radiation is emitted, but also the back of the light source unit, where considerable heat is often generated. Thus, the back of the light source unit can be cooled by the fluid being treated and prevent the UV LEDs from overheating.

[0017] FIG. 1 shows a perspective top view of an exemplary fluid treatment system 100, and FIG. 2 is a cross-sectional view of the fluid treatment system taken along line A-A in FIG. 1. As shown in FIGS. 1 and 2, the treatment system 100 includes a reactor vessel 102 including a treatment chamber 110 for receiving a flow of fluid for UV radiation treatment. The treatment chamber 110 extends along a longitudinal axis L and includes an inlet 106 through which fluid is introduced into the treatment chamber 110 and an outlet 108 through which the fluid is discharged from the treatment chamber 110 after being treated. The longitudinal axis L may substantially coincide with a longitudinal axis of the reactor vessel 102. The inlet 106 and the outlet 108 are in fluid communication with the treatment chamber 110, and the fluid may flow within the treatment chamber 110 from the inlet 106 to the outlet 108 generally along the longitudinal axis L of the treatment chamber. For example, the inlet 106 and the outlet 108 may be arranged on opposite sides of the treatment chamber 110 along the longitudinal axis L. The treatment chamber 110 may be separate from the reactor vessel 102 that contains the fluid flow. For example, the treatment chamber 110 could be located within an outer reactor vessel 102, with its own inlet and outlet connections, that directs flow to the inlet and outlet of the treatment chamber 110.

[0018] In one embodiment, the fluid treatment system 100 may be a residential system for disinfecting water for household use. The system 100 may be installed between a water source, such as a well or municipal water facility, and the household piping. For example, the system 100 may installed at a point of entry of the water into the household piping. The system 100 can be integrated into existing piping for treating the fluid flowing through the piping. For example, the inlet 106 and the outlet 108 may be coupled to the piping for providing in-line flow and a simple connection to the piping without using an L- shape or elbow pipe connector. The system 100 may be installed so as to be integrated with the household piping in the basement of a home at a position where the water flowing from external piping in fluid communication with a well or water treatment facility enters the home. The inlet 106 may receive water flowing from the water source, the treatment chamber may treat the water with UV radiation, making the water safe for use, and the outlet 108 may deliver the treated water to downstream household piping for household use. For residential systems, the treatment chamber 110 can have a volume that is in a range of about 0.25 L to 10 L, from 0.5 L to 5 L, or from 1 L to 3 L, for example. By way of example, when used in a residential system, the reactor 102 may be designed for a flow of fluid, such as water or other aqueous fluids (e.g., fluids including at least 75% or at least 90% water), through the treatment chamber 110 at a flow rate in a range of 1 to 25 gallons per minute (gpm), 5 to 20 gpm, or 10 to 15 gpm. Of course, at times, the fluid in the reactor 102 may be substantially stagnant, in which case the flow rate may be less than 1 gpm, less than 0.5 gpm, or less than 0.25 gpm. The fluid treatment system 100, however, is not limited to use in a residential system, and may be used in other systems, such as industrial or municipal systems. In that case, the volume of the treatment chamber 100 and/or the flow rate of fluid through the treatment chamber 110 may be higher.

[0019] The treatment system 100 further includes first and second light source assemblies 120a, 120b that are removably coupled to the reactor vessel 102. The first and second light source assemblies 120a, 120b respectively include first and second light source units 122a, 122b that are arranged inside the treatment chamber 110 to treat the fluid flowing through the chamber 110 with UV radiation for disinfection, purification, sterilization, or the like. The first and second light source units 122a, 122b each include an array of UV LEDs 124a, 124b that are configured to emit UV radiation inside the treatment chamber 110 of the reactor vessel 102. The UV LEDs 124a, 124b may emit light in the UV spectrum, for example, in a wavelength band of about 100 nm to about 405 nm, a wavelength band of about 140 to about 330 nm, or a wavelength band of about 200 nm to about 320 nm. The UV light in the above wavelength bands has high germicidal efficacy and may kill at least 99% of microorganisms, such as bacteria, parasites, fungi, viruses, mold, and the like, in the fluid, making the fluid safe for use and consumption. The LEDs 124a, 124b may have an efficiency in converting electrical energy to UV light energy in a range of about 3% to about 30%, a range of about 4% to about 15%, or a range of about 5% to about 10%. The reactor may be designed to deliver a UV dose of 5 mJ/cm² to 100 mJ/cm², or about 30mJ7cm², to the fluid at the target flow rate and target water quality, or may be designed to deliver any other suitable UV dose to the fluid.

[0020] As shown in FIG. 2, the first and second light source units 122a, 122b may respectively include a first housing 130a and a second housing 130b in which the first and second arrays of LEDs 124a, 124b are respectively arranged. The first and second housings 130a, 130b may further respectively include first and second UV transparent windows 132a, 132b that are arranged to cover the first and second arrays of LEDs 124a, 124b, respectively. The UV transparent windows 132a, 132b may be sealed in the housing 130a, 130b via O-ring 134a, 134b. Details regarding the first and second light source units 122a, 122b will be discussed further with respect to FIGs. 5A-7.

[0021] In FIGS. 1 and 2, the "y" direction is parallel to the longitudinal axis L of the treatment chamber 110 and the direction of fluid flow through the treatment chamber 110 between the inlet 106 and the outlet 108. The "x" and "z" directions are radial directions of the reactor vessel 102, where the "z" direction is parallel to an insertion/removal direction of the light source units 122a, 122b into the treatment chamber 110 of the reactor vessel 102.

[0022] The first and second light source assemblies 120a, 120b further include first and second caps 138a, 138b that are arranged outside of the reactor vessel 102 and removably coupled to first and second lateral ports 112a, 112b formed in the outer wall 104 of the reactor vessel 102 to support the light source units 122a, 122b suspended inside the treatment chamber 110. [0023] As shown in FIG. 2, the first and second light source assemblies 120a, 120b are removably coupled to the reactor vessel 102 via the caps 138a, 138b such that the first and second light source units 122a, 122b are arranged inside the treatment chamber 110 and are oriented for directing UV radiation into the fluid flowing through the treatment chamber 110. In the example shown in FIG. 2, the light source units 122a, 122b are concentric with the chamber 110 and are orthogonal to both the longitudinal axis L of the treatment chamber 110 and the direction of fluid flow (along the Y direction) through the treatment chamber 110 between the inlet 106 and the outlet 108. However, the present disclosure is not limited to this, and the light source units 122a, 122b can be arranged in any suitable orientation for sufficiently treating the fluid flowing through the treatment chamber 110 with UV radiation. The light source units 122a, 122b may be oriented so that a plane of the UV transparent windows 132a, 132b and/or a plane of the backside (z.e., non-emitting side) of the housing 130a, 130b is transverse or orthogonal to the longitudinal axis of the reactor 102 and/or is transverse or orthogonal to a direction of fluid flow through the treatment chamber 110. For example, the plane of the windows 132a, 132b and/or the plane backside of the light source units 122a, 122b may be oriented at any suitable angle transverse to the longitudinal axis L of the treatment chamber 110, such as an angle in a range of 20° to 160°, a range of 30° to 150°, or a range of 45° to 135°. The plane of the windows 132a, 132b and/or the plane backside of the light source unit 122a, 122b may additionally or alternatively be transverse or orthogonal to the direction of fluid flow through the treatment chamber 110 so as to be oriented at an angle with respect to the direction of fluid flow in a range of 20° to 160°, a range of 30° to 150°, or a range of 45° to 135°.

[0024] Similarly, the first and second arrays of LEDs 124a, 124b may be arranged in a plane that is transverse or orthogonal to the longitudinal axis L of the reactor 102 and/or is transverse or orthogonal to a direction of the fluid flow through the treatment chamber 110. The plane of the first and second arrays of LEDs 124a, 124b may be oriented at any suitable angle transverse to the longitudinal axis L of the treatment chamber 110, such as an angle in a range of 20° to 160°, a range of 30° to 150°, or a range of 45° to 135°. The LED arrays 124a, 124b may additionally or alternatively be transverse or orthogonal to the direction of fluid flow through the treatment chamber 110 so as to be oriented at an angle with respect to the direction of fluid flow in a range of 20° to 160°, a range of 30° to 150°, or a range of 45° to 135°.

[0025] The first and second light source assemblies 120a, 120b can be arranged so that the first and second arrays of LEDs 124a, 124b face each other inside the treatment chamber 110. For example, in this context, "face" may mean the first and second light source units 122a, 122b are arranged so that the beams of UV radiation from the first and second arrays of LEDs 124a, 124b at least partially overlap each other. For instance, the lightemitting sides of the light source units 122a, 122b (z.e., the sides through which UV light passes, e.g., on the sides of the UV transparent windows 132a, 132b) may be directly opposed to each other at a normal angle, offset with respect to each other along the longitudinal axis L or other direction, or angled with respect to each other, as discussed in more detail below.

[0026] In the embodiment shown in FIG. 2, the first and second light source assemblies 120a, 120b are arranged so that the main directions of the radiation beams emitted by the first and second arrays of LEDs 124a, 124b are along arrows R_a and Rb towards each other. In particular, the first light source assembly 120a is arranged so that the first array of LEDs 124a emits UV radiation generally in the direction R_a toward the second light source unit 122b, whereas a back side of the first light source unit 122a faces the outlet 108, and the second light source assembly 120b is arranged so that the second array of LEDs 124b of the second light source unit 122b emits UV radiation generally in the direction Rb toward the first light source unit 122a, whereas a backside of the second light source unit 122b faces the inlet 106. In FIG. 2, the UV LED arrays 124a, 124b are each arranged in a plane orthogonal to the longitudinal axis L and the LED arrays 124a, 124b are directly opposed to each other along the longitudinal axis L so that the main directions R_a and Rb of the beams of radiation are generally parallel to and/or coincident with the longitudinal axis L. However, the present disclosure is not limited to this arrangement, and the first and second light source assemblies 120a, 120b may be arranged in any suitable manner, for example, where the beams of radiation from the first and second arrays of LEDs 124a, 124b at least partially overlap each other.

[0027] For example, in another embodiment, the light-emitting sides of the light source units 122a, 122b may face each other (e.g., be directly opposed) along a direction transverse to the longitudinal axis L, such as a direction at an angle in a range of 20 to 160°, a range of 30° to 150°, or a range of 45° to 135° from the longitudinal axis L. In this case, a direction extending between the light-emitting sides of the first and second light source units 122a, 122b and normal to the planes of the first and second LED arrays 124a, 124b is transverse to the longitudinal axis L, such as at an angle in one of the above ranges.

[0028] Alternatively or additionally, the first and second light source assemblies 120a, 120b may be arranged so that the light source units 122a, 122b are offset from each other. For example, one or both of the light source units 122a, 122b may be offset from the longitudinal axis or each other in a radial or width direction of the reactor 102 (e.g., in a direction transverse to the longitudinal axis L) so that the beams of UV radiation emitted from the light source units 122a, 122b only partially overlap. In such an arrangement, a center of the first LED array 124a may not be aligned with a center of the second LED array 124a, and the center of one or both of the LED arrays 124a, 124b may be offset from the longitudinal axis and/or offset from each other.

[0029] In the above embodiments, the first and second light source assemblies 120a, 120b may be arranged so that the planes of the first and second LED arrays 124a, 124b are generally parallel to each other. However, the present disclosure is not limited to this arrangement, and the first and second light source assemblies 120a, 120b may be arranged so that the planes of the LED arrays 124a, 124b are angled with respect to each other. For example, the planes of the LED arrays 124a, 124b may be angled with respect to each other, for example, at an angle in a range of 5 to 175°, a range of 20° to 150°, or a range of 45° to 135°, or any other suitable angle.

[0030] By arranging the first and second light source assemblies 120a, 120b so that the first and second arrays of LEDs 124a, 124b face each other (e.g., such that the beams of UV radiation at least partially overlap each other), the time that the fluid is exposed to the UV radiation can be extended. This can ensure that the fluid flowing through the treatment chamber is sufficiently irradiated with UV radiation for disinfecting the fluid to make it safe for use and consumption. For example, by arranging the first and second light source assemblies 120a, 120b so that the first and second arrays of LEDs 124a, 124b face each other, and emit UV radiation in the main directions R_a, Rb towards each other generally along the longitudinal axis L of the treatment chamber 110 and/or the direction of fluid flow, the fluid flowing through the chamber 110 can be irradiated with UV light along substantially the entire length of the chamber 110 or along substantially most of or a majority of the length of the chamber 110.

[0031] Alternatively, the light source assemblies 120 may be arranged to as to not face each other. For example, one or more of the light source assemblies 120 (first, second, third, etc.) may be arranged to generally face in the same direction. For example, one or more of the light source assemblies 120 may be arranged to generally face (e.g., emit UV light towards) the inlet 106, or the light source assemblies 120 may be arranged to generally face the outlet 108. In another embodiment, one or more of the light source assemblies 120 may be arranged to face in opposite directions. For example, the first light source assembly 120a may face generally toward the inlet 106 and the second light source assembly 120b may face generally toward the outlet 108, or vice versa.

[0032] Continuing to refer to FIG. 2, the light source units 122a, 122b are arranged in the treatment chamber 110 so as to be immersed in the fluid flowing through the treatment chamber 110 for UV treatment. In other words, the fluid flowing through the treatment chamber 110 impinges on and flows around the light source units 122a, 122b. The fluid not only impinges on the front, light-emitting side of the light source units 122a, 122b, but also impinges on and flows around the back side of the light source units 122a, 122b, where considerable heat is often generated. Thus, the fluid being treated can be used to continuously cool the light source units 122a, 122b.

[0033] Although FIGs. 1 and 2 show an exemplary fluid treatment system 100 including two light source assemblies 120a, 120b, the present disclosure is not limited to any particular number of light source assemblies so long as the number of light source assemblies is sufficient to disinfect the fluid. The number of light source assemblies 120 may be determined based on the flow rate and/or level of disinfection. For example, the treatment system 100 may include any suitable number of light source assemblies for disinfecting the fluid, such as at least one, at least two, or at least three light source assemblies, and up to twenty light source assemblies, up to ten light source assemblies, or up to five light source assemblies.

[0034] The fluid treatment system 100 may further include a flow sensor 114 for measuring a flow rate of the fluid flowing through the treatment chamber 110. As shown in FIGs. 1 and 2, the flow sensor 114 may be integrated in the outlet 108. Alternatively, the flow sensor 114 may be integrated in the inlet 106 or inside the treatment chamber 110. The flow rate may be used to modulate UV LED power proportional to flow. For example, when there is low flow or no flow, power to the UV LEDs 124 may be turned off or reduced to a low, idle power. This may include, for example, switching to pulse width modulation at the idle power.

[0035] FIGs. 3 A and 3B show an example of removably coupling a light source assembly 120 to a reactor vessel 102. FIG. 3A shows an open state in which the light source assembly 120 is not coupled to the reactor vessel 102, and FIG. 3B shows a closed state in which the light source assembly 120 is coupled to the reactor vessel 102. In FIG. 3A, the light source assembly 120 is in a state of being coupled to or removed from the reactor vessel 102. As shown in FIG. 3A, the light source assembly 120 can be removably coupled to the reactor vessel 102 by inserting the light source unit 122 into the treatment chamber 110 through an opening in the port 112 of the reactor vessel 102 in a direction (e.g., the Z direction) transverse to the longitudinal axis L, and coupling the cap 138 to the port 112 of the reactor vessel 102. Likewise, the light source assembly 120 can be uncoupled from the reactor vessel 102 by uncoupling the cap 138 from the port 112 and removing the light source unit 122 from the treatment chamber 110 of the reactor vessel 102 in a direction (e.g., the Z direction) transverse to the longitudinal axis L. As shown in FIG. 3B, the cap 138 is coupled to the lateral port 112 of the reactor vessel 102 to removably couple the light source assembly 120 to reactor vessel 102. The light source assembly may include sealing elements, such as O-rings or gaskets (e.g., 136 in FIG. 5B) to create a water-tight seal between the light source assembly and the lateral port 112. The light source assembly may also include sealing elements to create a water tight seal between the light source assembly and a port in the treatment chamber 110.

[0036] In FIGs. 3 A and 3B, the light source unit 122 is inserted into and removed from the treatment chamber 110 along the Z direction, which is orthogonal (e.g., at an angle of about 90°) to the longitudinal axis L of the treatment chamber 110. However, the present disclosure is not limited to this arrangement, and the light source unit 122 may be inserted into and removed from the treatment chamber 110 by movement along a direction at any suitable angle transverse to the longitudinal axis L of the treatment chamber 110, such as an angle in a range of 20° to 160°, a range of 30° to 150°, or a range of 45° to 135°.

[0037] During use, the light source unit 122 of the light source assembly 120 may periodically become fouled with foreign materials, which can inhibit its ability to transmit the UV radiation to the fluid. Once fouling has reached a certain point, the light source unit 122 may be cleaned to remove the fouling materials and optimize the system. By arranging the light source assembly 120 to be insertable and removable along a direction transverse to the longitudinal axis L of the treatment chamber 110, the light source assembly 120 can be easily removed from the reactor vessel 102 without disturbing the piping connection for cleaning to remove fouling materials from the light source unit 122, as well as for other routine maintenance or servicing or replacement. This is particularly advantageous when the system is installed in existing household piping, where there is limited space.

[0038] Referring to FIG. 4, the reactor vessel 102 may have a substantially cylindrical body defined by an outer wall 104. For example, the reactor vessel 102 may have a circular cross-sectional shape, as shown in FIG. 4. However, the present disclosure is not limited to any particular cross-sectional shape, and the reactor vessel 102 may have various other cross-sectional shapes, for example, an elliptical shape, a polygonal shape including, for example, a square or rectangular shape, and a semicircular shape. For residential systems, the reactor 102 may have a length, in a direction along the longitudinal axis L from the inlet 106 to the outlet 108, in a range of 100 mm to 1,000 mm, 200 mm to 500 mm, or 240 mm to 350 mm. The treatment chamber 110 of the reactor 102 may have a diameter or width dimension in a direction orthogonal to the longitudinal axis L in a range of 25 mm to 250 mm, 50 mm to 200 mm, or 75 mm to 150 mm. The treatment chamber and the reactor vessel may be the same item, or the treatment chamber may be a separate chamber within the reactor vessel.

[0039] As discussed above, the reactor vessel 102 includes first and second lateral ports 112a, 112b including openings formed in the outer wall 104 for receiving the first and second light source assemblies 120a, 120b. However, the present disclosure is not limited to this, and may have any number of ports corresponding to the number of light source assemblies. For example, the reactor vessel 102 may include at least one, at least two, or at least three ports 112, and up to twenty, up to ten, or up to five ports 112. The ports 112a, 112b may include an internal or external thread 113a, 113b designed to threadedly engage threads 137 (shown in FIG. 5B) of the cap 138 of the light source assembly 120. Alternatively, the ports 112a, 112b may include any other connecting mechanism suitable for detachably connecting to the light source assemblies 120a, 120b.

[0040] FIGs. 5A and 5B show perspective views of an exemplary light source assembly 120, FIG. 6 shows a perspective view of an exemplary light source unit 122 including an array of a plurality of UV LEDs 124, and FIG. 7 shows an exploded view of the light source unit 122. The light source unit 122 of the assembly 120 has a disc shape. For example, the light source unit may have a shape resembling a puck. However, the present disclosure is not limited to any particular shape, and the light source unit 122 may have any suitable shape, including but not limited to cylindrical, conical, frustoconical, cubical, rectangular, or the like. For example, the light source unit 122 may have a circular cross- sectional shape, as shown in FIG. 5A, 5B, and 6. However, the present disclosure is not limited to any particular cross-sectional shape, and the light source unit 122 may have various other cross-sectional shapes, for example, an elliptical shape, a polygonal shape including, for example, a square or rectangular shape, and a semicircular shape. Regardless of shape, the light source units 122a, 122b can be sized relative to the treatment chamber 110 to allow for sufficient fluid flow within the reactor 102 so that the treatment of the fluid is efficient. In this regard, a cross-sectional area of one of the light source units 122a, taken on a plane orthogonal to the longitudinal axis L, can be from 25%-60% of the cross-sectional area of the treatment chamber 110, or from 35%-45% of the cross-sectional area of the treatment chamber 110. The light source assembly may include optical elements to optimize the light distribution reaching the fluid. Those elements could comprise: a window 132 that has a curved surface; individual lens or lens assemblies associated with each LED source; a parabolic or other curved reflector associated with each LED source; a parabolic or other curved reflector associated with the entire LED assembly.

[0041] The light source unit 122 may include a thickness dimension that is oriented in the treatment chamber 110 along the longitudinal axis L of the treatment chamber 110 and a width dimension that is oriented in the treatment chamber 110 orthogonally to the longitudinal axis L of the treatment chamber 110. A maximum width dimension of the light source unit 122 may be at least twice that of a maximum thickness dimension of the light source unit 122. The maximum width dimension of the light source unit 122 may be 2 to 20 times larger than the maximum thickness dimension, 3 to 15 times larger than the maximum thickness dimension, or 5 to 10 times larger than the maximum thickness dimension of the light source unit 122. For example, in a case where the light source unit 122 is cylindrical and has a circular cross-sectional shape, the width dimension may correspond to a diameter of the light source unit 122, and the thickness dimension may correspond to a length of the cylindrical light source unit 122 that is oriented in the treatment chamber 110 along the longitudinal axis of the treatment chamber 110 and is orthogonal to the diameter of the light source unit 122.

[0042] The light source unit 122 includes a housing 130 in which the array of UV LEDs 124 is arranged. The housing 130 may be made at least partially of a heat-conductive material, such as stainless steel, aluminum, copper, or alloys thereof, to facilitate heat dissipation from the light source unit 122 to the fluid being treated in the chamber 110. For example, at least a backside of the housing 130, which is opposite to the light-emitting side, may be made of a heat-conductive material to facilitate dissipation of the heat away from the light source unit 122, e.g., into the fluid being treated.

[0043] The housing 130 may define the shape of the light source unit 122. For example, the housing 130 may have a disc shape, such as a shape resembling a puck. However, the present disclosure is not limited to any particular shape, and the housing 130 may have any suitable shape, including but not limited to cylindrical, conical, frustoconical, cubical, rectangular, or the like. For example, the housing 130 may have a circular cross- sectional shape, as shown in FIG. 5A, 5B, and 6. However, the present disclosure is not limited to any particular cross-sectional shape, and the housing 130 may have various other cross-sectional shapes, for example, an elliptical shape, a polygonal shape including, for example, a square or rectangular shape, and a semicircular shape. The side opposite the window, and the lateral face, have been depicted as a flat surfaces, but may be shaped to optimize fluid flow by incorporating curves, baffles, protrusions, or other features. Similarly, the support post 146 may be rectangular, elliptical, or round (e.g., circular) in cross-section.

[0044] The housing 130 may include a thickness dimension that is oriented in the treatment chamber 110 along the longitudinal axis L of the treatment chamber 110 and a width dimension that is oriented in the treatment chamber 110 orthogonally to the longitudinal axis L of the treatment chamber 110. A maximum width dimension of the housing 130 may be at least twice that of a maximum thickness dimension of the housing 130. The maximum width dimension of the housing 130 may be 2 to 20 times larger than the maximum thickness dimension, 3 to 15 times larger than the maximum thickness dimension, or 5 to 10 times larger than the maximum thickness dimension of the housing 30. For example, in a case where the housing 130 is cylindrical and has a circular cross-sectional shape, the width dimension may correspond to a diameter of the housing 130, and the thickness dimension may correspond to a length of the cylindrical housing 130 that is oriented in the treatment chamber 110 along the longitudinal axis L of the treatment chamber 110 and is orthogonal to the diameter of the housing 130.

[0045] A UV transparent window 132 may be arranged on the other side (z.e., the light-emitting side) of the housing 130 so as to cover the UV LEDs 124. The UV LEDs 124 are arranged to emit UV radiation through the UV transparent window 132. The window 132 may be made of any material that is suitably transparent to UV radiation, such as quartz or silica glass. The UV transparent window 132 may be machined and have a substantially flat surface or may have a curved face. A plane of the UV transparent window 132 may be parallel to the width dimension of the light source unit 122 and the housing 130. The window may be sealed to prevent fluid from entering the lights source unit 122. For example, as shown in FIG. 7, the window 132 may be secured to the housing by a cap 131 or other sealing material. The cap 131 may threadedly engage external threads on the housing 130 to secure the window 132 against the array of UV LEDs 124 arranged in the housing 130. Alternatively, the cap 131 may couple to the housing 130 by any other suitable connection mechanism, for example, snapping into a groove in housing 130. One or more O-rings 134 may be used to seal the window 132 against the body of the housing 130. A second O-ring or flat ring 135 may be incorporated to act as a buffer between the window 132 and the cap 131 or housing 130. For example, one or more of the O-rings 134, 135 may be made of polytetrafluoroethylene (PTFE). One or both of the O-rings or flat rings 134, 135 may provide a cushion to protect the window 132 from damage due to pressure in the treatment chamber 110.

[0046] The UV LEDs 124 are mounted on and electrically coupled to a circuit board 128, such as a printed circuit board (PCB) or a metal core printed circuit board (MCPCB), which is also arranged in the housing 130 on an opposite side of the window 132. The circuit board 128 may be inset inside the housing 130. A plane of the circuit board 128 may be oriented parallel to the width dimension of the light source unit 122 and the housing 130. The UV LEDs 124 may be arranged in any suitable pattern on the circuit board 128. The number of UV LEDs 124 arranged in the light source unit 122 may be determined based on the flow rate and/or level of disinfection. In one example, the light source unit 122 may include a number of UV LEDs 124 in a range of 5 to 100, a range of 15 to 50, or a range of 10 to 30.

[0047] The circuit board 128 may include a metal backing or metal core made of a heat-conductive material, such as copper, aluminum, and alloys thereof, in order to facilitate conducting heat away from the light source unit 122. For example, the heat generated by the light source unit 122 can be dissipated to the fluid being treated into the treatment chamber 110 through the heat-conductive backing or core and the heat-conductive housing 130. The heating-conductive backing on the circuit board 128 may be in direct contact with the thermally-conductive back of the housing 130 to facilitate heat dissipation to the fluid. Alternatively, a heat-conducting paste, pad, or solder may be used to conduct heat from the circuit board 128 to the housing 130.

[0048] The light source unit 122 may be arranged in the treatment chamber 110 such that the UV transparent window 132, the array of LEDs 124, the circuit board 128, and the backside (non-emitted side) of the housing 130 are stacked in this order along a direction of the thickness dimension of the light source unit 122, which extends along the longitudinal axis L of the treatment chamber 110.

[0049] The treatment chamber 110 and/or the light source unit 122 may optionally include a UV reflector for facilitating irradiation of the UV light into the fluid flowing through the chamber 110. For example, the UV reflector may be made of any suitably reflective material, such as polytetrafluoroethylene (PTFE), aluminum, stainless steel, or the like. The UV reflector may be provided as a coating applied on an inner surface of the treatment chamber 110, or may be a polished inner surface of the chamber 110, for example, where the chamber wall is made of a reflective material. Alternatively or additionally, a UV reflector may be provided in the light source unit 122, for example, as a parabolic reflector or a reflective coating material, for example, provided on the circuit board 128.

[0050] The light source unit 122 may further include one or more sensors. The sensors may be mounted on the circuit board 128 and electrically coupled thereto, or they may be otherwise provided in the light source unit 122 or may include their own circuit board. For example, as shown in FIG. 5A, the light source unit 122 may include a UV light intensity sensor 126. The intensity sensor 126 may be arranged in the center of the light source unit 122, such as a center of the circuit board 128, as shown in FIG. 5 A or any other suitable location in or on the light source unit 122 or on the circuit board 128. The intensity sensor 126 may be designed to measure an intensity of UV light incident thereon. For example, the intensity sensor 126 may measure an intensity of UV light emitted by an opposing light source unit or it may measure an intensity of UV light emitted by the light source unit in which it is arranged (the self source unit) through lateral emission or back reflected light from the window 132, or light reflected by the treatment chamber. The intensity sensor 126 may be, for example, an intensity sensor chip, photodiode, photodetector, photoresistor, a UV phototube, or any other suitable sensor for measuring the intensity of UV light.

[0051] The intensity measurements may be used to evaluate and monitor the health of the light source unit 122. LEDs degrade over time, and monitoring the intensity of light emitted by the LEDs 124 can help evaluate how the LEDs are aging. Additionally, the UV sensor 126 may be used to monitor fouling of the light source unit 122 to determine whether the light source unit 122 should be cleaned. As discussed above, during use, the light source unit 122 periodically becomes fouled with foreign materials, which can inhibit its ability to transmit UV radiation to the fluid, resulting in a decrease in intensity. Thus, the intensity sensor 126 may be used to determine whether the light source unit 122 should be removed for cleaning or other servicing. When a decrease in intensity is detected by the sensor 126, the system may output a notification, for example, in the form of a sound, light, or other error message, indicating that the light source unit 122 requires servicing or cleaning.

[0052] For example, referring to FIG. 2, to determine the health or condition of the light source units 122a, 122b, the intensity sensor 126 in the first light source unit 122a may measure an intensity of light emitted by the second light source unit 122b while the first light source unit 122a is temporarily turned off to evaluate the health of the second light source unit 122b or to determine whether the second light source unit 122b should be cleaned or serviced. The second light source unit 122b then may be temporarily turned off, and the intensity sensor 126 in the second light source unit 122b may measure an intensity of light emitted by the first light source unit 122a to evaluate the health of the first light source unit 122a and/or determine whether the first light source unit 122a should be cleaned or serviced. The intensity sensor 126 may additionally be able to monitor the health and fouling condition of the light source unit 122 in which the sensor 126 is arranged (the self source unit) by temporarily turning off the other light source unit and measuring the intensity light of the self source unit 122 through lateral emission from the LEDs 124 or back reflected light from the window 132 of the self source unit 122.

[0053] By arranging an intensity sensor 126 in or on at least one of the light source units 122a, 122b, there may be no need to provide a separate sensor module including housing, a dedicated window, seals, and electrical components for the sensor 126, which can increase cost and reliability issues. Instead, the sensor 126 can be sealed in the light source unit 122 and electrically coupled to the same circuit board 128 as the UV LEDs 124.

[0054] The light source unit 122 may include any other suitable sensor in place of or in addition to the intensity sensor 126, or the light source unit 122 may not include any such sensors. For instance, as shown in FIG. 5A, the light source unit 122 may include a temperature sensor 127 for measuring the temperature of the light source unit 122. In FIG. 5A, the temperature sensor 127 is mounted on the circuit board 128 near the intensity sensor 126, but the present disclosure is not limited to this arrangement and the temperature sensor 127 may be mounted anywhere on the circuit board 128, or may be otherwise provided in the light source unit 122. The temperature sensor 127 may be provided in a center of the light source unit 122, where the light source unit 122 may get hottest during use. The temperature sensor 127 may be a thermistor or a thermocouple any other sensor suitable for sensing a temperature in the light source unit 122. The temperature sensor 127 may be used to determine whether fluid is flowing through the chamber 110. For example, when the fluid flows through the chamber 110, the light source unit 122 may be cooled by the flowing fluid, and thus, there may be a corresponding decrease in the temperature of the light source unit 122 upon fluid flow through the chamber 110. The temperature sensor 127 may be used to monitor the condition of the flow sensor 114. For example, if the temperature sensor 127 measures a change in temperature indicative of fluid flow, but the flow sensor 114 has not detected flow, this may indicate that the flow sensor 114 is not working properly. In such a case, the flow rate may be determined from the temperature change of the lights source unit 122 and the temperature of the water, and the determined flow rate may be temporarily used for modulating power to the UV LEDs 124 instead of shutting down the system. The light source could also include a humidity sensor that could be used to detect leakage. [0055] The circuit board 128 may further include a connector 142, such as a multipin connector for electrically connecting the circuit board 128 to a power source. For example, the connector may be connected to one end of a ribbon cable 140 (shown in FIG. 5B). As discussed in more detail below, the ribbon cable 140 extends outside of the light source unit 122. For example, the other end of the ribbon cable 140 may be connected to a circuit board 148 arranged in the cap 138.

[0056] As mentioned above, the light source assembly 120 also includes a cap 138 for coupling the assembly to the reactor vessel 102. The light source unit 122 is mounted on a mounting arm 146 that extends from the cap 138. The ribbon cable 140 may be arranged to extend from the connector 142 through an inner channel of the mounting arm 146 to inside of the cap 138, where it is coupled to a connector 144 provided on the circuit board 148. The circuit board 148 inside the cap 138 may be coupled to a power source. For example, referring to FIG. 8, the circuit board 128 in each of the light source assemblies 120a, 120b is electrically coupled to a power source via cables 121a, 121b.

[0057] The cap 138 further includes threads 137 for coupling to a lateral port 112 of the reactor vessel 102. For example, the threads 137 of the cap 138 may be designed to threadedly engage threads 113 provided on the lateral port 112 of the reactor vessel 102. However, the present disclosure is not limited to a threaded connection, and any other suitable connection mechanism may be used.

[0058] Referring to FIG. 8, the fluid treatment system 100 may further include a controller 150 that is connected to a power source, such as an electrical grid, via the plug 151. The controller 150 may be configured to control the transmission of electrical power to the system 100. For instance, the controller 150 may transmit power from the electrical grid to each of the light source assemblies 120a, 120b via cables 121a, 121b for powering the arrays of LEDs 124a, 124b and any sensors, such as an intensity sensor 126 or temperature sensor 127 housed within the light source assemblies 120a, 120b. Similarly, the controller may transmit power from the electrical grid to the flow sensor 114 via cable 116.

[0059] The controller 150 may be configured to control the functioning of the system 100 based on measurements received from one or more sensors, including, for example, the flow sensor 114, the intensity sensor 126, and the temperature sensor 127 according to the methods described above. For instance, the controller 150 may control the flow sensor 114 to periodically measure the flow rate of fluid flowing through the treatment chamber 110. The flow sensor 114 may transmit the measured flow rate to the controller 150. The controller 150 may use the measured flow rate to modulate power supplied to the light source assemblies 120a, 120b.

[0060] The controller 150 may also periodically control the system 100 to evaluate the health and/or fouling of the light source units 122a, 122b by measuring the intensity of UV light using one or more intensity sensors 126 in the light source units 122a, 122b according to the methods discussed above. The intensity sensor 126 may transmit the measured intensity to the controller 150. If it is determined that one or more of the light source units 122a, 122b is malfunctioning or needs servicing or maintenance, including cleaning to remove fouling materials, the controller 150 may output a notification, such as a sound, light, or other notification according to the methods discussed above.

[0061] The controller 150 includes hardware, such as a circuit for processing digital signals and a circuit for processing analog signals, for example. The controller may include one or a plurality of circuit devices (e.g., an IC) or one or a plurality of circuit elements (e.g., a resistor, a capacitor) on a circuit board, for example. The controller 150 may be a central processing unit (CPU) or any other suitable processor. The controller 150 may be or form part of a specialized or general purpose computer or processing system. One or more controllers, processors, or processing units, memory, and a bus that operatively couples various components, including the memory to the controller, may be used. The controller 150 may include a module that performs the methods described herein. The module may be programmed into the integrated circuits of the processor, or loaded from memory, storage device, or network or combinations thereof. For example, the controller 150 may execute operating and other system instructions, along with software algorithms, machine learning algorithms, computer-executable instructions, and processing functions of the fluid treatment system.

[0062] The controller 150 may be operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well- known computing systems, environments, and/or configurations that may be suitable for use with the disclosed embodiments may include, but are not limited to, personal computer systems, server computer systems, thin clients, thick clients, handheld devices, such as tablets and mobile devices, laptop devices, multiprocessor systems, microprocessor-based systems, set top boxes, programmable consumer electronics, network PCs, minicomputer systems, mainframe computer systems, and distributed cloud computing environments that include any of the above systems or devices, and the like. [0063] The present disclosure further relates to a non-transitory computer-readable storage medium configured to store a computer-executable program that causes a computer to perform functions, such as those for implementing the disclosed methods. The computer- readable storage medium may further store the real time data collected by the controller 150 and computer-executable instructions. The storage medium may include a memory and/or any other storage device. The memory may be, for example, random-access memory (RAM) of a computer. The memory may be a semiconductor memory such as an SRAM and a DRAM. The storage device may be, for example, a register, a magnetic storage device such as a hard disk device, an optical storage device such as an optical disk device, an internal or external hard drive, a server, a solid-state storage device, CD-ROM, DVD, other optical or magnetic disk storage, or other storage devices.

[0064] Although embodiments disclosed herein have been described with respect to treating water and/or aqueous fluids with UV radiation treatment, the present disclosure is not limited to water and aqueous fluids, and may be used to treat any fluid, including liquids, vapors, gels, plasmas, and gases. Similarly, the present disclosure is not limited to residential UV treatment systems, and may be applied to industrial, municipal, and commercial systems.

[0065] It will be appreciated that the above-disclosed features and functions, or alternatives thereof, may be desirably combined into different systems and methods. Also, various alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art, and are also intended to be encompassed by the disclosed embodiments. As such, various changes may be made without departing from the spirit and scope of this disclosure.

Claims

WHAT IS CLAIMED IS

1. A fluid treatment system for treating a fluid with ultraviolet (UV) radiation, the system comprising: a reactor vessel including a treatment chamber that includes an inlet where the fluid enters the treatment chamber and an outlet where the fluid exits the treatment chamber, the reactor vessel being configured so that the fluid flows within the treatment chamber from the inlet to the outlet generally along a longitudinal axis of the treatment chamber; and at least one light source assembly that is removably coupled to the reactor vessel so that the light source assembly can be inserted into the treatment chamber in a direction transverse to the longitudinal axis, the at least one light source assembly comprising a light source unit including an array of light-emitting diodes (LEDs) configured to emit UV radiation into the treatment chamber to treat the fluid.

2. The fluid treatment system according to claim 1, wherein the array of LEDs is arranged in a plane that is orthogonal to the longitudinal axis of the treatment chamber.

3. The fluid treatment system according to claim 1, wherein the array of LEDs is arranged in a plane that is transverse to a direction of fluid flow through the treatment chamber.

4. The fluid treatment system according to claim 1, wherein the light source unit of the at least one light source assembly is arranged in the treatment chamber so as to be immersed in the fluid flowing through the treatment chamber.

5. The fluid treatment system according to claim 1, wherein the at least one light source assembly is configured to be removed from the treatment chamber in the direction transverse to the longitudinal axis through an opening in an outer wall of the reactor vessel.

6. The fluid treatment system according to claim 1, wherein the at least one light source assembly includes: a first light source assembly including a first light source unit arranged in the treatment chamber, and a second light source assembly including a second light source unit arranged in the treatment chamber.

7. The fluid treatment system according to claim 6, wherein the first light source unit and the second light source unit are configured to emit UV radiation towards each other along the longitudinal axis of the treatment chamber.

8. The fluid treatment system according to claim 6, wherein the first light source unit and the second light source unit are configured to emit UV radiation in the same direction along the longitudinal axis of the treatment chamber.

9. The fluid treatment system according to claim 1, wherein the light source unit of the at least one light source assembly includes a housing, and the array of LEDs is mounted on a circuit board inside the housing.

10. The fluid treatment system according to claim 9, wherein the housing is made of a heat-conductive material.

11. The fluid treatment system according to claim 10, wherein the housing comprises at least one material selected from the group consisting of stainless steel, aluminum, copper, and alloys thereof.

12. The fluid treatment system according to claim 9, wherein the housing includes a UV transparent window arranged to cover the array of LEDs, and the array of LEDs is configured to emit the UV radiation through the UV transparent window.

13. The fluid treatment system according to claim 9, wherein the housing includes a thickness dimension that is oriented in the treatment chamber along the longitudinal axis of the treatment chamber and a width dimension that is oriented in the treatment chamber orthogonally to the longitudinal axis of the treatment chamber, and wherein a maximum width dimension of the housing is at least twice that of a maximum thickness dimension of the housing.

14. The fluid treatment system according to claim 1, wherein the light source unit of the at least one light source assembly has a shape of a disc.

15. The fluid treatment system according to claim 1, wherein the at least one light source assembly further includes a cap that is removably coupled to a lateral port formed in an outer wall of the reactor vessel, and the light source unit is mounted on an end of a mounting arm extending from the cap into the treatment chamber.

16. The fluid treatment system according to claim 1, wherein the light source unit of the at least one light source assembly is concentric with the treatment chamber.

17. The fluid treatment system according to claim 1, wherein the light source unit further includes an intensity sensor configured to measure an intensity of UV radiation incident thereon.

18. The fluid treatment system according to claim 1, wherein the light source unit of the at least one light source assembly further includes a temperature sensor configured to measure a temperature of the light source unit.

19. The fluid treatment system according to claim 1, wherein the fluid treatment system is configured to be installed in-line in piping at a point of entry of water from a water source.

20. A method of assembling the fluid treatment system according to claim 1, the method comprising: inserting the light source unit of the at least one light source assembly into the treatment chamber in the direction transverse to the longitudinal axis of the treatment chamber, and coupling the at least one light source assembly to the reactor vessel.

21. A method of disassembling the fluid treatment system according to claim 1, the method comprising: uncoupling the at least one light source assembly from the reactor vessel, and removing the light source unit from the treatment chamber of the reactor vessel through an opening in an outer wall of the reactor vessel in the direction transverse to the longitudinal axis.

22. A method of treating fluid with UV radiation via the fluid treatment system according to claim 1, the method comprising: introducing fluid into the treatment chamber of the reactor vessel through the inlet; and irradiating the fluid flowing through the treatment chamber with the UV radiation emitted by the light source unit of the at least one light source assembly.