US20050023211A1 - Composite filter medium and fluid filters containing same - Google Patents
Composite filter medium and fluid filters containing same Download PDFInfo
- Publication number
- US20050023211A1 US20050023211A1 US10/924,066 US92406604A US2005023211A1 US 20050023211 A1 US20050023211 A1 US 20050023211A1 US 92406604 A US92406604 A US 92406604A US 2005023211 A1 US2005023211 A1 US 2005023211A1
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- Prior art keywords
- filter
- filter medium
- adsorbent
- fluid
- web substrate
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/001—Processes for the treatment of water whereby the filtration technique is of importance
- C02F1/003—Processes for the treatment of water whereby the filtration technique is of importance using household-type filters for producing potable water, e.g. pitchers, bottles, faucet mounted devices
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
- B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
- B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28002—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their physical properties
- B01J20/28004—Sorbent size or size distribution, e.g. particle size
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28023—Fibres or filaments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28028—Particles immobilised within fibres or filaments
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/2803—Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28033—Membrane, sheet, cloth, pad, lamellar or mat
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28052—Several layers of identical or different sorbents stacked in a housing, e.g. in a column
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28054—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their surface properties or porosity
- B01J20/28078—Pore diameter
- B01J20/28085—Pore diameter being more than 50 nm, i.e. macropores
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/28—Treatment of water, waste water, or sewage by sorption
- C02F1/281—Treatment of water, waste water, or sewage by sorption using inorganic sorbents
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- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/28—Treatment of water, waste water, or sewage by sorption
- C02F1/283—Treatment of water, waste water, or sewage by sorption using coal, charred products, or inorganic mixtures containing them
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/42—Treatment of water, waste water, or sewage by ion-exchange
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/44—Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis
- C02F1/444—Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis by ultrafiltration or microfiltration
-
- C—CHEMISTRY; METALLURGY
- C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
- C02F2307/00—Location of water treatment or water treatment device
- C02F2307/04—Location of water treatment or water treatment device as part of a pitcher or jug
Definitions
- the present invention relates to filters and filter media. More particularly, the present invention relates to a composite filter media for filtering contaminants from a fluid and fluid filters containing the composite filter medium.
- Fluids such as liquids or gases, typically contain contaminants which include particulates, chemicals, and organisms. In many cases, it is desirable to remove some or all of such contaminants from the fluid. Usually, contaminants are removed from a fluid supply by passing the fluid through a filter whereby the contaminants are separated from the filtered fluid or filtrate.
- Water is probably the most highly filtered fluid as it is filtered in industrial processes as well as in the household. Purification of water to produce potable water often requires the simultaneous reduction of particulate contaminants, dissolved organic chemicals and inorganic heavy metals. Particulate contaminants may include dirt, rust, silt, and other particles as well as potentially hazardous microorganisms such as chlorine resistant protozoan cysts, such as Cryptosporidium Parvum or Giardia , or bacteria such as Cholera and E. coli .
- Organic chemicals may include those that contribute to taste and odor as well as potentially toxic pesticides, chlorinated hydrocarbons, and other synthetic organic chemicals. Free chlorine reduction is also a major objective when the residual concentration of this disinfectant is sufficiently high to cause a bad taste.
- the most common heavy metal found in domestic water is lead derived from brass fixtures, leaded solder, lead pipes or other sources. Other heavy metals often found in drinking water include copper, zinc, manganese and iron.
- the most common household water filters are typically small trapezoidal shaped plastic containers filled with a loose adsorbent medium such as activated carbon, ion exchange resins or zeolites. Water is filtered by such water filters by passing it through the loose adsorbent medium in an axial direction from a wider to a narrower portion of the trapezoidal container.
- a loose adsorbent medium such as activated carbon, ion exchange resins or zeolites.
- the trapezoidal shaped filter element is often used in a carafe and when used in a carafe is typically called a gravity-flow carafe filter.
- Such filters are typically installed within a household carafe having an upper reservoir, a lower reservoir and a filter receptacle fitted at the bottom of the upper reservoir.
- the trapezoidal shaped filter element is installed in the carafe by wedging it into the receptacle so as to effect a seal between the two reservoirs. Water passing from the upper reservoir to the lower reservoir must pass through the filter element. Typically, water enters the filter element through a series of small perforations at the wider top of the trapezoid.
- one or more non-woven pads functioning as a fines filter, may be installed at the bottom, top or both bottom and top of the filter element to prevent the release of fine particles from the adsorbent bed.
- the flow rate through present day gravity-flow carafe filters as described above is generally slow, typically about 200 ml per minute for a filter loaded with 100 grams of mixed wet resin-carbon filter medium containing water in an amount of about 30 to 35 percent by weight.
- the slow flow rate occurs because: (1) the water must traverse a deep bed of adsorbent particles; (2) the filter operates in a low pressure environment—only the pressure of the overlying water in the upper reservoir, typically several inches of water, is available to force the water through the filter; and (3) the size of the adsorbent particles are limited. Excessively large particles that would permit faster flow rates, would also have slower adsorption kinetics. This forces the use of relatively small particles (about 35 mesh) having faster adsorption kinetics but greater flow restriction. In view of the above constraints, a liter of water normally takes about 5 to 10 minutes or more to process through the present day carafe filter.
- the foregoing primary objective is realized by providing a low flow resistance composite filter medium for removing at least 99.95 percent of particulates of a size in the 3 to 4 micron range and dissolved chemical contaminants from a fluid comprising an adsorbent layer containing an adsorbent agent and a hydrophilic particulate intercepting layer disposed adjacent to the adsorbent layer.
- the composite medium has a mean flow pore diameter of about 1 to 10 microns, a bubble point of about 3 to 15 microns and an air permeability of about 0.5 to 7 liters per minute/cm 2 with a pressure drop of about 0.1 bar.
- FIG. 1A which is a sectional view of a first embodiment of the composite filter medium of the present invention
- FIG. 1B which is a sectional view of a second embodiment of the composite filter medium of the present invention.
- FIG. 1C which is a sectional view of a third embodiment of the composite filter medium of the present invention.
- FIG. 1D which is a sectional view of a fourth embodiment of the composite filter medium of the present invention.
- FIG. 1E which is a sectional view of a fourth embodiment of the composite filter medium of the present invention.
- FIG. 1F which is a sectional view of a fourth embodiment of the composite filter medium of the present invention.
- FIG. 2A which is an isometric view of a flat sheet filter
- FIG. 2B which is a partial cross-sectional view of the filter illustrated in FIG. 2A ;
- FIG. 3A which is an isometric view of a basic cylindrical pleated filter
- FIG. 3B which is an axial cross-sectional view of the filter illustrated in FIG. 3A ;
- FIG. 4A which is a partially cut away isometric view of a basic spiral wound filter
- FIG. 4B which is a cross-sectional view of a flow through filter medium configuration for the filter illustrated in FIG. 4A ;
- FIG. 4C which is a cross-sectional view of a tangential flow filter medium configuration for the filter illustrated in FIG. 4A ;
- FIG. 5A which is a cutaway perspective view of a pleated fluid filter employing the composite filter medium of the present invention
- FIG. 5B which is a top plan view of the filter illustrated in FIG. 5A ;
- FIG. 5C which is a cross-sectional view of the pleated filter illustrated in FIG. 5B , taken along the line 5 C- 5 C;
- FIG. 5D which is an end view of the filter illustrated in FIG. 5A showing the outlet end panel
- FIG. 5E which is a partial cross-sectional view illustrating the edges of the pleated filter medium joined together by insert molding in a frame;
- FIG. 5F which is partial cross-sectional view illustrating the edges of the pleated filter medium joined together by a hot-melt adhesive
- FIG. 6 which is a partial perspective view of a drainage directing support member
- FIG. 7 which is a cross-sectional view of a carafe containing the filter of the illustrated in FIGS. 5A through 5F .
- FIGS. 1A through 1F illustrate several embodiments of the composite filter medium 10 of the present invention useful for removing contaminants from a fluid, which generally comprises an adsorbent layer 11 and a hydrophilic particulate intercepting layer 19 .
- the adsorbent layer 11 comprises an adsorbent supporting web substrate 12 having a front surface 14 and a back surface 15 . At least a portion of the front surface 14 is coated with adsorbent particles 16 and binder particles 18 which are fused to the front surface 14 and to the adsorbent particles 16 .
- the coating on the adsorbent supporting web substrate 12 is obtained according to a method which is described in co-pending U.S. patent application Ser. No.
- the coating is obtained by preparing a mixture of adsorbent particles and binder particles.
- the binder particles Preferably, the binder particles have an average particle size not exceeding approximately 80 microns.
- the mixture is applied to part or all of the front surface 14 of the adsorbent supporting web substrate 12 to produce a loose powder coating on the front surface.
- the loose powder coating is heated to at least the Vicat softening temperature of the binder particles but below the melting temperature of the adsorbent supporting substrate 12 and the adsorbent particles to form softened binder particles 18 .
- Pressure is applied to the web substrate 12 to cause the softened binder particles 18 to fuse with the adsorbent particles 16 and to the adsorbent supporting web substrate 12 .
- the hydrophilic particulate intercepting layer 19 in the embodiment shown in FIG. 1A comprises a fiber supporting web substrate 20 having a front surface 21 positioned adjacent to the adsorbent supporting web substrate 12 such that its front surface faces the back surface of the adsorbent supporting web substrate.
- a mixture of glass micro fibers 22 and an FDA approved epoxy binder resin (not shown) is positioned between the back side 15 of the adsorbent supporting web substrate 12 and the front side 21 of the fiber supporting 20 web substrates.
- the glass fibers and binder resin may be adhered to one or both of the web substrates 12 , 20 with a hot melt adhesive, if desired, and the resin is preferably treated to obtain a hydrophilic character.
- hydrophilic character of the particulate intercepting layer may be obtained in a number of ways including: adding surface active agents to the resin, glass micro fibers or supporting web substrates; post-treating the resulting composite medium to provide a surfactant on its surfaces; or using intrinsically hydrophilic materials, such as Nylon micro fibers.
- the steps for making the first embodiment illustrated in FIG. 1A can be taken out of order.
- the mixture of glass fibers 22 and resin may be provided between the adsorbent supporting 12 and fiber supporting 20 web substrates prior to the application of the adsorbent particles 16 and the binder 18 on the adsorbent supporting web substrate 12 as described above.
- Laminated glass filter medium products made by Hollingsworth & Voss Company and marketed under the trademark HOVOGLAS may be used to form both the adsorbent supporting and fiber supporting web substrates having the glass micro fiber 22 and binder resin material therebetween.
- the adsorbent particles 16 and binder particles 18 may be applied to the laminated glass filter medium product according to the method steps described above.
- sheet-like adsorbent product manufactured and marketed by KX Industries under the trademark PLEKX may be suitably modified by providing the glass micro fiber and resin mixture between the back, uncoated side of the adsorbent supporting web substrate of the PLEX material and the front side of an adjacently placed fiber supporting web substrate.
- non-woven fibrous materials such as high strength spunbonded polyesters or polyolefins, wet or dry laid fibrous materials and porous membranes can be used to form the adsorbent supporting 12 and fiber supporting 20 web substrates illustrated in the FIG. 1A embodiment.
- the adsorbent supporting web substrate 12 is formed from non-woven fibrous materials such as the high strength spunbonded polyesters and polyolefins and the fiber supporting web substrate 20 is formed from non-woven high strength spunbonded polyester.
- Materials such as iodinated resin, activated carbon, activated alumina, alumina-silicates, ion-exchange resins, and manganese or iron oxides can be used as adsorbent particles 16 .
- Materials forming the binder particles 18 typically include thermoplastics such polypropylene, linear low density polyethylene, low density polyethylene and ethylene-vinyl acetate copolymer.
- the composite filter medium 10 of FIG. 1A can be modified to include an overlying web substrate 30 which has a surface 32 facing the front surface 14 of the particle supporting web substrate 12 .
- the coating of binder particles 18 fused to the adsorbent particles and the surface 14 of the particles supporting web substrate 12 may also be fused to the surface 32 of the overlying web substrate 30 .
- the fusing of the binder particles 18 to the particle supporting 12 and overlying 30 web substrates can be accomplished according to the disclosure in co-pending U.S. application Ser. No. 08/813,055.
- the overlying web substrate 30 is applied over the adsorbent supporting web substrate 12 and powder coating thereon.
- the particle supporting web substrate 12 , the overlying web substrate 30 , and powder coating are heated to at least the Vicat softening temperature of the binder particles but below the melting temperature of the material forming the particle supporting web substrate, the overlying web substrate, the adsorbent particles and the binder.
- the adsorbent layer could be made by only heating the binder to the Vicat softening temperature before application thereof as a coating on the adsorbent supporting web substrate 12 and the application of the overlying web substrate 30 .
- the embodiment illustrated in FIG. 1B also includes the fiber supporting web substrate 20 and the mixture of glass micro fibers 22 and binder resin between the fiber supporting web substrate 20 as described and illustrated with respect to the embodiment illustrated in FIG. 1A .
- FIG. 1C illustrates a third embodiment of the composite filter medium of the present invention.
- the filter medium illustrated in FIG. 1A is modified by disposing an intermediate web substrate 40 between the glass micro fiber and resin mixture 22 and the back side 15 of the adsorbent supporting web substrate 12 .
- This embodiment may be made by combining a single ply PLEKX sheet and the HOVOGLAS glass micro fiber laminate.
- FIG. 1D illustrates a fourth embodiment of the composite filter medium of the present invention.
- the embodiment illustrated in FIG. 1C is modified by including the overlying web substrate 30 which has the surface 32 facing the surface 14 of the particle supporting web substrate 12 .
- the coating of binder particles 18 fused to the adsorbent particles and the surface 14 of the adsorbent supporting web substrate 12 are also fused to the surface 32 of the overlying web substrate 30 in the same manner as illustrated in the embodiment of FIG. 1B .
- This embodiment may be made by simply combining a two ply PLEKX sheet and the HOVOGLASS glass micro fiber laminate.
- FIGS. 1E through 1F illustrate other embodiments of the composite filter medium.
- the composite medium 210 comprises an adorbent layer 11 formed by an adsorbent supporting web substrate 12 having adsorbent particles 16 and binder particles 18 fused to the adsorbent particles 16 and to the surface 14 of the supporting web substrate 12 .
- the particulate intercepting layer 19 is formed from a hydrophilic melt-blown micro fiber medium or any other suitable hydrophilic micro fiber structure. Also, the particulate intercepting layer 19 may be formed from a hydrophilic membrane such as a Supor® porous membrane made by Pall-Gelman Sciences of Ann Arbor, Mich. In the embodiment illustrated in FIG.
- the adsorbent layer also includes the overlying web substrate 30 and the binder particles 18 are fused to the surface 32 of the overlying web substrate that faces the surface 14 of the supporting web substrate 12 .
- the particulate intercepting layer 19 may be formed from a hydrophilic melt-blown micro fiber medium or hydrophilic porous membrane as described above.
- a pressure drop of about no more than about 1 to 3 inches of water is available to push water through a filter medium.
- the adsorbent layer 11 and the particulate intercepting layer 19 are selected from the materials described above such that when tested with a COULTER Porometer II, the composite filter medium has a mean flow pore diameter of about 1 to 10 microns, a bubble point in the range of about 3 to 15 microns and an air permeability rating of about 0.5 to 7 liters per minute/cm 2 with a pressure drop of about 0.1 bar.
- Mean flow pore diameter is the pore diameter at which 50 percent of the flow is through pores that are larger and 50 percent of the flow is through pores that are smaller. Bubble point indicates the largest pore size in the filter medium and air permeability is the flow rate of a gas through the sample at a given differential pressure.
- optimization of the composite filter medium in the various illustrated embodiments to obtain the above described flow properties can be achieved by one or more of the following: (1) varying the density, fiber diameter and basis weight of the glass micro fiber and resin mixture; (2) including or excluding the overlying substrate, the intermediate substrate or both; (3) varying the adsorbent and binder particle sizes, concentrations and lay down weights; and (4) varying the properties of the web substrate by use of different materials.
- the composite filter medium 10 of the present invention may be used in a simple flat sheet filter apparatus 50 .
- the flat-sheet filter 50 includes a rim 52 which defines a filtration area.
- the composite filter medium 10 covers the filtration area defined by the rim 52 .
- the edge 54 of the medium 10 is sealably affixed to the rim 10 by insert molding the rim over the edge 54 or by other suitable means such as affixation with a bead of hot melt adhesive between the edge 54 and the rim 52 .
- the filter is provided with an inlet support member 56 a on the inlet side 57 a of the filter medium 10 and outlet support member 56 b on the outlet side 57 b of the filter medium 10 .
- the support members 56 a , 56 b extend from the rim into the filtration area defined by the rim 52 .
- Those skilled in the art will appreciate that only the inlet or outlet support member may be required for a particular filtering application and that such members may be formed with any structural shape including that illustrated in FIG. 2A .
- a portion of the rim 52 on the outlet side 57 b of the filter medium 10 may be provided with a groove 58 for sealably engaging with the rim of a container (not shown).
- the rim may be formed from a resiliently deformable material such as rubber, thermoplastic elastomer or low density polyethylene.
- a portion of the rim on an inlet side 57 a of the filter medium may be provided with a nesting ridge 59 .
- a plurality of filters 50 may be stacked such that nesting ridge 59 of one filter may reside in the groove 58 of an adjacent filter and so on.
- the composite filtration medium 10 of the present invention may be used in a cylindrical pleated filter 60 for filtering contaminants from a fluid.
- the filter has a base 62 (shown in dotted line) having an outlet opening therein (not shown).
- the filter 60 also includes a top 64 and a fluid permeable tube 66 extending from the base 62 to the top 64 . The end of the tube adjacent to the base 62 is connected with the outlet opening in the base.
- the sheet-like filter medium 10 of the present invention may be sealably disposed in a generally cylindrical configuration between the base 62 and the top 64 and is provided with a plurality of outer radial pleats that extend lengthwise from the base 62 to the top 64 and a plurality of inner radial pleats 72 located near the tube 66 .
- the outer and inner radial pleats define a plurality of filtration panels 68 . Fluid to be filtered may be caused to flow in a general direction from the outer radial pleats to the inner radial pleats and then to the tube as indicated by the flow arrows in the figures.
- the composite filter medium of the present invention may be used in a spiral wound filter configuration 80 .
- the spiral wound filter configuration has a top 82 with a plurality of perforations 84 therein for permitting fluid to enter the filter.
- the filter has bottom 86 which also has a plurality of perforations for permitting fluid to exit the filter.
- the top 82 and bottom 86 of the filter are held in a spaced apart relationship by a support tube 88 which extends from the top to the bottom.
- the sheet-like filter medium of the present invention 10 having a top edge 90 a adjacent to the top and a bottom edge 90 b adjacent to the bottom is spirally wound around the support tube 88 .
- a cylindrical housing 92 extending from the top to the bottom is provided to cover and enclose the spirally wound filter medium 10 .
- the fluid is permitted to flow tangentially relative to the filter medium 10 as shown by the flow arrows.
- this arrangement is generally only effective for chemical and heavy metals reduction and is not highly effective for the reduction of small particles.
- FIG. 4C to force the fluid to flow through the filter medium before exiting the filter at the bottom 86 as shown by the flow arrows, alternating adjacent edges of the spiral wound filter medium are provided with barriers 94 .
- the barriers 94 may be formed from a hot melt adhesive, polyurethane or other suitable material.
- the composite filter medium 10 of the present invention may be used to form a pleated panel filter 100 for filtering contaminants from a fluid.
- the panel filter 100 includes an outlet end panel 102 having an opening 104 therein.
- the composite filter medium 10 sealably covers the opening 104 of the outlet end panel.
- the composite filter medium 10 is pleated so as to have a first outward pleat 106 a located remotely from the outlet end panel, an inward pleat 106 b located closely to the outlet end panel, and a second outward pleat 106 c located remotely from the outlet end panel.
- the pleats 106 a - 106 c collectively define four filter medium panels.
- a first panel 108 a extends between the outlet end panel 102 and the first outward pleat 106 a .
- a second panel 108 b extends from the first outward pleat 106 a to the inward pleat 106 b .
- a third panel 108 c extends from the inward pleat 106 b to the second outward pleat 106 c .
- a fourth panel 108 d extends from the second outward pleat 106 c to the outlet end panel 102 .
- the filter 100 may be provided with one or more drainage support members to prevent collapsing of the filter medium upon itself. If unsupported, collapsed filter surfaces would close and could increase the pressure drop across the filter and undesirably restrict fluid flow through the filter. As illustrated in FIGS. 5A and 5C , the filter is provided with a first drainage support member.
- the support members such as the first support member 110 a , may comprise a rigid or semi-rigid sheet 112 including one or more elongated ribs 114 extending from the surface of the member.
- the members may be disposed between the panels such that the elongated ribs 112 are aligned to point substantially towards the opening 104 in the outlet end panel 102 to direct the flow of fluid towards the opening 104 .
- Apertures 116 may be provided in the sheet between the ribs 114 to permit fluid flow from one side of the drainage support member to the other.
- Materials sold by Applied Extrusion Technologies or Middletown, Del. under the trademark DELNET or by Amoco Fabrics Company of Atlanta, Ga. under the trademark VEXAR may be used as the drainage support members.
- the filter is further provided with a frame 120 extending from the outlet end panel 102 .
- the edges 122 a , 122 b of the filter medium 10 may be attached to and supported by the frame 120 .
- the respective edges 122 a , 122 b of the filter medium may be bonded together with a bead of hot melt adhesive 124 .
- any of the above described filters employing the filter medium of the present invention can be used in a gravity flow, filtering carafe.
- a carafe 130 is divided into an upper reservoir 132 and a lower reservoir 134 by a partition 136 that is provided with a filter receiving receptacle 138 having an opening (not shown) in the bottom thereof.
- a filter such as the filter illustrated in FIGS. 5A through 5F , is inserted into the receptacle 138 so that it is supported on its outlet end panel 102 in the receptacle 138 .
- a gasket (not shown) may be provided between the outlet end panel 102 and the bottom of the receptacle 138 to seal the upper reservoir from the bottom reservoir 134 .
- the filter medium of the present invention is very useful for making filters for water filtering carafes because it permits the use of filter configurations capable of providing high filtration flow rates with the several inches of water pressure that is typically available in such carafe filters.
- the high flow rate is a result of a substantially increased cross-sectional filter flow area (up to about 20 times) as compared to a traditional trapezoidal carafe filter element. Accordingly, because a greater cross-sectional flow area may be provided, the adsorbent bed depth presented to the flow of fluid can be reduced by up to 60 times as compared to conventional carafe filter elements.
- the size of adsorptive particles can be reduced from the size currently in use with conventional carafe filters. Because smaller particles provide better adsorption kinetics, the overall performance of the filter of the present invention can be greatly improved as compared to the conventional carafe filter under the same pressure drop and flow rate conditions. Use of small adsorbent particles that are more effective allows a substantial reduction in the volume of adsorbent required to meet performance goals.
- the low flow resistance provided by the filter medium of the present invention can be used to intercept very small particles, such as those within the 3 to 4 micrometer range, a range which is required to intercept waterborne pathogenic oocysts such as Giardia and Cryptosporidium Parvum.
- the filter of the present invention permits high filtration flow rates to be obtained in low pressure environments, such as those typically found in gravity flow carafe filters.
- the filtering apparatus has been described with respect to one or more particular embodiments; it will be understood that other embodiments of the present invention may be employed without departing from the spirit and scope of the present invention. Hence, the present invention is deemed limited only by the appended claims and the reasonable interpretation thereof.
Abstract
Description
- 1. Field of the Invention
- The present invention relates to filters and filter media. More particularly, the present invention relates to a composite filter media for filtering contaminants from a fluid and fluid filters containing the composite filter medium.
- 2. Description of the Prior Art
- Fluids, such as liquids or gases, typically contain contaminants which include particulates, chemicals, and organisms. In many cases, it is desirable to remove some or all of such contaminants from the fluid. Usually, contaminants are removed from a fluid supply by passing the fluid through a filter whereby the contaminants are separated from the filtered fluid or filtrate.
- Water is probably the most highly filtered fluid as it is filtered in industrial processes as well as in the household. Purification of water to produce potable water often requires the simultaneous reduction of particulate contaminants, dissolved organic chemicals and inorganic heavy metals. Particulate contaminants may include dirt, rust, silt, and other particles as well as potentially hazardous microorganisms such as chlorine resistant protozoan cysts, such as Cryptosporidium Parvum or Giardia, or bacteria such as Cholera and E. coli. Organic chemicals may include those that contribute to taste and odor as well as potentially toxic pesticides, chlorinated hydrocarbons, and other synthetic organic chemicals. Free chlorine reduction is also a major objective when the residual concentration of this disinfectant is sufficiently high to cause a bad taste. The most common heavy metal found in domestic water is lead derived from brass fixtures, leaded solder, lead pipes or other sources. Other heavy metals often found in drinking water include copper, zinc, manganese and iron.
- The most common household water filters are typically small trapezoidal shaped plastic containers filled with a loose adsorbent medium such as activated carbon, ion exchange resins or zeolites. Water is filtered by such water filters by passing it through the loose adsorbent medium in an axial direction from a wider to a narrower portion of the trapezoidal container.
- The trapezoidal shaped filter element is often used in a carafe and when used in a carafe is typically called a gravity-flow carafe filter. Such filters are typically installed within a household carafe having an upper reservoir, a lower reservoir and a filter receptacle fitted at the bottom of the upper reservoir. The trapezoidal shaped filter element is installed in the carafe by wedging it into the receptacle so as to effect a seal between the two reservoirs. Water passing from the upper reservoir to the lower reservoir must pass through the filter element. Typically, water enters the filter element through a series of small perforations at the wider top of the trapezoid. The water flows through the filter to the narrower bottom while traversing the porous bed of loose adsorbent. The water passes through a series of micro perforations in the narrower bottom of the filter exiting into the lower reservoir. In some filters, one or more non-woven pads, functioning as a fines filter, may be installed at the bottom, top or both bottom and top of the filter element to prevent the release of fine particles from the adsorbent bed.
- The flow rate through present day gravity-flow carafe filters as described above is generally slow, typically about 200 ml per minute for a filter loaded with 100 grams of mixed wet resin-carbon filter medium containing water in an amount of about 30 to 35 percent by weight. The slow flow rate occurs because: (1) the water must traverse a deep bed of adsorbent particles; (2) the filter operates in a low pressure environment—only the pressure of the overlying water in the upper reservoir, typically several inches of water, is available to force the water through the filter; and (3) the size of the adsorbent particles are limited. Excessively large particles that would permit faster flow rates, would also have slower adsorption kinetics. This forces the use of relatively small particles (about 35 mesh) having faster adsorption kinetics but greater flow restriction. In view of the above constraints, a liter of water normally takes about 5 to 10 minutes or more to process through the present day carafe filter.
- It is desirable to have a high flow rate, gravity-flow carafe filter which is capable of intercepting the very small chlorine resistant cysts such as Giardia and Cryptosporidium Parvum. It is also desirable to provide a high flow rate, gravity-flow carafe filter with enhanced chlorine, taste and odor reduction as well as a filter that can absorb heavy metals such as lead. It is desirable to provide a high flow filter that supports high flow with a 1 inch water column and that intercepts 99.95 percent of 3 to 4 micron particles which makes it suitable for cyst reduction and which generally meets NSF Class 1 particle reduction requirements. Mass production of carafe filters with simple equipment and at low cost is a necessity.
- It is a primary object of the present invention to provide a fluid filter that is capable of filtering contaminants from a fluid at relatively high flow rates while providing a relatively low resistance to fluid flow.
- It is another object of the present invention to provide a fluid filter capable of filtering chlorine resistant cysts such as Giardia and Cryptosporidium Parvum.
- It is yet another object of the present invention to provide a high flow rate carafe filter with enhanced chlorine, taste and odor reduction as well as a filter that can absorb heavy metals such as lead.
- It is still another object of the present invention to provide a carafe filter that can be mass produced with simple equipment and at low cost.
- In accordance with the objects of the present invention, the foregoing primary objective is realized by providing a low flow resistance composite filter medium for removing at least 99.95 percent of particulates of a size in the 3 to 4 micron range and dissolved chemical contaminants from a fluid comprising an adsorbent layer containing an adsorbent agent and a hydrophilic particulate intercepting layer disposed adjacent to the adsorbent layer. The composite medium has a mean flow pore diameter of about 1 to 10 microns, a bubble point of about 3 to 15 microns and an air permeability of about 0.5 to 7 liters per minute/cm2 with a pressure drop of about 0.1 bar.
- Other objects and advantages of the invention will be apparent from the following detailed description and the accompanying drawings.
- The drawings, not drawn to scale, include:
-
FIG. 1A , which is a sectional view of a first embodiment of the composite filter medium of the present invention; -
FIG. 1B , which is a sectional view of a second embodiment of the composite filter medium of the present invention; -
FIG. 1C , which is a sectional view of a third embodiment of the composite filter medium of the present invention; -
FIG. 1D , which is a sectional view of a fourth embodiment of the composite filter medium of the present invention; -
FIG. 1E , which is a sectional view of a fourth embodiment of the composite filter medium of the present invention; -
FIG. 1F , which is a sectional view of a fourth embodiment of the composite filter medium of the present invention; -
FIG. 2A , which is an isometric view of a flat sheet filter; -
FIG. 2B , which is a partial cross-sectional view of the filter illustrated inFIG. 2A ; -
FIG. 3A , which is an isometric view of a basic cylindrical pleated filter; -
FIG. 3B , which is an axial cross-sectional view of the filter illustrated inFIG. 3A ; -
FIG. 4A , which is a partially cut away isometric view of a basic spiral wound filter; -
FIG. 4B , which is a cross-sectional view of a flow through filter medium configuration for the filter illustrated inFIG. 4A ; -
FIG. 4C , which is a cross-sectional view of a tangential flow filter medium configuration for the filter illustrated inFIG. 4A ; -
FIG. 5A , which is a cutaway perspective view of a pleated fluid filter employing the composite filter medium of the present invention; -
FIG. 5B , which is a top plan view of the filter illustrated inFIG. 5A ; -
FIG. 5C , which is a cross-sectional view of the pleated filter illustrated inFIG. 5B , taken along theline 5C-5C; -
FIG. 5D , which is an end view of the filter illustrated inFIG. 5A showing the outlet end panel; -
FIG. 5E , which is a partial cross-sectional view illustrating the edges of the pleated filter medium joined together by insert molding in a frame; -
FIG. 5F , which is partial cross-sectional view illustrating the edges of the pleated filter medium joined together by a hot-melt adhesive; -
FIG. 6 , which is a partial perspective view of a drainage directing support member; and -
FIG. 7 , which is a cross-sectional view of a carafe containing the filter of the illustrated inFIGS. 5A through 5F . -
FIGS. 1A through 1F illustrate several embodiments of thecomposite filter medium 10 of the present invention useful for removing contaminants from a fluid, which generally comprises anadsorbent layer 11 and a hydrophilicparticulate intercepting layer 19. Referring to the embodiment illustrated inFIG. 1A , theadsorbent layer 11 comprises an adsorbent supportingweb substrate 12 having afront surface 14 and aback surface 15. At least a portion of thefront surface 14 is coated withadsorbent particles 16 andbinder particles 18 which are fused to thefront surface 14 and to theadsorbent particles 16. The coating on the adsorbent supportingweb substrate 12 is obtained according to a method which is described in co-pending U.S. patent application Ser. No. 08/813,055, filed on Mar. 3, 1997, which is incorporated in its entirety herein by reference. As basically described in the co-pending application, the coating is obtained by preparing a mixture of adsorbent particles and binder particles. Preferably, the binder particles have an average particle size not exceeding approximately 80 microns. The mixture is applied to part or all of thefront surface 14 of the adsorbent supportingweb substrate 12 to produce a loose powder coating on the front surface. The loose powder coating is heated to at least the Vicat softening temperature of the binder particles but below the melting temperature of theadsorbent supporting substrate 12 and the adsorbent particles to form softenedbinder particles 18. Pressure is applied to theweb substrate 12 to cause the softenedbinder particles 18 to fuse with theadsorbent particles 16 and to the adsorbent supportingweb substrate 12. - The hydrophilic
particulate intercepting layer 19 in the embodiment shown inFIG. 1A comprises a fiber supportingweb substrate 20 having afront surface 21 positioned adjacent to the adsorbent supportingweb substrate 12 such that its front surface faces the back surface of the adsorbent supporting web substrate. A mixture of glassmicro fibers 22 and an FDA approved epoxy binder resin (not shown) is positioned between theback side 15 of the adsorbent supportingweb substrate 12 and thefront side 21 of the fiber supporting 20 web substrates. The glass fibers and binder resin may be adhered to one or both of theweb substrates - Of course those skilled in the art will now appreciate that the steps for making the first embodiment illustrated in
FIG. 1A can be taken out of order. For example, the mixture ofglass fibers 22 and resin may be provided between the adsorbent supporting 12 and fiber supporting 20 web substrates prior to the application of theadsorbent particles 16 and thebinder 18 on the adsorbent supportingweb substrate 12 as described above. Laminated glass filter medium products made by Hollingsworth & Voss Company and marketed under the trademark HOVOGLAS may be used to form both the adsorbent supporting and fiber supporting web substrates having theglass micro fiber 22 and binder resin material therebetween. Theadsorbent particles 16 andbinder particles 18 may be applied to the laminated glass filter medium product according to the method steps described above. Alternatively, sheet-like adsorbent product manufactured and marketed by KX Industries under the trademark PLEKX may be suitably modified by providing the glass micro fiber and resin mixture between the back, uncoated side of the adsorbent supporting web substrate of the PLEX material and the front side of an adjacently placed fiber supporting web substrate. - Generally, non-woven fibrous materials, such as high strength spunbonded polyesters or polyolefins, wet or dry laid fibrous materials and porous membranes can be used to form the adsorbent supporting 12 and fiber supporting 20 web substrates illustrated in the
FIG. 1A embodiment. Preferably, the adsorbent supportingweb substrate 12 is formed from non-woven fibrous materials such as the high strength spunbonded polyesters and polyolefins and the fiber supportingweb substrate 20 is formed from non-woven high strength spunbonded polyester. Materials such as iodinated resin, activated carbon, activated alumina, alumina-silicates, ion-exchange resins, and manganese or iron oxides can be used asadsorbent particles 16. Materials forming thebinder particles 18 typically include thermoplastics such polypropylene, linear low density polyethylene, low density polyethylene and ethylene-vinyl acetate copolymer. - Referring to the embodiment in
FIG. 1B , thecomposite filter medium 10 ofFIG. 1A can be modified to include anoverlying web substrate 30 which has asurface 32 facing thefront surface 14 of the particle supportingweb substrate 12. The coating ofbinder particles 18 fused to the adsorbent particles and thesurface 14 of the particles supportingweb substrate 12 may also be fused to thesurface 32 of theoverlying web substrate 30. The fusing of thebinder particles 18 to the particle supporting 12 and overlying 30 web substrates can be accomplished according to the disclosure in co-pending U.S. application Ser. No. 08/813,055. Essentially, after applying the mixture of particles to the surface of the adsorbent supportingweb substrate 12 to produce a powder coating covering the portion of the surface thereof as described above, the overlyingweb substrate 30 is applied over the adsorbent supportingweb substrate 12 and powder coating thereon. Preferrably, the particle supportingweb substrate 12, the overlyingweb substrate 30, and powder coating are heated to at least the Vicat softening temperature of the binder particles but below the melting temperature of the material forming the particle supporting web substrate, the overlying web substrate, the adsorbent particles and the binder. Once the binder particles are heated to the Vicat softening temperature, pressure is applied to the particle supporting 12 and overlying 30 web substrates to cause the softened binder particles to fuse with the adsorbent particles and theadjacent web substrates web substrate 12 and the application of theoverlying web substrate 30. The embodiment illustrated inFIG. 1B also includes the fiber supportingweb substrate 20 and the mixture of glassmicro fibers 22 and binder resin between the fiber supportingweb substrate 20 as described and illustrated with respect to the embodiment illustrated inFIG. 1A . -
FIG. 1C illustrates a third embodiment of the composite filter medium of the present invention. In this embodiment, the filter medium illustrated inFIG. 1A is modified by disposing anintermediate web substrate 40 between the glass micro fiber andresin mixture 22 and theback side 15 of the adsorbent supportingweb substrate 12. This embodiment may be made by combining a single ply PLEKX sheet and the HOVOGLAS glass micro fiber laminate. -
FIG. 1D illustrates a fourth embodiment of the composite filter medium of the present invention. The embodiment illustrated inFIG. 1C is modified by including theoverlying web substrate 30 which has thesurface 32 facing thesurface 14 of the particle supportingweb substrate 12. The coating ofbinder particles 18 fused to the adsorbent particles and thesurface 14 of the adsorbent supportingweb substrate 12 are also fused to thesurface 32 of theoverlying web substrate 30 in the same manner as illustrated in the embodiment ofFIG. 1B . This embodiment may be made by simply combining a two ply PLEKX sheet and the HOVOGLASS glass micro fiber laminate. -
FIGS. 1E through 1F illustrate other embodiments of the composite filter medium. InFIG. 1E , thecomposite medium 210 comprises anadorbent layer 11 formed by an adsorbent supportingweb substrate 12 havingadsorbent particles 16 andbinder particles 18 fused to theadsorbent particles 16 and to thesurface 14 of the supportingweb substrate 12. The particulate interceptinglayer 19 is formed from a hydrophilic melt-blown micro fiber medium or any other suitable hydrophilic micro fiber structure. Also, the particulate interceptinglayer 19 may be formed from a hydrophilic membrane such as a Supor® porous membrane made by Pall-Gelman Sciences of Ann Arbor, Mich. In the embodiment illustrated inFIG. 1F , the adsorbent layer also includes theoverlying web substrate 30 and thebinder particles 18 are fused to thesurface 32 of the overlying web substrate that faces thesurface 14 of the supportingweb substrate 12. The particulate interceptinglayer 19 may be formed from a hydrophilic melt-blown micro fiber medium or hydrophilic porous membrane as described above. - In commercially available filtering water carafes, a pressure drop of about no more than about 1 to 3 inches of water is available to push water through a filter medium. To make a high flow filter with the
composite filter medium 10 of the present invention which is suitable for such end applications, theadsorbent layer 11 and the particulate interceptinglayer 19 are selected from the materials described above such that when tested with a COULTER Porometer II, the composite filter medium has a mean flow pore diameter of about 1 to 10 microns, a bubble point in the range of about 3 to 15 microns and an air permeability rating of about 0.5 to 7 liters per minute/cm2 with a pressure drop of about 0.1 bar. Mean flow pore diameter is the pore diameter at which 50 percent of the flow is through pores that are larger and 50 percent of the flow is through pores that are smaller. Bubble point indicates the largest pore size in the filter medium and air permeability is the flow rate of a gas through the sample at a given differential pressure. Those skilled in the art will appreciate that optimization of the composite filter medium in the various illustrated embodiments to obtain the above described flow properties can be achieved by one or more of the following: (1) varying the density, fiber diameter and basis weight of the glass micro fiber and resin mixture; (2) including or excluding the overlying substrate, the intermediate substrate or both; (3) varying the adsorbent and binder particle sizes, concentrations and lay down weights; and (4) varying the properties of the web substrate by use of different materials. - All of the embodiments of the composite filter medium illustrated in
FIGS. 1A through 1F can be incorporated into a variety of fluid filter configurations. Examples of such fluid filter configurations are illustrated inFIGS. 2A through 5F . Referring toFIGS. 2A and 2B , thecomposite filter medium 10 of the present invention may be used in a simple flatsheet filter apparatus 50. The flat-sheet filter 50 includes arim 52 which defines a filtration area. Thecomposite filter medium 10 covers the filtration area defined by therim 52. Theedge 54 of the medium 10 is sealably affixed to therim 10 by insert molding the rim over theedge 54 or by other suitable means such as affixation with a bead of hot melt adhesive between theedge 54 and therim 52. In the embodiment illustrated inFIGS. 2A and 2B , the filter is provided with aninlet support member 56 a on theinlet side 57 a of thefilter medium 10 andoutlet support member 56 b on theoutlet side 57 b of thefilter medium 10. Thesupport members rim 52. Those skilled in the art will appreciate that only the inlet or outlet support member may be required for a particular filtering application and that such members may be formed with any structural shape including that illustrated inFIG. 2A . A portion of therim 52 on theoutlet side 57 b of thefilter medium 10 may be provided with agroove 58 for sealably engaging with the rim of a container (not shown). To provide good sealing qualities, the rim may be formed from a resiliently deformable material such as rubber, thermoplastic elastomer or low density polyethylene. A portion of the rim on aninlet side 57 a of the filter medium may be provided with anesting ridge 59. A plurality offilters 50 may be stacked such thatnesting ridge 59 of one filter may reside in thegroove 58 of an adjacent filter and so on. - Referring to
FIGS. 3A and 3B , thecomposite filtration medium 10 of the present invention may be used in a cylindricalpleated filter 60 for filtering contaminants from a fluid. InFIG. 3A , the filter has a base 62 (shown in dotted line) having an outlet opening therein (not shown). Thefilter 60 also includes a top 64 and a fluidpermeable tube 66 extending from the base 62 to the top 64. The end of the tube adjacent to thebase 62 is connected with the outlet opening in the base. The sheet-like filter medium 10 of the present invention may be sealably disposed in a generally cylindrical configuration between the base 62 and the top 64 and is provided with a plurality of outer radial pleats that extend lengthwise from the base 62 to the top 64 and a plurality of innerradial pleats 72 located near thetube 66. The outer and inner radial pleats define a plurality offiltration panels 68. Fluid to be filtered may be caused to flow in a general direction from the outer radial pleats to the inner radial pleats and then to the tube as indicated by the flow arrows in the figures. - Referring to
FIGS. 4A through 4C , the composite filter medium of the present invention may be used in a spiralwound filter configuration 80. The spiral wound filter configuration has a top 82 with a plurality ofperforations 84 therein for permitting fluid to enter the filter. Similarly, the filter has bottom 86 which also has a plurality of perforations for permitting fluid to exit the filter. The top 82 and bottom 86 of the filter are held in a spaced apart relationship by asupport tube 88 which extends from the top to the bottom. The sheet-like filter medium of thepresent invention 10 having atop edge 90 a adjacent to the top and abottom edge 90 b adjacent to the bottom is spirally wound around thesupport tube 88. Acylindrical housing 92 extending from the top to the bottom is provided to cover and enclose the spirallywound filter medium 10. - In the embodiment in
FIG. 4B , the fluid is permitted to flow tangentially relative to thefilter medium 10 as shown by the flow arrows. However, this arrangement is generally only effective for chemical and heavy metals reduction and is not highly effective for the reduction of small particles. Referring toFIG. 4C , to force the fluid to flow through the filter medium before exiting the filter at the bottom 86 as shown by the flow arrows, alternating adjacent edges of the spiral wound filter medium are provided withbarriers 94. Thebarriers 94 may be formed from a hot melt adhesive, polyurethane or other suitable material. - Referring to
FIGS. 5A through 5F , thecomposite filter medium 10 of the present invention may be used to form apleated panel filter 100 for filtering contaminants from a fluid. Thepanel filter 100 includes anoutlet end panel 102 having anopening 104 therein. Thecomposite filter medium 10 sealably covers theopening 104 of the outlet end panel. Thecomposite filter medium 10 is pleated so as to have a firstoutward pleat 106 a located remotely from the outlet end panel, aninward pleat 106 b located closely to the outlet end panel, and a secondoutward pleat 106 c located remotely from the outlet end panel. The pleats 106 a-106 c collectively define four filter medium panels. Afirst panel 108 a extends between theoutlet end panel 102 and the firstoutward pleat 106 a. Asecond panel 108 b extends from the firstoutward pleat 106 a to theinward pleat 106 b. Athird panel 108 c extends from theinward pleat 106 b to the secondoutward pleat 106 c. Finally, afourth panel 108 d extends from the secondoutward pleat 106 c to theoutlet end panel 102. - When the panels 108 a-108 d are made to be relatively large due to the desire to have a high surface area of filter medium in the
filter 100, thefilter 100 may be provided with one or more drainage support members to prevent collapsing of the filter medium upon itself. If unsupported, collapsed filter surfaces would close and could increase the pressure drop across the filter and undesirably restrict fluid flow through the filter. As illustrated inFIGS. 5A and 5C , the filter is provided with a first drainage support member. 110 a disposed between the first andsecond filter panels drainage support member 110 b disposed between the second andthird filter panels drainage support member 110 c disposed between the third andfourth filter panels - Referring to
FIG. 6 , the support members, such as thefirst support member 110 a, may comprise a rigid orsemi-rigid sheet 112 including one or more elongated ribs 114 extending from the surface of the member. The members may be disposed between the panels such that theelongated ribs 112 are aligned to point substantially towards the opening 104 in theoutlet end panel 102 to direct the flow of fluid towards theopening 104. Apertures 116 may be provided in the sheet between the ribs 114 to permit fluid flow from one side of the drainage support member to the other. Materials sold by Applied Extrusion Technologies or Middletown, Del. under the trademark DELNET or by Amoco Fabrics Company of Atlanta, Ga. under the trademark VEXAR may be used as the drainage support members. - Referring to
FIGS. 5A, 5B , 5E and 5F, the filter is further provided with aframe 120 extending from theoutlet end panel 102. To sealably cover the opening in theoutlet end panel 102, theedges filter medium 10 may be attached to and supported by theframe 120. Alternatively, to sealably cover the opening in theoutlet end panel 102, therespective edges - Any of the above described filters employing the filter medium of the present invention can be used in a gravity flow, filtering carafe. As shown in
FIG. 7 , such acarafe 130 is divided into anupper reservoir 132 and alower reservoir 134 by apartition 136 that is provided with afilter receiving receptacle 138 having an opening (not shown) in the bottom thereof. A filter, such as the filter illustrated inFIGS. 5A through 5F , is inserted into thereceptacle 138 so that it is supported on itsoutlet end panel 102 in thereceptacle 138. A gasket (not shown) may be provided between theoutlet end panel 102 and the bottom of thereceptacle 138 to seal the upper reservoir from thebottom reservoir 134. When a quantity of water is poured into theupper reservoir 132, it flows under gravity through the filter containing the filter medium of the present invention into thelower reservoir 134. Filtered water may be poured from the lower reservoir viaoutlet 140. - As can be seen by the foregoing discussion, the filter medium of the present invention is very useful for making filters for water filtering carafes because it permits the use of filter configurations capable of providing high filtration flow rates with the several inches of water pressure that is typically available in such carafe filters. The high flow rate is a result of a substantially increased cross-sectional filter flow area (up to about 20 times) as compared to a traditional trapezoidal carafe filter element. Accordingly, because a greater cross-sectional flow area may be provided, the adsorbent bed depth presented to the flow of fluid can be reduced by up to 60 times as compared to conventional carafe filter elements.
- Also, to take advantage of the increased cross-sectional area provided by the filter medium of the present invention, the size of adsorptive particles can be reduced from the size currently in use with conventional carafe filters. Because smaller particles provide better adsorption kinetics, the overall performance of the filter of the present invention can be greatly improved as compared to the conventional carafe filter under the same pressure drop and flow rate conditions. Use of small adsorbent particles that are more effective allows a substantial reduction in the volume of adsorbent required to meet performance goals. The low flow resistance provided by the filter medium of the present invention can be used to intercept very small particles, such as those within the 3 to 4 micrometer range, a range which is required to intercept waterborne pathogenic oocysts such as Giardia and Cryptosporidium Parvum.
- As can be seen from the foregoing detailed description and drawings, the filter of the present invention permits high filtration flow rates to be obtained in low pressure environments, such as those typically found in gravity flow carafe filters. Although the filtering apparatus has been described with respect to one or more particular embodiments; it will be understood that other embodiments of the present invention may be employed without departing from the spirit and scope of the present invention. Hence, the present invention is deemed limited only by the appended claims and the reasonable interpretation thereof.
Claims (37)
Priority Applications (1)
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US10/924,066 US20050023211A1 (en) | 1998-08-27 | 2004-08-23 | Composite filter medium and fluid filters containing same |
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US09/140,924 US6550622B2 (en) | 1998-08-27 | 1998-08-27 | Composite filter medium and fluid filters containing same |
US10/290,859 US6797167B2 (en) | 1998-08-27 | 2002-11-08 | Composite filter medium and fluid filters containing same |
US10/924,066 US20050023211A1 (en) | 1998-08-27 | 2004-08-23 | Composite filter medium and fluid filters containing same |
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US10/290,859 Expired - Lifetime US6797167B2 (en) | 1998-08-27 | 2002-11-08 | Composite filter medium and fluid filters containing same |
US10/924,066 Abandoned US20050023211A1 (en) | 1998-08-27 | 2004-08-23 | Composite filter medium and fluid filters containing same |
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US10/290,859 Expired - Lifetime US6797167B2 (en) | 1998-08-27 | 2002-11-08 | Composite filter medium and fluid filters containing same |
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JP (2) | JP2002535111A (en) |
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Also Published As
Publication number | Publication date |
---|---|
US20020139746A1 (en) | 2002-10-03 |
EP1064069A4 (en) | 2004-02-25 |
WO2000012194A8 (en) | 2000-06-02 |
US20030111404A1 (en) | 2003-06-19 |
EP1064069A1 (en) | 2001-01-03 |
CA2302701C (en) | 2005-08-23 |
IL135814A (en) | 2004-03-28 |
CA2302701A1 (en) | 2000-03-09 |
JP5227353B2 (en) | 2013-07-03 |
JP2010167416A (en) | 2010-08-05 |
WO2000012194A1 (en) | 2000-03-09 |
IL135814A0 (en) | 2001-05-20 |
US6550622B2 (en) | 2003-04-22 |
US6797167B2 (en) | 2004-09-28 |
JP2002535111A (en) | 2002-10-22 |
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Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |
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Owner name: KX INDUSTRIES, LP,CONNECTICUT Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KOSLOW, EVAN E.;KOSLOW TECHNOLOGIES CORPORATION;REEL/FRAME:018688/0565 Effective date: 20051128 Owner name: KX INDUSTRIES, LP, CONNECTICUT Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:KOSLOW, EVAN E.;KOSLOW TECHNOLOGIES CORPORATION;REEL/FRAME:018688/0565 Effective date: 20051128 |