HK1063306B - A lamp assembly - Google Patents

Description

Lamp assembly

The present invention is in accordance with 35 U.S.C. § 119(e) a provisional application entitled "Point-Of-Use water treatment system", filed No. 60/140,090, filed on 21.6.1999, and a priority application entitled "water treatment system with inductively coupled stabilizer", filed on 21.6.1999, filed No. 60/140,159, the disclosures Of which are incorporated herein by reference. In addition, the disclosure of the disclosure in a patent application entitled "fluid handling System" filed on even date herewith is also incorporated herein by reference.

Technical Field

The present invention relates to a point of use Water Treatment System (WTS) unit for home and office use capable of filtering and treating impurities in water.

Background of the invention

The present invention minimizes or overcomes several problems associated with existing point-of-use home or office Water Treatment System (WTS) units. The first problem is that the conventional WTS device using the lamp assembly with the ultraviolet bulb installed therein is low in energy efficiency. When a conventional lamp assembly is turned on, a long start-up time is required before the gas in the ultraviolet bulb assembly is sufficiently excited to output light of the intensity required to ensure adequate killing of microorganisms within the WTS device. The water discharged from the WTS unit may contain a significant amount of viable microorganisms before the ultraviolet bulb assembly is sufficiently excited and the microorganisms are sufficiently irradiated. Therefore, conventional lamp assemblies require continuous operation, which consumes a significant amount of energy. In addition, when conventional light assemblies are operated continuously, such as overnight, the water present in the WTS device may be uncomfortably warm. Finally, the average life of the lamp assembly remaining in continuous operation is substantially less than the average life of a lamp assembly that is only activated when water treatment is required.

A second problem is the design of the reflector assembly in the WTS unit. In an attempt to increase the efficiency of the lamp, a reflector assembly may be placed around the ultraviolet bulb assembly and the water conduit in which the microorganisms are irradiated. Light emitted from the ultraviolet bulb assembly and not impinging on the water conduit is reflected back by the reflector wall and may impinge the water conduit again. These reflector assemblies are generally circular in cross-section. Unfortunately, the large amount of ultraviolet light generated by these circular reflectors never strikes the water duct. Instead, most of the reflected light is reabsorbed by the ultraviolet bulb assembly and never strikes the water conduit.

A third problem relates to the electrical connection of the lamp assembly to the WTS device. Each time the lamp assembly is installed in or removed from the WTS unit, the lamp assembly must be mechanically and electrically connected and disconnected with respect to the WTS unit. This typically requires a complex and excessive number of electrical mounting components. Further, it should be noted that it must be ensured that the electrical connector cannot become wet when the WTS device is powered on.

Coaxially aligned lamp assemblies and filter assemblies are sometimes used to minimize the size of the WTS unit. The lamp assembly and filter assembly in a particular WTS may or may not be removable from the WTS unit at the same time. These assemblies are often quite heavy if they are removed at the same time, due to their own weight and possible water filling. Alternatively, even if the lamp assembly and filter assembly are separately removed from the WTS unit, there is often a problem of water spilling from these components during operation.

Another problem faced by WTS devices with ultraviolet bulb assemblies is that complex monitoring systems are required to monitor the lamp assembly. As the lamp assembly ages, the intensity of the ultraviolet light output from the lamp assembly typically decreases. Eventually, the ultraviolet light intensity will drop below that required to achieve a microbial kill rate. The lamp assembly should be replaced before the desired minimum ultraviolet light intensity is reached. Therefore, a monitoring system for detecting the intensity of ultraviolet light is required within the WTS device. These monitoring systems are typically relatively expensive. They often require relatively expensive uv sensors with quartz windows.

Because microbial growth can occur if an in-situ water treatment system is shut down, it is often desirable to maintain such a system in continuous operation. The lamp assembly in a conventional WTS device takes a long time to reach the critical value of the emitted radiation intensity needed to achieve the desired kill rate. Thus, water containing a large number of viable microorganisms may be transported out of the WTS unit before a critical value of the light intensity is reached.

Other problems and drawbacks with conventional WTS devices include the complex assembly and locking mechanisms for mounting the filter and lamp assembly, which may include nuts, bolts, O-rings, etc., which must be manually installed.

The present invention overcomes these and other deficiencies in existing WTS devices that use lamp assemblies and filter assemblies.

Summary of The Invention

The invention relates to a lamp assembly comprising: a housing; a bulb positioned within the housing to generate radiation; a conduit adjacent the bulb, the conduit carrying fluid through the housing; a reflector assembly adjacent the bulb, the reflector assembly including a central curvilinear portion including a constant radius portion and a converging radius portion having a decreasing radius of curvature, and the reflector assembly reflecting substantially all light emitted from the bulb toward the conduit.

The invention also relates to a lamp assembly, preferably for use in a water treatment system, comprising a bulb assembly, a reflector assembly and a conduit for transporting water through the lamp assembly. The reflector assembly is formed to reflect and focus light emitted by the light bulb assembly onto the tube and to return the reflected light out of the tube back to the light bulb assembly, thereby increasing the efficiency of the light assembly.

The present invention also relates to a replaceable lamp assembly including a water conduit secured between a pair of end caps and a bulb assembly for illuminating the conduit. The conduit serves as a reaction vessel in which microorganisms and other impurities may be treated. An enclosure may be used that cooperates with the end cap to form a closed container that encloses the ultraviolet bulb assembly and the tube. The lamp assembly may also include two or more tubes extending between the end caps. The lamp assembly is typically self-contained and can be easily installed into a test fixture or water treatment system.

Another aspect of the invention is the use of a condensing element to cool the middle portion of the bulb assembly between its filaments. A condensable material, such as mercury, is condensed on the intermediate portion of the bulb between its filaments, whereby said intermediate portion is cooled. When the lamp assembly is energized, the condensed mercury may be quickly revaporized when it is located in the arc path between the filaments. Conversely, when the condensed mercury is located outside of the arc path, it takes more time for the condensed mercury to fully vaporize when the lamp assembly is re-energized. The condensation of mercury in the arc path helps the lamp assembly reach a critical value of light intensity in a short period of time. The condensing element extending between the bulb and the pipe carrying the cold water may be used as a kind of heat sink capable of cooling the intermediate portion of the bulb in contact with the condensing element. The condensation element may also serve as a shock absorber if the condensation element is elastic.

Another feature of the present invention is the use of a plastic light pipe filled with a fluorescent dye to convert ultraviolet light to visible light. This conversion allows the relative intensity of the ultraviolet light produced by the lamp assembly to be readily detected by a relatively inexpensive visible light detector. The light pipe may include a polished and angled surface to receive incident ultraviolet light and cause the light pipe to emit visible light at a particular emitting surface where the intensity of the visible light can be detected. The color of the fluorescent dye is preferably in the green wavelength range.

Another feature is the use of an inductively coupled base portion and lamp assembly to provide the ultraviolet light illumination needed to kill microorganisms passing through the water treatment system. In addition, Radio Frequency Identification (RFID) and communication links between the base portion, the filter assembly and the sensitive chips on the lamp assembly may provide information regarding the operation of the water treatment system, such as the life and usage of the filters and lamps, the identification of the particular filter assembly or lamp assembly, and other desired information. The use of inductive coupling and RFID may allow the filter assembly and light assembly to operate without being hardwired to the base portion. The base portion will include a microprocessor to control the operation of the water treatment system.

It is an object of the present invention to provide a WTS unit that does not require a direct physical electrical connection to be established between a removable lamp assembly and a base portion that powers the lamp assembly.

It is another object of the present invention to provide a WTS device having a base portion with a primary winding and a lamp assembly with a secondary winding, the primary winding providing energy to the secondary winding to energize the lamp assembly, thereby generating high intensity ultraviolet light in the WTS device.

It is another object of the present invention to provide a reflector assembly in a WTS unit wherein the ultraviolet light generated by the ultraviolet bulb assembly is reflected and focused onto one or more conduits carrying water to be treated while minimizing the reflected light reaching and being absorbed by the ultraviolet bulb assembly.

It is another object of the present invention to provide a WTS device wherein a filter assembly is cooperatively mounted to the base portion and the lamp assembly to allow water to pass through the filter assembly and wherein the filter assembly is self-sealing to prevent water from escaping from the filter assembly when the filter assembly is removed from the base portion and the lamp assembly.

It is another object of the present invention to provide a WTS unit having a stabilizer and a lamp assembly, wherein the ultraviolet bulb assembly produces ultraviolet light of sufficiently high intensity virtually instantaneously after start-up, thereby allowing the lamp assembly to operate intermittently while maintaining a desired microbial kill rate.

It is another object of the present invention to provide a WTS unit that operates intermittently and has an ultraviolet bulb assembly with a pair of filaments spaced apart and a heat sink in contact with the ultraviolet bulb assembly to form a cooling spot between the filaments of the ultraviolet bulb assembly, wherein when the ultraviolet bulb assembly is de-energized, at least one ionized gas condenses near the cooling spot between the filaments. This allows the condensed gas to be quickly reionized when the ultraviolet light bulb assembly is re-energized.

It is another object of the present invention to provide a light pipe that is capable of receiving ultraviolet light, fluorescing and outputting visible light that is substantially linearly proportional in intensity to the incident ultraviolet light.

It is another object of the present invention to provide a smart chip in one or more of the filter and lamp assembly that communicates information (transactions) with the electronic assembly on the base portion to record usage information of the filter and lamp assembly.

Brief description of the drawings

These and other features, objects, and advantages of the present invention will become more readily apparent from the following detailed description, from the appended claims, and from the accompanying drawings in which:

FIG. 1 is a perspective view of a WTS device in accordance with the present invention;

FIG. 2 is a left side view of the WTS device;

FIG. 3 is a rear view of the WTS device;

FIG. 4 is a perspective view of the base portion of the WTS unit with the top cover of the WTS unit removed and the filter assembly and lamp assembly removed from the base portion;

FIG. 5 is an exploded perspective view of the major components of the WTS unit;

6A-E are exploded, elevational, cross-sectional views of the filter assembly taken along line 6C-6C in FIG. 6B, enlarged partial views of the enclosed area indicated by 6D in FIG. 6C and 6E in FIG. 6C;

FIGS. 7A-F are top perspective, bottom perspective, front elevational view, cross-sectional view taken along line 7D-7D in FIG. 7C, top plan view, and bottom plan view of the base and inner sleeve;

FIGS. 8A-C are exploded perspective, front and top plan views of a lamp assembly;

FIGS. 9A-C are an exploded perspective view, a top plan view and a cross-sectional view taken along line 9C-9C of FIG. 9B of the bottom component of the lamp assembly;

FIGS. 10A-E are exploded perspective, front, bottom plan, side and top plan views of a bottom assembly of the lamp assembly;

11A-C are perspective, top plan and bottom plan views of a bottom support of the bottom assembly;

12A-C are perspective, top plan and bottom plan views of a bottom shield of the bottom assembly;

FIGS. 13A-C are perspective views of the secondary winding, a top plan view of the coil, and a cross-sectional view of the coil along line 13C-13C in FIG. 13B;

FIG. 14 is a perspective view of a sensitive chip;

15A-B are rear perspective and rear elevational views of the light pipe;

FIG. 16 is an exploded perspective view of the top support assembly;

FIG. 17 is a bottom perspective view of the top cover;

FIG. 18 is a top perspective view of the top shield;

FIG. 19 is an exploded perspective view of the lamp assembly;

20A-B are interior front and side views of a closure;

FIGS. 21A-B are perspective and top end views of the reflector;

FIG. 22 is a cross-sectional view of a lamp assembly, exemplary showing ultraviolet light being reflected;

FIGS. 23A-D are front elevation views of the ultraviolet bulb assembly, a schematic view in an upright position, a schematic view in an inverted position, and a schematic view with a heat sink and in an upright position;

FIG. 24 is a graph relating the relative light intensities produced by the ultraviolet bulb assembly shown in FIGS. 23B-D;

FIGS. 25A-F are enlarged front perspective, top, rear, front, bottom and side views of the light pipe;

26A-C are top plan, bottom plan and exploded perspective views of the bottom shield assembly;

FIGS. 27A-F are rear perspective, front elevational, rear elevational, top plan, side elevational and bottom plan views of an electronic assembly;

FIGS. 28A-D are bottom perspective, top plan, cross-sectional views taken along line 28C-28C in FIG. 28B, and cross-sectional views taken along line 28D-28D in FIG. 28B of the outlet cup assembly;

FIGS. 29A-C are an exploded view, an elevational view, and a cross-sectional view taken along line 29C-29C in FIG. 29B of the intake valve;

30A-C are exploded perspective, top plan and bottom plan views of the inner sleeve assembly;

FIGS. 31A-D are perspective, bottom plan, front elevational views, and cross-sectional views taken along line 31D-31D of FIG. 31B of the inner sleeve and outlet cup assembly;

FIGS. 32A-C are exploded perspective, top plan and front views of the front shield and lens assembly;

33A-C are rear perspective, rear elevational and top plan views of the front shield;

34A-E are front perspective, rear perspective, top plan, rear and side views of the rear shield;

35A-B are front perspective and top plan views of the top shield assembly;

FIGS. 36A-D are front perspective, front elevational, sectional and top plan views of the top shield taken along line 36C-36C in FIG. 36B;

FIG. 37 is an enlarged cross-sectional view of the WTS device taken along line 37-37 in FIG. 3;

FIG. 38 is an enlarged cross-sectional view taken along line 38-38 of FIG. 2;

FIG. 39 is an enlarged cross-sectional view taken along line 39-39 of FIG. 40;

FIG. 40 is a cross-sectional view taken along line 40-40 of FIG. 39;

FIG. 41 is a cross-sectional view taken along line 41-41 of FIG. 39;

FIG. 42 is a cross-sectional view taken along line 42-42 of FIG. 39; and

fig. 43 is a cross-sectional view taken along line 43-43 in fig. 39.

Best mode for carrying out the invention

A perspective view of an exemplary Water Treatment System (WTS) unit 20 according to the present invention is shown in fig. 1. Fig. 2 and 3 are a left side view and a rear view of the WTS device 20, respectively. Fig. 4 is an exploded view showing the main components of the WTS unit, which includes a base portion 22, a lamp assembly 24 and a filter assembly 26. The lamp assembly 24 and the filter assembly 26 can be separately removed and replaced from the base portion 22. Filter assembly 26 may be removed from base portion 22 prior to removal of lamp assembly 24 from base portion 22. Also, lamp assembly 24 may be mounted to base portion 22 first. Then, when the WTS unit 20 is re-assembled, the filter assembly 26 is placed in a coaxial manner over the lamp assembly 24 and is inserted onto the base portion 22.

Referring now to fig. 1-3, the exterior of the WTS unit is formed by a bottom shroud 32, a rear shroud 34, a front shroud 36 and a top shroud 40. The lens 42 is mounted in an opening in the front shroud 36. The lens 42 accommodates visual display of operating parameters of the WTS device. Fig. 2 is a left side view of the WTS device 20, and fig. 3 is a rear view of the WTS device 20. A power plug assembly 44 for receiving power is located on the back of the rear shroud 43. Shown in fig. 4, the top shield 40 is first removed before removing the filter assembly 26 and lamp assembly 24 from the base portion 22.

Referring now to fig. 5, fig. 5 is a perspective view of the major components of the WTS device. The base portion 22 includes an inner sleeve 50 with three inner sleeve caps 52, a feed valve assembly 54, an outlet cup assembly 56 with an outlet cup 58, a bottom shield assembly 60 with a bottom shield 32 and inlet and outlet elbows 62 and 64, and an electronics assembly 66. These components are enclosed within the bottom shield 32, front shield 36 and lens 42, rear shield 34 and top shield 40. Also shown are a magnet mount 68 and a magnet 70 attached to the top shield 40. If the top shield 40 and magnet 70 are not positioned atop the rest of the WTS device in a suitable manner, the magnetic field of the magnet 70 will not be detected by the sensor on the electronics assembly 66, and the WTS device 20 will not be energized.

Lamp assembly 24 includes a base assembly 72, a secondary winding 74, a base support assembly 76, a top support assembly 78, a pair of quartz sleeves 80, an ultraviolet bulb assembly 82, and a pair of interfitting enclosure and reflector assemblies 86. Filter assembly 26 includes a filter block assembly 88 having a filter block 90, a base and inner housing 92, a threaded ring 94, a filter housing 96, and a resilient filter housing clamp 98.

The above components will be described in more detail below, respectively. The assembly and fit of the various components is then described using multiple cross-sectional views of the WTS device.

A. Filter assembly

Referring to fig. 6A-E, the filter assembly 26 includes a filter block assembly 88, a domed cylindrical filter housing 96, inlet check balls 100, outlet check balls 102, a base and inner housing 92, a filter threaded ring 94, a filter block gasket 104, and a filter housing clamp 98. In the exemplary embodiment, filter housing clamp 98 is resilient and made of rubber. The filter housing clamp 98 is extended and frictionally mounted to the upper domed end of the filter housing 96. The filter block assembly 88 has an annular carbon block 90 disposed between a bottom filter end cap 106 and a top filter end cap 108. The filter block assembly 88 also has a carbon sleeve 110 that surrounds the outer periphery of the carbon block 90. The carbon sleeve 110 is constructed of a nylon mesh, and the carbon sleeve 110 serves to filter or trap any large particles that attempt to pass radially inward through the carbon block 90. A sense die 112 is secured in the base and bottom of inner housing 92. Sense die 112 is used to record parameters related to the use of the filter. Sensors on electronics assembly 66 are inductively powered and communicate with sense die 112 to obtain details regarding filter usage.

6C-D, filter block assembly 88 is positioned within filter housing 96 and rests against filter block gasket 104 and the lower portion of base and inner housing 92. Filter block gasket 104 is clamped in grooves in the base and inner housing 92. The carbon block assembly 88 is screwed onto the filter threaded ring 94. And the filter threaded ring 94 is permanently secured to the base and inner sleeve 92 by a welding process. The filter housing 96 is welded at its open end to the outer periphery of the base and inner case 92. The inlet check ball 100 is movably clamped near the bottom of the base and inner housing 92, while the outlet check ball 102 is movably clamped atop the base and inner housing 92 and below the top end cap 108 of the filter block assembly 88.

Referring to fig. 6D, the bottom filter end cap 106 has an annular hub 114, the annular hub 114 supporting a horizontally extending annular tray portion 116. An internal thread 120 is formed on the radially inner surface of the hub portion 114. Four concentric channels 122 are formed in the tray portion 116, and the tray portion 116 also has inner and outer flanges 124, 126. The bottom of the carbon block 90 is supported on the tray portion 116 and is sandwiched between the inner flange 124 and the outer flange 126. Referring now to FIG. 6E, the top filter end cap 108 includes an annular tray portion 130 having an inner flange 132 and an outer flange 134, an annular cap portion 136, and a downwardly opening ball-gripping cup portion 140. Although not clearly shown, the tray portion 130 also includes four concentric grooves disposed opposite the carbon blocks 90. An upper end cap 108 is provided in the form of a movable catch for the outlet check ball 102 atop the upper portion of the inner sleeve 92.

The filter housing 96 includes a closed domed end 142 and a cylindrical portion 144. As shown in fig. 6C-D, the open end of the cylindrical portion 144 is a reduced thickness end 146, the end 146 being configured to be permanently connected to the base and inner sleeve 92. The EMA band 148 is located in the gap formed between the end 146 and the outer periphery of the base and inner sleeve 92 to facilitate welding.

The base and inner sleeve 92 are shown in fig. 7A-F, respectively. The base and inner housing 92 includes a bottom portion 150, an intermediate cylindrical portion 152 and a top portion 154. The top 154 includes a disk-shaped end cap 156, and the disk-shaped end cap 156 has an outlet 160 extending through the disk-shaped end cap 156. Three circumferentially spaced arcuate projections 162 surround the outlet 160 and serve to surround and position the outlet check ball 102. A ball seat 164 surrounds the perimeter of the outlet 160. The upper end of the cylindrical portion 152 includes a stepped portion 166, which stepped portion 166 is shaped to engage a corresponding portion (not shown) of the lamp assembly 24.

As best seen in fig. 6D, the base 150 includes a gasket groove 170 for receiving the filter block gasket 104, an inlet 172 surrounded by a ball seat 174, and three arcuate projections 176 that cooperate with one another and are circumferentially spaced from one another for guiding the inlet check ball 100. Referring to fig. 7A-D, three circumferentially spaced inclined scallops 178 and L-shaped gripping tangs 180 are formed on the base of the base 150 to allow the filter assembly 26 to be inserted into the inner housing 50. The angled scallops 178 help lift the filter assembly 26 away from the base assembly 22 when the filter assembly 26 is removed from the base assembly 22. A rectangular sense die clamping cavity 184 having an opening 186 therein is also formed in the base of bottom 150. Opening 186 is sized in such a way that sense die 112 can be secured in an interference or press fit. Sense die 112 is used to record information and transmit information to electronic assembly 66.

The filter threaded ring 94 includes external threads 192. The inner radial periphery of the filter threaded ring 94 is sized in such a way that it can mate with the outer diameter of the cylindrical portion 152 of the base and inner sleeve 92. As shown in fig. 6C and D, the filter threaded ring 94 is sonically welded (sonic) to the cylindrical portion 152 of the base and inner housing 92 adjacent the base 150.

The assembly process of the filter assembly 26 is as follows. The filter threaded ring 94 is placed on the base adjacent the bottom 150 and the cylindrical portion 152 of the inner housing 92. The filter threaded ring 94 is permanently attached to the cylindrical portion 152 using a sonic welding process. The inlet check ball 100 is disposed within the interfitting projections 176 and against the ball seat 174. Similarly, the outlet check ball 102 is disposed within the protrusion 162 and rests on the ball seat 164. The filter block gasket 104 is positioned within the filter block groove 170 of the base and bottom 150 of the inner housing 92. The base and cylindrical portion 152 of the inner sleeve 92 are then slid within the inner radial periphery of the filter block assembly 88. Such that the outlet check ball 102 is captured within the protrusion 162 and below the cup portion 140 of the upper end cap 108 of the filter assembly 26. The filter block assembly 88 is then threaded onto the filter threaded ring 94 and compressed against the gasket 104 between the filter block assembly 88 and the base and inner housing 92. The filter housing 96 is placed over the filter block assembly 88 and pressed against the base 150. The end portion 146 (emawedd) of the filter housing 96 is welded to the radially outer portion of the base 150 using an EMA band 148, thus forming the hermetically sealed pressure vessel or filter assembly 26. Sense die 112 is pressed into clamping cavity 184.

During operation of the WTS unit 20, water flows through the filter assembly 26 along the path shown by the arrows in fig. 6C-D. Water under pressure is introduced at the filter inlet 172 and lifts the inlet check ball 100 from its ball seat 174. (it should be noted that water cannot flow back from the filter assembly 26 through the inlet 172 of the filter because the inlet check ball 100 and ball seat 174 form a one-way check valve.) water fills the annular region formed below the bottom filter end cap 106 of the filter block assembly 88 and above the base and the bottom 150 of the inner housing 92. The water then flows upwardly to the annular region formed between the radially outer portion of the carbon block 90 and the interior of the filter housing 96. The water enters the radially outer periphery of the carbon block 90 and is filtered as it passes through the radially inner periphery of the carbon block 90. The water is then received in the annular space formed between the carbon blocks 90 and the cylindrical portion 152 of the base and inner sleeve 92. The water must then flow upwardly over the top 154 of the base and inner sleeve 92 and under the cover 136. The outlet check ball 102 is seated in the ball seat 164 and prevents water from flowing out of the filter assembly 26 unless the outlet check ball 102 is moved upward. As will be described later, this condition occurs only when the filter assembly 26 is properly positioned on the lamp assembly 24. When the filter assembly 26 is removed from the base assembly 22 and lifted from the lamp assembly 24, the outlet check ball 102 will be located within the ball seat 164 and water retained in the filter assembly 26 will remain within the filter assembly 26.

B. Lamp assembly

Fig. 8A-C show lamp assembly 24. Lamp assembly 24 includes a base assembly 72, a secondary winding 74, a base support assembly 76, a top support assembly 78, a pair of quartz sleeves 80, an ultraviolet bulb assembly 82, a condensing O-ring seal 84, and a pair of cooperating enclosure and reflector assemblies 86.

Fig. 9A-C illustrate the base assembly 72. The base assembly 72 includes a cup-shaped base 200, an outlet O-ring 202, an Oval seal 204, and a check ball 206. The base 200 has a cylindrical wall 210 and a bottom wall 212. An elliptical wall 214 extends upwardly from the bottom wall 212 and has an elliptical sealing step 216 on the outer surface of the elliptical wall 214. Located within the elliptical wall 214 is a bottom wall 220 with a pocket 222, the pocket 222 for receiving the check ball 206. The positioning groove 224 extends vertically along the inside of the cylindrical wall 210. Located on the cylindrical wall 210 is a light pipe pocket 226. The outlet 228 is formed in a hub 230 disposed below the bottom wall 212. A pair of L-shaped bayonet elements 232 are formed below bottom wall 212. The bayonet elements 232 are used to releasably secure the lamp assembly 24 to the outlet cup 58 when the WTS device 20 is assembled. A groove 234 is formed in the outside of the hub 230 to receive the outlet O-ring 202. The elliptical seal 204 abuts against an elliptical seal step 216.

Check ball 206 prevents water from flowing out of lamp assembly 24 when ultraviolet bulb assembly 24 is removed from base assembly 22. As best seen in fig. 37 and 38, the elliptical seal 204 is used to form a seal between the base assembly 72 and the base support assembly 76. An outlet O-ring 202 is used to form a seal between the base assembly 72 and the inside of the outlet cup 58.

The bottom support assembly 76 is shown in an exploded view in fig. 10A and an assembled view in fig. 10B-E. The bottom support 240 and bottom shield 242 cooperate to enclose a pair of seal rings 244 therein. Thermistor 246 is connected to bottom shield 242. As will be described in greater detail below, sensitive chip 250 and light pipe 252 are secured within bottom support assembly 76. Sense die 250 is in electrical communication with electronics assembly 66. Sense die 250 measures various operating parameters of lamp assembly 24. The light pipe 252 converts the ultraviolet light from within the lamp assembly 24 into visible light that can be sensed by the light sensors on the electronics assembly 66. Thermistor 246 is used to sense the temperature within lamp assembly 24. Alternatively, a separate temperature sensing circuit may be utilized to control the temperature within the WTS device. The WTS unit 20 will be automatically switched on to prevent the water inside the WTS unit 20 from freezing.

The bottom support 240 is shown in fig. 11A-C. The pair of bottom cups 260 each have an O-ring seat 262 for retaining the O-ring 244. A water outlet 264 is located at the bottom of each cup 260. A pair of rectangular bayonet openings 266 is used to secure secondary winding 74 under bottom support 240. Eight positioning ribs are formed on the outer periphery to position the bottom support 240 within the channel 224 of the base 200. A pair of U-shaped slots 270 and a pair of L-shaped slots 272 are located at the outer periphery of the bottom support 240. A bow-tie shaped support 274 is formed at the center of the bottom support 240 and is capable of functioning as an energy splitter when the bottom shield 242 is sonically welded to the bottom support 240. As best seen in FIG. 11C, an oval wall 276 is provided on the bottom of bottom support 240 and oval wall 276 is used to interface with oval wall 214 (FIG. 9A) of bottom assembly 72 and surround oval wall 214. A support structure 280 having a guide hole 282 is centrally located. Two pairs of long positioning ribs 284 and short positioning ribs 286 form a T-shaped structure. The free ends of ribs 284 and 286 and the ends of oval wall 276 serve to guide the inner radial circumference of secondary winding 74.

Bottom shields 242 are shown in fig. 12A-C, respectively. A pair of top cups 290 are positioned in such a manner that they oppose the bottom cup 260 on the bottom support 240 and that the O-ring seal 244 is sandwiched between the bottom cup 260 and the top cup 290. An opening 292 in each cup 290 is adapted to receive the lower end of the quartz sleeve 80 (fig. 8A). Six upwardly extending ribs 294 are arranged in a substantially elliptical manner to capture the lower end of the ultraviolet bulb assembly 82 (fig. 8A). Substantially rectangular cavity 296 is sized to receive the dovetail mount of light pipe 252 and sensitive chip 250 therein (FIG. 15B). The upper portion of the recessed well 296 is defined by four inwardly extending wedge-shaped ribs 300. The ribs 300 cooperate to secure the light pipe 252 in the dovetail bearing. The bottom of pocket 296 is formed by middle cross member 302 and end cross member 304. The wire openings 306 are formed in bosses 310 located on the opposite side of the pocket 296 from the bottom support 240. The wire opening 306 is adapted to receive the thermistor 246. Additionally, four triangular ribs 312 are formed on bottom shroud 240 and are used to position enclosure assembly 76. The underside 314 of the top cup 290 forms a seat for retaining the O-ring 244 (fig. 10A).

Secondary winding 74 is shown in fig. 13A. Windings 74 include a toroidal bobbin 320, toroidal bobbin 320 having a coil 326 wound thereon. The wire on coil 326 is wound 55 turns. The spool 320 includes a pair of diametrically spaced gripping tangs 322 and a pair of apertured bosses 324. A pair of wires 330 extend through the apertured bosses 324. The clamping tangs 322 are configured to be secured within the tang openings 266 (fig. 11A-C) in the bottom support 240 to secure the secondary winding 74 below the bottom support assembly 76 (fig. 8A).

A sense die 250 is shown in fig. 14. Sense die 250 has a main body 340, and main body 340 has a computer die 342 embedded or molded therein. The main body 340 includes a rectangular portion 344 and a wedge portion 346. The computer chip 342 is slid into the pocket 296 and maintains an interference fit between the rectangular portions 344, with the wedge portions 346 extending outwardly.

The light pipe 252 is shown in FIGS. 15A and B. The light pipe 252 includes a curvilinear portion 350 and a mounting block portion 352. A wedge-shaped dovetail portion 354 is on the outside of the mounting block 352. The wedge-shaped dovetails 354 engage the four wedge-shaped ribs 312 (fig. 12A-C) of the pocket 296 to securely fasten the light pipe 252 to the bottom shield 242. The curvilinear portion 350 includes a polished top surface 360, the top surface 360 capable of receiving ultraviolet light from within the lamp assembly 24. The ultraviolet light causes the light pipe 252 to fluoresce and emit visible light that is reflected and transmitted to the outer surface 362 of the light pipe 252. The curved inner surface 364 faces the bottom of the ultraviolet bulb assembly 82 and when the lamp assembly is in operation, the curved inner surface 364 actually receives substantially less ultraviolet light than the top surface 360. Light pipe 252 will be described in more detail later in connection with the operation of lamp assembly 24.

Fig. 16 is an exploded view of the top support assembly 78. The components of the top support assembly 78 include a top cover 366, a top shield 368, an inlet O-ring 370, and a pair of quartz O-rings 372. The top cover 366 and top shield 368 are shown in fig. 17 and 18, respectively. The top cover 366 has a disk-shaped body 374 with a button 376 extending upwardly from a top side of the disk-shaped body 374. When the filter assembly 26 is placed on the lamp assembly 24, the button 376 may be operated to unseat the outlet check ball 102 of the filter assembly 26. A flange 380 surrounds the outer periphery, the flange 380 having a groove 382 for receiving the inlet O-ring 370. A pair of top cups 384 are provided on the underside of the disk-shaped body 374. A sealing step 386 is formed in the top cup 384. An opening 388 extends through the top cover 366. The top shield 368 has a circular body 390 with a recess 392 formed in the circular body 390 that is adapted to mate with the top cup 384. A pair of openings 394 extend through the top shield 368. A quartz O-ring 372 is sandwiched between the top cup 384 and the groove 392 to provide a seal for the top support assembly 78 to seal around the quartz sleeve 80 during assembly of the lamp assembly 24.

Fig. 19 is an exploded view of lamp assembly 24. Figures 20A-B illustrate front and side views of the enclosure 400. Each enclosure and reflector assembly 86 includes an enclosure 400 and a reflector 402. Each enclosure 400 includes a curved central portion 404 connected between a pair of planar portions 405. On the bottom of each enclosure 400 is a pair of L-shaped gripping tangs 406. Along the longitudinal perimeter of each closure 400 is a flange 407, the flange 407 having a plurality of pins 408 and mating holes 410. When pressed together, closure 400 fits together and opposing pins 408 and holes 410 fit together in a interfitting fashion. At the top of enclosure 400 are opposing lower and upper flanges 412, 414, forming a lid receiving gap 416 between lower and upper flanges 412, 414. The gap 416 receives the top support assembly 78 when the lamp assembly 24 is assembled. A generally rectangular opening 420 is formed in the top of closure 400 to receive a portion of elastomeric O-ring seal 370. On the bottom of each enclosure 400 are an outer flange 422 and an inner flange 424. The inner flange 424 is configured to surround the bottom support assembly 76. The outer flange 422 is received by the base 200. The gripping tangs 406 are received into grooves on the inner surface of the base 200. The closure 400 has a plurality of ribs 426 spaced longitudinally from one another to increase structural strength.

Fig. 21A and B show an exemplary reflector 402. The reflector 402 is generally omega-shaped in cross-section, with the reflector 402 having a flange 430 and a central curved portion 432. The curved portion 432 includes a constant radius portion 434 and a converging radius portion 436. The constant radius portion 434 extends over an angle of about 90. The radius of curvature of central curvilinear portion 432 is constant. While the radius of curvature of the converging radius portion 436 decreases from the inflection point 438 to the flange 430.

As can be seen in fig. 22, this omega-shaped reflector 402 enhances the focusing or reflection of the ultraviolet light rays on the quartz sleeve 80 while minimizing the reflection or focusing of light rays on the bulb 440 of the ultraviolet bulb assembly 82. Light rays propagating from a point on the surface of the bulb 440 perpendicular or normal to the surface of the bulb 440 have the greatest angle of reflection at the converging radius portion 436 adjacent the flange 430, with the angle of reflection of normal light rays decreasing as one moves toward the inflection point 438. That is, the closer the portion of the bulb 440 is to the reflector 402, the greater the angle of reflection provided by the reflector 402, thereby helping to avoid the return of the orthogonal rays to the ultraviolet bulb assembly 82. Similarly, light striking the reflector 402 at an angle insufficient to directly eject the light onto the quartz sleeve 80 may strike other portions of the reflector 402 one or more times and subsequently strike the quartz sleeve 80 instead of striking the light bulb 440. Using these omega-shaped reflectors 402, an estimated 40% increase in the intensity of light striking the quartz sleeve directly or within 3 reflections or bouncing off the inner mirror surface is obtained over using reflectors that are completely circular in cross-section and surround the bulb 440. In a preferred embodiment, the reflector 402 is made of aluminum, and the interior of the reflector 402 is polished to enhance reflectivity. The reflector 402 should be made of a material that reflects light rays that are not absorbed in the ultraviolet range of the electromagnetic spectrum. Although the reflector 402 preferably has a substantially smooth and continuously curved inner surface, reflectors having facets may be used, as long as the facets enhance the redirection or focusing properties of the reflected light exiting the bulb 440 and directed toward the quartz sleeve 80.

Fig. 23A shows an ultraviolet bulb assembly 82. The ultraviolet bulb assembly 82 includes two side-by-side emission bulbs 440 with an upper passageway 442 between the bulbs 440 for gas to pass through. A pair of filaments 444 is electrically connected to a corresponding pair of lead wires 446. The lead 446 passes through a base 448 of the ultraviolet bulb assembly 82. Wire 436 is connected to secondary winding 74 to provide power to lamp assembly 24. The ultraviolet bulb assembly 82 is filled with a neon-argon (Ne-Ar) mixture, preferably mixed at a ratio of 99: 1. It is also envisioned that mixtures in the ratio of 50:50 to 99.5:0.5 may be used in the present invention. The bulb 440 may also be filled with mercury (Hg), which is in a solidified state at room temperature. Mercury (Hg) is vaporized during operation of the uv bulb assembly 82. A neon-argon mixture is used as a starter to help keep mercury (Hg) in a plasma state. The use of a neon-argon mixture gas can produce a higher instantaneous light output than conventional ultraviolet bulb assemblies that use gases such as argon in excess of 50%. The use of a neon-argon mixture provides greater overall stability at higher wall temperatures of the bulb 440 than found in conventional ultraviolet bulb assemblies. This is particularly important in cold weather or cold operating conditions, such as when cold water flows through the WTS unit 20. These features contribute to increased intensity and reduced start-up time as compared to previous ultraviolet bulb assemblies used in WTS devices.

The energy transferred from the filament 444 is directed upward to the arc, which passes through the passage 444 and then downward to the other filament 444. In this process, the gas is excited and light is generated. During cathode warm-up, the filament produces orange red ionization. When the neon-argon mixture starts to be excited, red light is generated. Finally, ionization of the neon-argon mixture forces the Hg to vaporize and produce ultraviolet light at a wavelength of 254 nanometers. The most effective at killing microorganisms passing through the quartz sleeve 80 of the lamp assembly 24 is the ultraviolet light.

The condensation O-ring 84 is used to prevent the ultraviolet bulb assembly 84 from contacting the quartz sleeve 80. The O-ring 84 also acts as a heat sink to transfer heat from the bulb 440 to the quartz sleeve 80, through which quartz sleeve 80 cooler water passes during operation of the WTS device 20. After the ultraviolet bulb assembly 82 begins to be energized and operated, the temperature of the portion of the bulb 440 in direct contact with the o-ring 84 is slightly lower than the temperature of the other portions of the bulb adjacent to that portion. Thus, whenever the lamp assembly 24 is turned off, the vaporized mercury plasma condenses within the bulb 440 adjacent the condensation O-ring 84. Without the condensing O-ring 84, more mercury would condense at the base of the lamp assembly 82 below the filament 444. It has been found that the lamp assembly 24 can be brought to a predetermined strength more quickly in the presence of the condensing O-ring 84 than in the absence of the condensing O-ring 24. This is because mercury condenses in the arc channel between the filaments 444, rather than below the filaments 444 and outside the arc channel.

Fig. 23B-D show the ultraviolet bulb assembly 82 operating under three experimental conditions. Fig. 24 shows the output of these components in graphical form. In the first case, the ultraviolet bulb assembly 82 is placed in an upright manner, as shown in fig. 23B, however without the condensation O-ring 84. In the second case, the ultraviolet bulb assembly 82 is placed in an inverted manner, as shown in fig. 23C, such that the condensed mercury falls to the end of the bulb 440 remote from the base 448. Also, there is no heat sink. Finally, as shown in fig. 23D, the ultraviolet bulb assembly 82 with the condensation O-ring 84 is placed in an upright manner, and the ultraviolet bulb assembly 82 has a brass rod serving as a heat sink for heat dissipation. The light intensity output of the ultraviolet light bulb assembly 82 in these experiments was recorded at two separate times t1 and t 2. These outputs are normalized with respect to the highest output recorded at time t 2.

As can be seen from the graph shown in fig. 24, for the third case where the ultraviolet bulb assembly 82 is bottom down and a heat sink is used, the highest normalized intensity of 1.0 is produced at time t 2. The second best result that occurs in the second embodiment, where the bottom is inverted or up and no heat sink is used, is to produce a normalized output that is 0.84 times that produced in the third case. Finally, in the first case where no heat sink is used and the ultraviolet bulb assembly 82 is placed in an upright manner, the ultraviolet bulb assembly 82 starts up the slowest, with an intensity of only 0.56 times the intensity that would be produced in the third case with the heat sink bottom down. Therefore, in the present invention, in the case where it is necessary to use the ultraviolet lamp unit 82 which can be started up virtually instantaneously and has strength, it is preferable to have the condensation O-ring 84. This rapid increase to maximum intensity allows the lamp assembly 24 to be operated intermittently and continuously while still being able to adequately kill microorganisms. Although not used in this embodiment, other auxiliary heat sinks may be used, such as aluminum foil wrapped around the O-ring 84.

The light pipe 252 will now be described in more detail. The light pipe 252 is preferably made of acrylic, model V826, which is substantially pure with 1% fluorescent green dye mixed therein. The green dye is a model number 60-3170 green dye sold by Uniform Color of Holland, Michigan. The dye is capable of fluorescing when exposed to ultraviolet light (e.g., light having a wavelength of 254 nanometers), thereby emitting visible light in the green range. It has been demonstrated that green provides very efficient light transmission through the light pipe 252, while other colors severely inhibit light transmission through the light pipe. For example, the blue light portion generated by the mercury in the ultraviolet lamp assembly 72 does pass through the light pipe 252 so that the light is visible from outside the WTS device 10 when the light pipe 252 is not illuminated by ultraviolet light. Thus, the user may know whether the lamp assembly 24 is operating in the presence of a blue light. However, this enables the intensity of blue light that can pass through the light pipe to be greatly reduced. Thus, the light sensor on the electronics assembly 66 primarily senses the intensity of visible light generated by the fluorescent light emitted by the ultraviolet light illuminating the light pipe 252 rather than sensing other visible light generated by the lamp assembly 24. Thus, the light pipe 252 functions almost the same as a bandpass filter.

Geometrically, the light pipe 252 has a forward curved inner surface 364 and a top surface 360. There is also a light emitting outer surface 362 at the end of the mounting block 352. Both the top surface 360 and the light emitting outer surface 362 are highly polished to readily receive or transmit light. As best seen in fig. 39, because the light pipe 252 is disposed adjacent the filament 444, a majority of the light entering the inner surface 364 comes from the filament region of the ultraviolet bulb assembly 82. The light emitted from the filament 444 is typically visible in the red range and is not readily transmitted through the light pipe 252. As shown in fig. 25C and 25F, the top surface 360 is slightly curved and slopes downward from the inner surface 364 toward the outer surface 362. This focuses the top surface 360 toward the middle portion of the specular reflector 402 and is also capable of receiving ultraviolet light primarily from the lamp assembly 24. When ultraviolet light illuminates the top surface 360, the dye in the light pipe 252 fluoresces and emits light in the green visible spectrum. As can be seen in FIG. 25F, the green visible light is reflected by the inner surface of the light pipe 252 and transmitted outward from the light emitting outer surface 362. It has been found that by using a green fluorescent dye in the light pipe 252, the intensity of the visible light output from the light pipe 252 is substantially linearly proportional to the ultraviolet light generated within the lamp assembly 24. Thus, the intensity of ultraviolet light in the lamp assembly 24 can be directly monitored by sensing the visible light emitted from the light emitting outer surface 362. If the output is not linear, a computer chip and look-up table may be used to establish a relationship between the output of light from the outer surface 362 and the intensity of ultraviolet light output by the lamp assembly 82. However, this additional requirement for the use of a computer chip and look-up table would greatly increase the complexity and cost of the monitoring circuitry. This method of detecting visible light rather than ultraviolet light can use an inexpensive visible light detector and acrylic light pipe without the need for more expensive ultraviolet light detectors and quartz windows or light pipes.

It is contemplated that the present invention is capable of monitoring the temperature of the lamp assembly 24 by monitoring the color output from the light pipe 252. When the ultraviolet bulb assembly 82 does not output ultraviolet light but only transmits visible light generated by a filament or a neon-argon gas mixture, very little intensity of light is output from the outer surface 362. The color may also be different from the normal output green when the light bulb assembly is operated at high intensity.

The assembly process of the lamp assembly 24 is as follows. The first step is to assemble the bottom support assembly 76. As can be seen in fig. 10A, an O-ring 244 is sandwiched between the bottom support 240 and the bottom shield 242. Sense die 250 is mounted in pocket 296 in a press fit and light pipe 252 is mounted over pocket 296 in a dovetail joint. The bottom support 240 and bottom shroud 242 are then sonically welded together. Referring to fig. 8A, secondary winding 74 is mounted to bayonet opening 266 on bottom support 240 using tang 322, with wire 330 extending outwardly from bottom support assembly 76. As shown in FIG. 16, the top support assembly 78 is then assembled and a quartz O-ring 372 is sandwiched between the top cover 366 and the top shield 368 to sonically weld the top cover 366 and the top shield 368 together. The O-ring seal 370 is secured in a groove 382 in the top cover 366.

The ultraviolet bulb assembly 82 is placed in the bulb receiving rib 294 of the bottom support assembly 76 while the wires 440 pass through the slots 270 and 272 of the bottom support 240. The quartz sleeve 80 is then pushed down into the sealing ring 244 of the base assembly 206. The condensation O-ring 84 is then slid down onto the top of the ultraviolet bulb assembly 82 to properly position the condensation O-ring 84 between the quartz sleeve 80 and the bulb 440. The top support assembly 78 is then placed over the quartz sleeve 80 while the quartz O-ring 372 is sealed around the sealed quartz sleeve 80.

The reflectors 402 are positioned within the respective enclosures 400 and the glue applied between the curved portions 404, 432 of the enclosures 400 and the enclosures 402. The first enclosure and reflector assembly 86 is placed horizontally in a fixture (not shown). The assembly consisting of the ultraviolet bulb assembly 82, the quartz sleeve 80, the bottom support assembly 76 and the top support assembly 78 is then placed in one half of the assembly 86. The other half of the closure and reflector assembly 86 is then placed over the first assembly 86 and the guide pins 408 are pressed into the mating holes 410. Two closure assemblies 86 are sonically welded together and flanges 407 are sonically welded together along each side of closure 400.

The base assembly 72 is then coupled to the base support assembly 76. The ball 206 is first inserted into the pocket 222 of the base 200. The foot assembly 72 is then mounted beneath the foot support assembly 76 with the light pipe 252 extending from the recess 226 of the foot assembly 72. Thus, when the ultraviolet light from the ultraviolet bulb assembly 82 impinges on the light pipe 252, the port sees green visible light from the exterior of the lamp assembly 24. The seal 204 forms a seal between the base 200 and the bottom support 240.

C. Base part

Fig. 26A-C are top, bottom, and exploded views of bottom shield assembly 60. The bottom shield assembly 60 includes the bottom shield 32, the inlet and outlet elbow assemblies 62, 64, four foot pads 582, a speaker screen 584, a receiver outlet cover 586, and a pair of C-clips 588. The C-shaped clips 588 secure the inlet and outlet elbow assemblies 62, 64 to the bottom shield 32. Inlet elbow assembly 62 and outlet elbow assembly 64 are comprised of inlet elbow 590, outlet elbow 592, O-ring 594, collet 596, and fitting 598.

The bottom shield 32 is shown in fig. 26C. Peripheral wall 602 is disposed adjacent to a recess 604 that surrounds a raised platform 606. The three threaded bosses 610 are adapted to receive threads for fixedly threading the inner sleeve 50 to the bottom shield 32. A pair of raised ribs 612 and four retaining ribs 614 are used to position the rear shroud 34 and the front shroud 36, the retaining ribs 614 extending between the peripheral wall 602 and the raised platform 606. Similarly, four raised cross ribs 616 are used to support the electronic components 66. Two locating bosses 620 are used to guide the mounting pins on the outlet cup 58. The inlet 622 and outlet 624 are sized so as to be able to receive the elbows 62 and 64 with a C-clip. Square opening 626 facilitates access to a receiver jack on electronics assembly 66. Arcuate portions 632 and 634 are formed on the underside of the bottom housing 32 to accommodate water inlet and outlet hoses (not shown) for delivering water to and from the WTS unit 20.

The electronic assembly 66 is shown in fig. 27A-F. The components of the electronics assembly 66 include a lower plate 648, an upper plate 650, a receiver jack 652, a primary winding 656, a sensitive sensor assembly 654, a power jack 660, a flow hall effect sensor 662, a VFD664, a speaker 666, and a magnetic sensor 668. The primary winding 656 is wound with 10 turns of wire. A clip 670 secures the VFD664 to the upper plate 650. The lower plate 648 has a pair of bosses through openings 672, an outlet 674 in which the sensor 662 is located, and an inlet 676. Boss pass through opening 672 allows passage of boss 610 on bottom shroud 32. The inlet 674 and outlet 676 ports provide for a passage of water in and out of the inner housing 50 and outlet cup assembly 56. The periphery of the lower plate 648 is formed so that it is supported by the stepped ribs 616 of the bottom shield 22. Sensitive sensor assembly 654 includes windings 674 and light sensor 6. Windings 674 are arranged so that windings 674 can communicate information to and power filter and lamp assembly sensitive chips 112 and 250. The light sensor 676 receives the visible light output from the light pipe 252. The magnet sensor 668 is mounted on the upper plate 650 for sensing when the top shield 40 and magnet 70 are properly mounted on the other portions of the bottom support 22.

28A-D, the outlet cup assembly 56 includes an outlet cup 58, an upper bearing 704, a flow regulator 706, a lower bearing 710, and a light pipe cup 712. The outlet cup 58 has a bottom wall 714, lower 716 and upper 720 sidewalls joined together by a step 722, and an upper flange 724. Referring to fig. 28B, a pair of retaining caps 726 are sonically welded to the bottom wall 714 to form a seal around an L-shaped opening 728 formed in the bottom wall 714. The opening 728 is adapted to receive the tang 232 on the bottom of the light assembly 24. Lower step 730 and upper step 732 are formed in portions of lower sidewall 716 and portions of upper sidewall 720. Steps 730 and 732 enable rotation of lamp tube 252 and cavity 296 when lamp assembly 24 is twisted to install and remove lamp assembly 24 relative to outlet cup assembly 56. Opening 734 in lower wall 716 allows lamp cup 712 to be mounted therein. When lamp assembly 24 is locked in place in outlet cup assembly 712, lamp tube 252 is aligned with opening 734 and lamp tube cup 712. As shown in fig. 41, the light cup 712 is aligned with the light sensor 676.

A conduit 736 depends downwardly from the bottom wall 714, the conduit 736 having a passage 738 through the conduit 736. A collar 740 is formed on the upper end of the conduit 736. The inside of the passage 738 has four longitudinally extending slots 742. Each of the upper bearing 704 and the lower bearing 710 has ribs (not shown) thereon that are received in the slots 742 to prevent the bearings 704 and 710 from rotating relative to the outlet cup 58. It should be noted that the upper bearing 704 has an upper tip and extends above the collar 740. When the lamp assembly 24 is installed on the outlet cup 58, the upper bearing 704 will unseat the check ball 206 left in the base 200 of the lamp assembly 24 to allow water to pass through the flow regulator 706 and then to the outlet elbow assembly 64. When the lamp assembly 24 is removed from the outlet cup 58, the check ball 206 will reseat itself in the ball seat and prevent water from escaping from the bottom of the lamp assembly 24.

The upper bearing 704 and the lower bearing 710 rotatably support the flow regulator 706, and the flow regulator 706 has a pair of spiral blades thereon. One magnetic chip is buried in one of the blades. As the flow regulator 706 rotates, the flow hall effect sensor 662 picks up the passing magnetic field generated by the magnetic chip, thereby sensing the flow rate of the WTS device 20. A pair of stepped alignment pins 744 are located on the underside of bottom wall 714, alignment pins 744 being formed such that alignment pins 744 are received in bosses 620 of bottom shroud 32. Notches 750 are formed in flange 724 to accommodate water delivery tubing on inner sleeve 50.

As best seen in FIG. 37, the inlet valve assembly 54 is mounted in the inner housing 50 and fluidly connects the inlet elbow assembly 62 of the bottom shield assembly 60 with the inlet 172 of the filter assembly 26. Fig. 29A-C illustrate the inlet valve assembly 54, respectively. The components of the inlet valve assembly 54 include an inlet valve housing 760, an inlet spring 762, an inlet check ball 764, an inlet biasing element 766, an inlet cup seal 768, and a pair of resilient O-ring seals 770. Inlet valve housing 760 has a pair of reduced diameter ends 772 and 774 for receiving O-ring seal 770. An internal bore 775 in the inlet valve housing 760 is stepped to include a seat 776 for receiving the end of the inlet spring 762. When the filter assembly 26 is installed on the inner housing 50, the inlet check ball 764 presses against the inlet spring 762 and is pressed by the inlet biasing element 766. When the filter assembly 26 is removed from the WTS device 20, the inlet check ball 764 is in a ball seat to prevent water from flowing through the inlet valve assembly 54 into the cavity left by the removal of the filter assembly 26. A pair of sealing strips 780 are formed on the outside of the inlet cup seal 768 to assist in forming a seal with the inner sleeve 50. The inlet biasing element 766 and the inlet cup seal 768 have interlocking ribs 784 and grooves 786 to prevent relative rotation between the inlet biasing element 766 and the inlet cup seal 768.

Fig. 30A-C show an inner sleeve 50 and three covers 52. Fig. 31A-D show the inner sleeve 50 welded together with the outlet cup assembly 56. The inner sleeve 50 has a circumferentially extending flange 804, the flange 804 extending around an upper periphery thereof. The inner sleeve 50 has a convex rear portion 806, the convex rear portion 806 curving downwardly to meet a lower front portion 808. A pair of spaced-apart, slotted clamping ribs 810 are formed on the front face of the front portion 808 to clamp the upper circuit board 650. Referring to fig. 30B and C, the bottom of the inner housing 50 includes three L-shaped clamping openings 812 for receiving the clamping tangs 180 on the filter assembly 26. There are three ramps 813 near the opening 812 that mate with corresponding ramped scallops 178 on the bottom of the filter assembly 26. The ramps 813 and scallops 178 facilitate the dropping and lifting of the filter assembly 26 as the filter assembly 26 is mounted to the inner housing 50 or removed from the inner housing 50. The caps 52 are welded under the respective grip openings 812 to seal the bottom of the inner sleeve 50 against leakage. A central opening 814 is formed in the bottom of the inner housing 50 to receive the outlet cup assembly 56. Three spacer struts 816 are circumferentially disposed about the bottom of the inner sleeve 50 in a spaced apart manner, and the spacer struts 816 are configured to interfit with the three bosses 610 to receive screws that secure the bottom shield 22 to the inner sleeve 50. The screw passes through boss 610 and screws into a hole 817 in spacer strut 816.

An inlet conduit 818 is formed in the bottom of the inner housing 50. As best seen in fig. 31D and 37, the tubing 818 includes a lower tubing portion 820, an upper tubing portion 822 and an intermediate neck portion 824. The lower conduit portion 820 receives the spring 762 and ball 764 of the inlet valve assembly 54, while the upper conduit portion 822 slidably retains the inlet biasing element 766 and the inlet cup seal 768. Step 726 surrounds central opening 814. Step 726 cooperates with flange 724 on outlet cup assembly 56 such that a sonic weld 730 may be formed between step 726 and flange 724.

Referring now to fig. 32A-C and 33A-C, the lens 42 and the front shield 36 are shown. The front shroud 36 is generally U-shaped and has a front 850 and a pair of rearwardly extending sides 852. A lens receiving opening 854 adapted to receive the underside and sides of the lens 42 is formed in the front face of the front portion 850. A pair of vertical slots 856 are located in the bottom of the front portion 850. Two pairs of hooked projections extend rearwardly along the inside of the side wall 852. A corresponding contoured ledge 862 is located atop the sidewall 852. As best seen in fig. 33C, the lens 42 interlocks with the lens receiving opening 854. Prior to assembly with other components, lens 42 is sonically welded to lens receiving opening 854 to form an assembly.

Rear shroud 34 is shown in fig. 35A-E. Rear shroud 34 includes a rear portion 902 and a pair of forwardly extending side portions 904. Two pairs of inner ribs 906 extend forward along the inner side of the side 904. At the front end of each rib 906 is a retaining groove 910, the retaining groove 910 being designed to releasably interfit with the hook-like projection 860 of the front shroud 36. A contoured and stepped top flange traverses the top of the aft shroud 34. Similarly, bottom flange 914 traverses the bottom of aft shroud 34 and is designed to be received within a groove in aft shroud 34. The power plug assembly 44 passes through a lower portion of the rear portion 902 and is retained by the lower portion of the rear portion 902.

Fig. 35A and B show the top shield 40, the magnet holder 68, and the magnet 70. Fig. 36A-D illustrate the top shield 40, respectively. The top shield 40 includes a front portion 940, a pair of side portions 942, a rear portion 944 and a top wall 946. The lower flange 948 extends around the lower perimeter of the top shield 40 and is configured to mate with the upper flanges of the rear and front shields 34, 36. An upper lens receiving opening 950 is formed that conforms to the upper contour of the lens 932. The magnet holder 68 is mounted adjacent the opening 950 and holds the magnet 70 adjacent the magnetic sensor 668 on the electronics assembly 66. When the top shield 40 is removed, the magnet 70 and sensor 668 are used to power down the WTS device 20.

D. Assembly and operation

The assembly process of the base portion 22 is as follows. The inner sleeve 50 is placed on top of a fixture (not shown). The cover 52 is sonically welded to the bottom of the inner housing 50 to form an inner housing assembly. The outlet cup assembly 56 is then assembled. The outlet cup 58 has a cap 726 sonically welded thereto. The upper and lower bearings 704, 706 and the flow regulator 706 are located within a channel 736 in the bottom of the outlet cup 58. Additionally, the light pipe cup 712 fits within the opening 734 of the outlet cup 58. The outlet cup assembly 56 is then placed within the bottom of the inner housing 50 and the flange 724 is welded to the inner housing 50 near the central opening 814 to form a weld 830. The inlet valve assembly 54 is then installed in the conduit 818 of the inner housing 50 as shown in fig. 29A-C and 37. The inlet valve housing 760, inlet spring 762 and inlet check ball 764 are placed into the lower conduit portion 820 of the conduit 818 and a seal is formed between the upper portion of the inlet valve housing 760 and the lower conduit portion 820 using an O-ring seal 770. The inlet cup seal 768 and the inlet biasing element 766 are placed within the neck 824 of the tubing 818 and seal within the tubing 818 with the seal ring 780.

The electronics assembly 66 is then coupled to the inner housing assembly. The lower plate 748 is placed onto the bottom of the outlet cup 58. The flange on the upper plate 650 is received within a slotted clamping rib 810 in the front of the inner housing 50. The lens 42 is sonically welded to the front shroud 36. The front and rear shrouds 36, 34 are then coupled to the inner sleeve 50. The VFD display 664 on the electronics assembly 66 is aligned with the lens 42.

Bottom shield assembly 60 is then assembled. With the inlet elbow assembly 62 and the outlet elbow assembly 64 secured to the bottom shroud 32. The bottom shield assembly 60 is placed over the electronics assembly 66 and the outlet cup assembly 58. The raised ribs 612 provide support for the lower plate 748. The inlet and outlet elbow assemblies 62, 64 receive the lower step 772 of the inlet valve housing 760 and the conduit 736 of the outlet cup 58, respectively. A stepped locating pin 744 passes through the lower plate 748 and is received in the locating boss 620 of the bottom shield 32. The two mounting bosses 610 pass through boss openings 672 in the lower plate 748. As can be seen in fig. 40 and 41, the third boss 610 passes outside the lower plate. The mounting bosses 610 mate with the mounting posts 816 on the inner housing 850. The assembly of the base portion 22 is completed with the exception of the top shield 40 by inserting three screws into the mounting bosses 610 and the screws into the openings 817 in the mounting struts 816 in a self-tapping manner to secure the bottom shield assembly 60 with the inner sleeve assembly, the rear shield 34 and the front shield 36.

The light assembly 24 is inserted and the clamping tangs 232 releasably engage the L-shaped clamping openings 726 of the outlet cup 58. In a similar manner, the filter assembly 26 is coaxially placed over the light assembly 24 and the clamping tangs 180 of the filter assembly 26 are inserted into the L-shaped clamping openings 812 in the inner housing 50. When the filter assembly 26 is installed, the filter assembly 26 rests on the inclined grooves.

The top shield 40 has a magnet mount 68 attached thereto. The magnet 70 is then placed into the magnet holder 68. The top shield 40 is placed over the filter assembly 26 and the top shield 40 is placed over the rear shield 34 and the front shield 36 to complete the assembly of the WTS unit 20. The magnet 70 is positioned near the magnetic sensor of the electronics assembly 66 to energize the WTS device 20.

Referring to fig. 37, water enters the outlet assembly 62 below the bottom shield 32 and passes through the inlet valve assembly 54. The inlet valve assembly 54 delivers water through the inner housing 50 to the inlet 172 of the filter assembly 26 and untreated water lifts the inlet ball 100 off its ball seat 174. Untreated water passes under the filter bottom end cap 106 and flows radially outward until it encounters the filter housing 96. The untreated water then passes upwardly into the filter housing 96 and radially outwardly of the filter block 90. The untreated water then passes radially inward through filter block 90 until it flows to the base and inner jacket 92. The water flows upward until it reaches the filter top end cap 108. Filtered water flows radially inwardly under the cap portion 136 of the filter end cap 108 and over the top 154 of the base and inner sleeve 92.

A button 376 on the top of the light assembly 24 enables the outlet check ball 102 to clear its ball seat 164 on the base and inner housing 92 when the light assembly 24 is installed in the filter assembly 26. Filtered water exits the filter assembly 26 through the outlet 160 of the filter assembly 26 and enters the lamp assembly 24 through the opening 388 in the top support assembly 78. The filtered water is irradiated with ultraviolet light emitted from the ultraviolet bulb assembly 82. The uv bulb assembly 82 is powered by the secondary winding 74 which receives power from the primary winding 656 of the electronics assembly 66. The ultraviolet light generated within the lamp assembly 24 illuminates the light pipe 252 and causes the fluorescent dye therein to fluoresce and produce visible light. Visible light emitted from the light pipe 252 passes through the light pipe cup 712 to the visible light sensor 676. It should be noted that filter sense die 112 and lamp sense die 250 are located proximate to sense sensor assembly 654.

Referring now to fig. 38, the filtered water is illuminated by the ultraviolet light emitted from the ultraviolet bulb assembly 82 until it reaches the bottom support assembly 76. The ultraviolet light reflected by the reflector 402 helps to increase the amount of light impinging on the quartz sleeve 80. The filtered and irradiated water passes through the openings 264 in the bottom support assembly 76 and is collected in the base 72. Since check ball 206 water does not exit the ball seat by the action of top bearing 704, the water is drained from lamp assembly 72 through outlet 228 in base 72. The water that has been sufficiently treated passes through and past the rotor or flow regulator 706. The hall effect sensor 662 picks up the passing magnetic field generated by rotating the flow regulator 706 to determine the flow rate through the WTS device 20. The treated water is then discharged from the WTS unit 20 through the outlet elbow assembly 60.

While in the foregoing this invention has been described in relation to certain preferred embodiments thereof, and certain details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that various changes may be made in the details described herein and that various modifications may be made without departing from the basic principles of the invention.

For example, instead of using a second water treatment device (such as a lamp assembly that emits ultraviolet light needed to kill microorganisms), other treatment devices may be used. Examples of such may include ozone generators, mineral addition distributors, ion exchangers, or equipment using hollow fiber media capable of treating water. These second water treatment devices are also desirably disposed in the cavity defined by the inner housing of the filter assembly. These second water treatment devices may also be inductively powered using a primary winding in a base portion that controls the operation of the water treatment system. In addition, the assembly of the valve and the seal may also be used to seal the second water treatment device in a similar manner as described above with respect to the base portion, the filter assembly and the lamp assembly.

Claims (7)

1. A lamp assembly, comprising:

a housing;

a bulb positioned within the housing to generate radiation;

a conduit adjacent the bulb, the conduit carrying fluid through the housing;

a reflector assembly adjacent the bulb, the reflector assembly including a central curvilinear portion including a constant radius portion and a converging radius portion having a decreasing radius of curvature, and the reflector assembly reflecting all light emitted from the bulb toward the conduit.

2. The lamp assembly of claim 1,

the reflector assembly includes a pair of reflectors that cooperate to enclose the conduit.

3. The lamp assembly of claim 2,

each pair of reflectors is elongated and has an omega-shaped cross-sectional shape with an opposing curved central portion and a pair of opposing flanges that mate with each other.

4. The lamp assembly of claim 1, further comprising:

a seat disposed at a lower portion of the lamp assembly, the seat being cup-shaped and including a check ball to prevent fluid from being expelled from the seat.

5. The lamp assembly of claim 1, further comprising:

a top end cap having an inlet.

6. The lamp assembly of claim 5,

the top end cap includes a button extending in a direction away from the bulb.

7. The lamp assembly of claim 1,

a pair of elongated and curvilinear enclosures surround the reflector assembly.