Abstract:
Disclosed herein are systems and methods for a lamp assembly having a novel design for fitting two or more tube-shaped lamps end-to-end. Such an end-to-end structure may be constructed for use inside a single protective sleeve, such as one constructed of transparent quartz in embodiments where the assembly is used in a decontamination reactor equipment. In exemplary embodiments, the lamps are securely coupled, or otherwise fastened or linked, together end-to-end using any appropriate means for ensuring the integrity and longevity of the connection between the ends of the lamps. The integrity of this end-to-end connection would prevail under any and all circumstances, such as shipping or otherwise moving the assembly, or under normal or abnormal operating conditions, or even in the event that any equipment in which the lamp assembly is used fails during its operation.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/037,620, filed on Mar. 18, 2008, and entitled “End-to-End Lamp Assembly,” which is commonly assigned with the present application and incorporated herein by reference for all purposes. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure relates generally to purification systems and methods, and more particularly to an end-to-end lamp assembly and method of manufacturing the same. 
       BACKGROUND 
       [0003]    Since almost all forms of life need water to survive, the improvement of water quality in decontamination systems has typically been a subject of significant interest. As a result, treatment systems and techniques for removing contaminants from contaminated fluids have been developed and refined over time. Prior approaches have included water treatment by applying various microorganisms, enzymes and nutrients for the microorganisms in water. Other approaches involve placing chemicals in the contaminated fluids, such as chlorine, in an effort to decontaminate supplies. Some such systems have proved to be somewhat successful; however, sever deficiencies in each approach may still be prominent. 
         [0004]    Some more advanced treatment systems and techniques include treatments using a photolytic or a photocatalytic process. Common photocatalytic treatment methods typically make use of a technique by which a photocatalyst is bonded to contaminants in order to destroy such biomaterials. Specifically, photocatalytic reactions are caused by irradiating, such as by ultraviolet light, on the fixed photocatalyst so as to activate it. Resulting photocatalytic reactions bring about destruction of contaminants, such as volatile organic contaminants or other biologically harmful compounds that are in close proximity to the activated photocatalyst. 
         [0005]    This irradiation may be provided by a lamp assembly in which a tubular lamp, protected by a transparent sleeve, is inserted in a cell of a photocatalytic reactor to irradiate contaminated fluid passing through that cell. Such a lamp assembly and photocatalytic reactor may be seen in U.S. Pat. No. 5,554,300 and U.S. Published Patent Application No. 2005/0211641, both of which are commonly assigned with the present disclosure and incorporated herein by reference in their entirety for all purposes. Unfortunately, even the advanced lamp assembly designs used with such system can prove to be bulky and complex in wiring, adding to both the size of the photocatalytic equipment, as well as to the overall cost of manufacturing such a system. Accordingly, what is need is a advantageous lamp assembly design that may be used with such photocatalytic equipment, that improves the efficiency in both operation and manufacturing of the overall system. 
       SUMMARY 
       [0006]    Systems and methods constructed and operated in accordance with the principles disclosed herein provide a novel design for fitting two or more tube-shaped lamps end-to-end. Such an end-to-end structure may be constructed for use inside a single protective sleeve, such as one constructed of transparent quartz in embodiments where the assembly is used in a decontamination reactor equipment. In exemplary embodiments, the lamps are securely coupled, or otherwise fastened or linked, together end-to-end using any appropriate means for ensuring the integrity and longevity of the connection between the ends of the lamps. The integrity of this end-to-end connection would prevail under any and all circumstances, such as shipping or otherwise moving the assembly, or under normal or abnormal operating conditions, or even in the event that any equipment in which the lamp assembly is used fails during its operation. 
         [0007]    In one aspect, a multiple lamp assembly is provided. In one embodiment, the lamp assembly comprises a first lamp and a second lamp, as well as a first connector on a near end of the first lamp having first and second power terminals for electrical connection to separate first and second power lines, and having a neutral terminal for electrical connection to a ground line. In addition, the assembly may comprise a second connector on a far end of the first lamp and having a second power terminal for electrical connection only to the second power line, and having a neutral terminal for electrical connection to the ground line. In some embodiments, the assembly may also contain a jumper wire electrically bypassing the second power line around the first lamp from the first connector to the second connector. Still further, the assembly may include a third connector on a near end of the second lamp having a second power terminal for electrical connection to the second power terminal of the second connector, and having a neutral terminal for electrical connection to the neutral terminal of the second connector, wherein the third connector physically couples to the second connector to couple the first and second lamps end-to-end. Also in such embodiments, a protective sleeve hermetically sealing the first and second lamps and the connectors may be provided. 
         [0008]    In another aspect, a lighting system is provided. In one embodiment, the lighting system comprises an electrical ballast providing separate first and second power lines and a ground line. In addition, the system may include a housing with an electrical receptacle providing the first and second power lines and the ground line, as well as a tubular lamp assembly having a mount on one end for suspending the assembly from the one end. In certain embodiments, the lamp assembly may comprise tubular first and second lamps, as well as a first connector on a near end of the first lamp having first and second power terminals for electrical connection to the first and second power lines, and having a neutral terminal for electrical connection to the ground line. The lamp assembly may also include a second connector on a far end of the first lamp and having a second power terminal for electrical connection only to the second power line, and having a neutral terminal for electrical connection to the ground line. A jumper wire electrically bypassing the second power line around the first lamp from the first connector to the second connector may also be provided, wherein the jumper wire is disposed on an external surface of the first lamp. Also, the lamp assembly may provide a third connector on a near end of the second lamp having a second power terminal for electrical connection to the second power terminal of the second connector, and having a neutral terminal for electrical connection to the neutral terminal of the second connector, wherein the third connector physically couples to the second connector to couple the first and second lamps end-to-end. The lamp assembly may also include a protective sleeve connected to the mount and hermetically sealing the first and second lamps and the connectors. Finally, the lighting system may include an electrical coupling configured to electrically connect the mount to the electrical receiver on the housing. 
         [0009]    In yet another aspect, a method of manufacturing a lamp assembly is provided. In one embodiment, the method comprises electrically connecting first and second power terminals of a first connector on a near end of a first lamp to separate first and second power lines, and electrically connecting a neutral terminal of the first connector to a ground line. The method may also include electrically connecting a second power terminal of a second connector on a far end of the first lamp to only the second power line, and electrically connecting a neutral terminal of the second connector to the ground line. Still further, such a method may include electrically bypassing the second power line around the first lamp from the first connector to the second connector. Also, the method may provide for electrically connecting a second power terminal of a third connector on a near end of the second lamp to the second power terminal of the second connector, and electrically connecting a neutral terminal of the third connector to the neutral terminal of the second connector. Additionally, in such embodiments, the method may also comprise physically coupling the third connector to the second connector to couple the first and second lamps end-to-end. Then, such a method could include connecting a protective sleeve to a mount configured to suspend the assembly from one end to hermetically seal the first and second lamps and the connectors, the mount providing the first and second power lines and the ground line to the first connector. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    Embodiments are illustrated herein by way of example in the accompanying figures, in which like reference numbers indicate similar parts, and in which: 
           [0011]      FIG. 1  illustrates one embodiment of an end-to-end lamp assembly constructed according to the principles disclosed herein; 
           [0012]      FIG. 2  illustrates an isometric view of an embodiment of the end-to-end lamp assembly disclosed herein similar to the assembly shown in  FIG. 1 ; 
           [0013]      FIG. 2A  illustrates a close-up view of the joint between the inside and outside lamps created by the second and third connectors; 
           [0014]      FIG. 3A  illustrates a detailed view of the near end of the embodiment of an end-to-end lamp assembly shown in  FIGS. 2 and 2A ; 
           [0015]      FIG. 3B  illustrates a detailed view of the middle section of the embodiment of an end-to-end lamp assembly shown in  FIGS. 2 and 2A ; 
           [0016]      FIG. 3A  illustrates a detailed view of the far end of the embodiment of an end-to-end lamp assembly shown in  FIGS. 2 and 2A ; and 
           [0017]      FIG. 4  illustrates isometric views of the near and far ends of the inside lamp depicted in the assembly of  FIGS. 2 and 2A . 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The present disclosure provides a novel design for fitting two lamps end-to-end. Such an end-to-end structure may be constructed for use inside a single protective sleeve and held from only one end, such as for use in reactors found in decontamination equipment. Looking initially at  FIG. 1 , illustrated is one embodiment of an end-to-end lamp assembly  100  constructed according to the principles disclosed herein. The disclosed end-to-end lamp assembly  100  includes two lamps  105 ,  105  in a single assembly to be powered from only one end of the end-to-end lamps  105 ,  110  by a single electrical ballast  115 . In exemplary embodiments, these lamps  105 ,  110  may be ultraviolet (UV) lamps, but other types of lamps  105 ,  110  may also be employed. 
         [0019]    In an advantageous embodiment, the near end of the inside lamp  105 , which is the lamp  105  closest to the ballast  115 , would first be plugged into the ballast  115  in a normal manner. For example, this near end may have a four-terminal connector  120 , and the ballast  115  has a receiving connector, such a Gaynor connector (not illustrated). The far end of the inside lamp  105  could also include a four-terminal connector  125 . The outside lamp  110 , which is the lamp  110  furthest from the ballast  115 , may also include a four-terminal connector  130  on its near end. Of course, for either or both lamps  105 ,  110 , different types or numbers of connectors or terminals may also be employed, so long as the power relay around the inside lamp  105  as discussed below is provided. Accordingly, although the terminals on the connectors are illustrated as pins or pin receivers, other shapes and types of terminals and connectors may be employed without departing from the spirit and scope of the present disclosure. 
         [0020]    The four-terminal connectors  120 ,  125 ,  130  illustrated in  FIG. 1  may be provided as two power or “line” terminals (denoted L 1  and L 2  in  FIG. 1 ) and two neutral terminals (denoted N in  FIG. 1 ). In addition, the neutral terminals N in each connector  120 ,  125 ,  130  may be electrically connected together, while the line terminals in the second and third connectors  125 ,  130  may be likewise electrically connected. However, the line terminals in the first connector  120  are electrically isolated, with one line terminal L 1  electrically connected to a first power line P 1  from the ballast  115 , and the other line terminal L 2  electrically connected to a second power line P 2  from the ballast  115 . The neutral terminals on the first connector  120  are thus electrically connected to a ground line from the ballast  115 . 
         [0021]    Continuing with  FIG. 1 , the first power line L 1  and the neutral line N are electrically connected to two electrical connections  135  of the inside lamp  105 . These two connections  135  power a filament on the near end of the inside lamp  105  and are jumpered around the outside casing of this lamp  105  to a filament at its far end in order to provide the power to cause the inside lamp  105  to illuminate. The electrical connections  140  and filaments for the outside lamp  110  are similarly wired. Thus, each of the lamps  105 ,  110  may include electrical connections  135 ,  140  jumpered on the outside of their casings, however, it should be noted that such an electrical layout is not required. In other embodiments, the lamps  105 ,  110  may be provided with different means for providing electricity to both ends of the lamps  105 ,  110 . 
         [0022]    In accordance with the disclosed principles, the outside lamp  110  is electrically connected to the inside lamp  105  to receive its power, rather than being directly connected to the ballast  115 . More specifically, as discussed above, the second power line P 2  from the ballast  115  is connected to the second power terminal L 2  in the first connector  120  at the near end of the inside lamp  105 . The second power line P 2  may then be jumpered around the inside lamp  105  via an electrical jumper wire  145  to one of the two power terminals L 1 , L 2  of the second connector  125  located at the far end of the inside lamp  105 . In addition, the ground connection is also provided to the neutral terminals N of the second connector  125 . By providing the second power line P 2  and a ground connection N to the second connector  125  fixed on the far end of the inside lamp  105 , the near end of the outside lamp  110  can then receive its power directly from the second connector  125 . 
         [0023]    To seal and protect the lamps  105 ,  110  and all of the electrical connections in the assembly  100 , a protective sleeve  145 , such as a transparent sleeve, may be provided for the assembly  100 . In embodiments employing a transparent sleeve  145 , the end-to-end lamp assembly  100  is ideal for use in the reactors found in some types of decontamination/purification equipment. For example, a photocatalytic reactor like the ones found in U.S. patent and pending U.S. patent application cited above, would benefit from a lamp assembly  100  constructed as disclosed herein. 
         [0024]    Turning to  FIG. 2 , illustrated is an isometric view of an embodiment of the end-to-end lamp assembly  200  disclosed herein similar to the assembly  100  shown in  FIG. 1 . The assembly  200  in  FIG. 1  also includes inside and outside lamps  205 ,  210 , which are again protected within a sleeve  245 . In addition, this embodiment of the assembly  200  includes the inside and outside lamps  205 ,  210  interconnected using first, second and third electrical connectors  220 ,  205 ,  230 . 
         [0025]    As before, the first connector  220  is located at the near end of the inside lamp  205 , the second connector  225  is located at the far end of the inside lamp  205 , and the third connector  230  is located at the near of the outside lamp  210 .  FIG. 2A  provides a close-up view of the joint between the inside and outside lamps  205 ,  210  created by the second and third connectors  225 ,  230 . As illustrated, the second connector  225 , located on the far end of the inside lamp  205 , may comprise four female terminals  255 , while the third connector  230 , located on the near end of the outside lamp  210 , may include four male terminals  260  configured to be plugged into the four female terminals  255  on the second connector  225 . 
         [0026]    As with the assembly  100  in  FIG. 1 , the four-terminal connectors  225 ,  230  illustrated in  FIG. 2A  may be provided as two power or “line” terminals (denoted L 1  and L 2  in  FIG. 1 ) and two neutral terminals (denoted N in  FIG. 1 ). As described above, the line terminals in the second connector  225  provide electricity from second power line P 2  of the ballast  115 , which is distinct from the first power line P 1  provided to operate the inside lamp  205 . The electricity from the second power line P 2  is then provided to the outside lamp  210  via one or both of the male line terminals in the third connector  230 . Also, the neutral terminals on the second connector  225  are electrically connected to the ground line from the inside lamp  205 , and that electrical ground is also provided to the outside lamp  210  via male neutral terminals on the third connector  230  when the outside lamp  210  is plugged into the inside lamp  205 . 
         [0027]    As a result of the disclosed electrical interconnection of the inside and outside lamps  205 ,  210 , the tubular lamps  205 ,  210  are physically connected to each other in series, or end-to-end, while these same lamps  205 ,  210  are each separately electrically connected using the jumper wire ( 145  in  FIG. 1 ) to bypass the inside lamp  205 . In advantageous embodiments, the ballast  115  may provide only a single output power, but this type of interconnection allows multiple lamps to be powered by that single output power in parallel. By being electrically connected in parallel, each lamp  205 ,  210  would thus operate with the same voltage while still being physically connected in “series” to one another. As a result, the disclosed assembly may take advantage of an in-line physical layout for multiple lamps, while maintaining the advantages of a parallel electrical configuration. Additionally, in embodiments where more than two lamps  205 ,  210  are employed, the second power line P 2  is provided to lamp  210  via only one of the line terminals in the second and third connectors  225 ,  230 , while a third power line (not illustrated) may be provided around both of the illustrated lamps  205 ,  210  to a third lamp (not illustrated). 
         [0028]    Among the other advantages a lamp assembly constructed according to the disclosed principles provides is that this unique design allows two or more lamps to be encased in a single protective sleeve, without additional wires or seals or process connections, thus reducing manufacturing costs. By connecting two or more lamps end-to-end, 50% less (or greater with more lamps in series) of the total number of protective sleeves, lamp plugs, seal, wiring harnesses, etc. are needed tubes thus, increasing the packing density of the equipment employing the lamp assembly. Also, by increasing the packing density, the overall footprint of the equipment may be reduced. Furthermore, the disclosed principles may reduce the complexity of the overall assembly, as well as the time required for assembly since there are less connections and quality control inspections to be performed. A reduction in the amount of time required for maintenance activities may also be realized. In sum, all of these advantages may come together to help improve the overall cost of the equipment by employing an assembly as disclosed herein that improves the efficiency in both operation and manufacturing of the overall system. 
         [0029]      FIGS. 3A-3C  illustrate multiple detailed views of the near end, middle, and far end of the embodiment of an end-to-end lamp assembly  200  shown in  FIGS. 2 and 2A . As discussed above, this assembly  200  employs inside and outside lamps  205 ,  210  physically connected end-to-end in series, while each is powered by distinct power lines. To seal and protect the lamps  205 ,  210  and all of the electrical connections in the assembly  200 , the protective sleeve  245  is provided over the components of the assembly  200 . 
         [0030]    In this embodiment, the two lamps  210 ,  220  are coupled together with male electrical terminals in the third connector  230  plugging in to female terminals in the second conductor  225  (see  FIG. 2B ). The coupling of these two connectors  225 ,  230  provides the electrical connection from the ballast  115  to the outside lamp  210 . Specifically, the jumper wire  245  is provided from the second power line P 2  of the ballast  115  to a line terminal in the second connector  225  at the far end of the inside lamp  205 . That line terminal is then electrically coupled to a line terminal of the third connector  230 , and thus the electricity from the second power line P 2  bypasses the inside lamp  205  and provided to the outside lamp  210 . As shown in  FIG. 3C , the lamps  205 ,  210  may also include external wires  240  provided down the outside casing of the lamps  205 ,  210  to provide electricity at both ends of the lamps  205 ,  210 . As mentioned above, however, different wiring for each illuminating lamp  205 ,  210  individually may also be provided instead of external return wires  240 . 
         [0031]    In addition, looking at  FIG. 3A  in combination with  FIG. 4 , which illustrates views of the near and far ends of the inside lamp  205 , the first connector unit  220  may also include four male terminals  265  (see  FIG. 4 ) extending from the near end of the inside lamp  205 . These terminals  265  on the near end of the inside lamp  205  may be configured to plug into receiving terminals electrically connected to the ballast  115 . These receiving terminals may be provided in a standard Gaynor connector  270 , but of course any type of connecter configured to receive the terminals  265  of the first connector  225  may be employed. The Gaynor connector  270  may then be coupled to a mount  275  configured to receive and secure the protective sleeve  250  in place. This mount  275  could be constructed to house the ballast  115  inside, or could include an electrical connector  280  of its own that is electrically coupled to the ballast  115 . In addition to the benefits of the disclosed assembly  200  discussed above, such a construction allows the lamps  210 ,  220  to be powered from only one end, which then further allows the entire assembly to be held from only one end. Accordingly, an assembly  200  constructed according to the principles of the present disclosure is capable of being inserted into other fixtures for use in various types of machinery, when being attached and powered for only the exposed end. 
         [0032]    While various embodiments in accordance with the disclosed principles have been described above, it should be understood that they have been presented by way of example only, and are not limiting. Thus, the breadth and scope of the invention(s) should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the claims and their equivalents issuing from this disclosure. Furthermore, the above advantages and features are provided in described embodiments, but shall not limit the application of such issued claims to processes and structures accomplishing any or all of the above advantages. 
         [0033]    Additionally, the section headings herein are provided for consistency with the suggestions under 37 C.F.R. 1.77 or otherwise to provide organizational cues. These headings shall not limit or characterize the invention(s) set out in any claims that may issue from this disclosure. Specifically and by way of example, although the headings refer to a “Technical Field,” such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not to be construed as an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Brief Summary” to be considered as a characterization of the invention(s) set forth in issued claims. Furthermore, any reference in this disclosure to “invention” in the singular should not be used to argue that there is only a single point of novelty in this disclosure. Multiple inventions may be set forth according to the limitations of the multiple claims issuing from this disclosure, and such claims accordingly define the invention(s), and their equivalents, that are protected thereby. In all instances, the scope of such claims shall be considered on their own merits in light of this disclosure, but should not be constrained by the headings herein.