CA2346750C - Antimicrobial filter cartridge - Google Patents
Antimicrobial filter cartridge Download PDFInfo
- Publication number
- CA2346750C CA2346750C CA002346750A CA2346750A CA2346750C CA 2346750 C CA2346750 C CA 2346750C CA 002346750 A CA002346750 A CA 002346750A CA 2346750 A CA2346750 A CA 2346750A CA 2346750 C CA2346750 C CA 2346750C
- Authority
- CA
- Canada
- Prior art keywords
- filter cartridge
- antimicrobial
- hollow fibers
- yarn
- antimicrobial filter
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- 230000000845 anti-microbial effect Effects 0.000 title claims abstract description 39
- 239000012510 hollow fiber Substances 0.000 claims abstract description 71
- 239000004599 antimicrobial Substances 0.000 claims abstract description 35
- -1 polypropylene Polymers 0.000 claims description 21
- 229920002301 cellulose acetate Polymers 0.000 claims description 17
- 239000011148 porous material Substances 0.000 claims description 16
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 14
- 239000012530 fluid Substances 0.000 claims description 13
- 229920000642 polymer Polymers 0.000 claims description 12
- 239000004743 Polypropylene Substances 0.000 claims description 11
- 229920001155 polypropylene Polymers 0.000 claims description 11
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 claims description 8
- 239000000155 melt Substances 0.000 claims description 8
- 239000004677 Nylon Substances 0.000 claims description 7
- 229920001778 nylon Polymers 0.000 claims description 7
- 229920000433 Lyocell Polymers 0.000 claims description 6
- 239000004698 Polyethylene Substances 0.000 claims description 6
- 229920000297 Rayon Polymers 0.000 claims description 6
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 229920000728 polyester Polymers 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- 239000002964 rayon Substances 0.000 claims description 6
- 229920000742 Cotton Polymers 0.000 claims description 4
- XKZQKPRCPNGNFR-UHFFFAOYSA-N 2-(3-hydroxyphenyl)phenol Chemical compound OC1=CC=CC(C=2C(=CC=CC=2)O)=C1 XKZQKPRCPNGNFR-UHFFFAOYSA-N 0.000 claims description 3
- 150000001875 compounds Chemical class 0.000 claims description 3
- 238000004891 communication Methods 0.000 claims description 2
- 229920005594 polymer fiber Polymers 0.000 claims 5
- 238000004804 winding Methods 0.000 claims 4
- 238000002386 leaching Methods 0.000 claims 1
- 238000001471 micro-filtration Methods 0.000 abstract description 11
- 239000012528 membrane Substances 0.000 description 64
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 39
- 241000894006 Bacteria Species 0.000 description 25
- 238000001223 reverse osmosis Methods 0.000 description 15
- 230000004888 barrier function Effects 0.000 description 12
- 230000001580 bacterial effect Effects 0.000 description 8
- 239000000835 fiber Substances 0.000 description 8
- 239000002609 medium Substances 0.000 description 8
- 239000004952 Polyamide Substances 0.000 description 7
- 229920002647 polyamide Polymers 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- 239000002131 composite material Substances 0.000 description 6
- 238000001914 filtration Methods 0.000 description 6
- 229920002981 polyvinylidene fluoride Polymers 0.000 description 6
- 239000000523 sample Substances 0.000 description 6
- 239000002033 PVDF binder Substances 0.000 description 5
- 239000003651 drinking water Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 4
- 230000000670 limiting effect Effects 0.000 description 4
- 229920002492 poly(sulfone) Polymers 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 3
- 239000000356 contaminant Substances 0.000 description 3
- 238000013461 design Methods 0.000 description 3
- 235000020188 drinking water Nutrition 0.000 description 3
- 239000012982 microporous membrane Substances 0.000 description 3
- 150000003839 salts Chemical class 0.000 description 3
- 238000000926 separation method Methods 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 238000000108 ultra-filtration Methods 0.000 description 3
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 2
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 2
- 239000004962 Polyamide-imide Substances 0.000 description 2
- 239000004642 Polyimide Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 230000002411 adverse Effects 0.000 description 2
- 230000000844 anti-bacterial effect Effects 0.000 description 2
- 235000012206 bottled water Nutrition 0.000 description 2
- 229910052801 chlorine Inorganic materials 0.000 description 2
- 239000000460 chlorine Substances 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 244000005700 microbiome Species 0.000 description 2
- 238000001728 nano-filtration Methods 0.000 description 2
- 230000017066 negative regulation of growth Effects 0.000 description 2
- 231100000252 nontoxic Toxicity 0.000 description 2
- 230000003000 nontoxic effect Effects 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229920002312 polyamide-imide Polymers 0.000 description 2
- 229920006393 polyether sulfone Polymers 0.000 description 2
- 229920001721 polyimide Polymers 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 229920001059 synthetic polymer Polymers 0.000 description 2
- 241000283690 Bos taurus Species 0.000 description 1
- 241000219357 Cactaceae Species 0.000 description 1
- 241000196324 Embryophyta Species 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 241000588724 Escherichia coli Species 0.000 description 1
- 241001360526 Escherichia coli ATCC 25922 Species 0.000 description 1
- 238000002768 Kirby-Bauer method Methods 0.000 description 1
- 241001465754 Metazoa Species 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000006065 biodegradation reaction Methods 0.000 description 1
- 239000010796 biological waste Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 201000010099 disease Diseases 0.000 description 1
- 208000037265 diseases, disorders, signs and symptoms Diseases 0.000 description 1
- 230000035622 drinking Effects 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 239000013505 freshwater Substances 0.000 description 1
- 239000001963 growth medium Substances 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 230000036039 immunity Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 230000005764 inhibitory process Effects 0.000 description 1
- 229920002521 macromolecule Polymers 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000004660 morphological change Effects 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 231100001223 noncarcinogenic Toxicity 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 230000037361 pathway Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 238000011012 sanitization Methods 0.000 description 1
- 239000013535 sea water Substances 0.000 description 1
- 230000001235 sensitizing effect Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000008399 tap water Substances 0.000 description 1
- 235000020679 tap water Nutrition 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000010409 thin film Substances 0.000 description 1
- 239000010891 toxic waste Substances 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 239000002351 wastewater Substances 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
- 235000020681 well water Nutrition 0.000 description 1
- 239000002349 well water Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
- B01D69/08—Hollow fibre membranes
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
- A61L2/02—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using physical phenomena
- A61L2/022—Filtration
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
- A61L2/16—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using chemical substances
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
- A61L2/00—Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
- A61L2/26—Accessories or devices or components used for biocidal treatment
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D61/00—Processes of separation using semi-permeable membranes, e.g. dialysis, osmosis or ultrafiltration; Apparatus, accessories or auxiliary operations specially adapted therefor
- B01D61/14—Ultrafiltration; Microfiltration
- B01D61/18—Apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
- B01D63/02—Hollow fibre modules
- B01D63/024—Hollow fibre modules with a single potted end
- B01D63/0241—Hollow fibre modules with a single potted end being U-shaped
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
- B01D69/02—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2313/00—Details relating to membrane modules or apparatus
- B01D2313/23—Specific membrane protectors, e.g. sleeves or screens
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2313/00—Details relating to membrane modules or apparatus
- B01D2313/44—Cartridge types
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2313/00—Details relating to membrane modules or apparatus
- B01D2313/90—Additional auxiliary systems integrated with the module or apparatus
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2325/00—Details relating to properties of membranes
- B01D2325/48—Antimicrobial properties
-
- 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
- C02F1/44—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
- C02F1/00—Treatment of water, waste water, or sewage
- C02F1/50—Treatment of water, waste water, or sewage by addition or application of a germicide or by oligodynamic treatment
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Animal Behavior & Ethology (AREA)
- Epidemiology (AREA)
- Public Health (AREA)
- Veterinary Medicine (AREA)
- Engineering & Computer Science (AREA)
- Water Supply & Treatment (AREA)
- General Chemical & Material Sciences (AREA)
- Separation Using Semi-Permeable Membranes (AREA)
Abstract
An antimicrobial microfiltration filter (10) is made from a bundle of polymeric semipermeable hollow fibers (22) treated with antimicrobial agent and a microporous filter medium (28) which may also be treated with an antimicrobial agent.
Description
ANTIINIICROBIAL FILTER CARTRIDGE
:FIELD OF THE INVENTION
The present invention relates generally to filters for the purification of liquids. In particular, the invention relater to antimicrobial semipermeable hollow fiber membranes used in reverse osmosis, ultrafiltration/nanofiltration and microfiltration.
In recent years, the public has become increasingly aware of the deteriorating quality and quantity of our nation's and the world's fresh water supply. Pollutants, biological and toxic waste and other contaminants are being introduced into water supplies at an ever increasing rate, making such water supplies unfit for drinking and other necessary uses. For example, medical patients with low immunity we now being requested not to drink tap water, and disease and illnesses linked to poor quality drinking water have increased dramatically in recent years. This problem is especially significa~at outside the United States where water quality has deteriorated to an all time low, with the major source of such contamination primarily being bacterial in nature.
In many areas of the world potable water is not only contaminated but it is also scarce.
In these areas people must rely upon expensive purification systems to remove dissolved solids from sea water or well water.
Reverse osmosis filtration systems are some of the most common solutions for improving water quality. Osmosis is the flow or diffusion that takes place through a semipermeable membrane (as in a living cell) typically separating either a solvent (as water) and a solution or a dilute solution and a concentrated solution. The semipermeable membrane controls the flow of solute from the concentrated solution to the dilute solution thus bringing about conditions for equalizing the concentrations of solute on the two sides of the membrane to form an equilibrium. In reverse osmosis, pressure is deliberately applied to the more concentrated solution causing; the flow of solvent in the opposite direction through the membrane, i.e., into the more dilute solution. In this way the liquid can be separated from solids and dissolved solids, decreasing the concentration of the solids and dissolved solids in the filtered fluid.
The wide spread use of reverse osmosis to produce potable water began in the early 1960's when Loeb and Sourirajan developed thin-skin cellulose acetate membranes for use in reverse osmosis systems. These cellulose acetate membranes provided much higher salt rejection (approaching 95%) and solvent flow than previously known reverse osmosis methods.
Cellulose acetate membranes are also relatively inexpensive and are very tolerant of chlorine which is commonly used to eliminate bacteria in water. Since the 1960's the use of reverse osmosis has grown dramatically in waste water applications and industrial desalinization plants to produce drinking water from brackish and sea waters. More recently cellulose acetate membranes have been incorporated into consumer filtration systems to produce drinking water at the point of use. Matsuura, T., Synthetic Membranes and Membrane Separation Processes, CRC Press, (1994). Although cellulose acetate membranes greatly expanded the utilization of reverse osmosis treatment systems, such systems are still restricted by operational problems.
For example, cellulose acetate membranes biodegrade readily.
Recently, thin film composite polyamide membranes have been developed that offer better performance than cellulose acetate membranes. These composite poIyamide membranes exhibit salt rejection rates greater than 99.5% at pressures much lower than the pressures used for cellulose acetate membrane:.. Additionally, polyamide membranes reject silica, nitrates, and organic materials much betteo than cellulose acetate membranes. Because of the high performance of composite polyamide membranes, these membranes are used in high purity or ultrahigh purity water systems in pharmaceutical and electronics industries.
However, just as cellulose acetate membranes exhibit a limiting characteristic (i.e., biodegradation) so do composite polyamide membranes. Composite polyamide membranes are susceptible to damage firm chlorine.
As the technology for manufacturing composite polyamide and cellulose acetate S membranes has progressed, new fields of filtration, called ullrafiltration (also called nanofiltration) and microfiltration have been created. Membranes based on polysulfone, polycarbonate, polypropylene, polyvinylidene difluoride and nylon have been developed for these applications.
For example, membranes used in hyperfiltration remove particles of 1-10 Angstrom units and include chemical compounds of about 180 to 15,000 molecular weights.
Ultrafiltration filters particles of 30 to 1,100 Angstrom units that includes macromolecules of molecular weight of 10,000 to 2.50,000. Microfiltration which is mainly used to remove bacteria from solutions covers the range of 500 Angstrom to 20,000 Angstroms or 0.05 to 2 microns.
(Lonsdale, H.K. "The Crrowth of Membrane Technology" Journal of Membrane Science, 10, p.80-81 (1982)). Unfortunately, these great strides in filtration have come at a cost, primarily in the form of bacteria contamination of filters and increased back pressures.
Bacteria contained in irdluent water may be arrested by reverse osmosis filters. In such a filter bacteria accumulate on the surface of the semipermeable membranes.
Bacteria multiply every 30-60 minutes. Their growth is logarithmic and a single bacterial cell will result in 16 million bacteria in 24 hours. The explosive growth of bacteria results in fouling of the membrane which reduces the f low of water through the membrane and can adversely affect the filtering properties of the membrane. For example, bacteria build-up typically has an adverse affect on salt rejection in a reverse osmosis membrane. (Wes Byrne, Reverse Osmosis, Chapter 9 - Biological Fouling). Fouled membranes require higher operating pressures which in turn increases operating costs.
:FIELD OF THE INVENTION
The present invention relates generally to filters for the purification of liquids. In particular, the invention relater to antimicrobial semipermeable hollow fiber membranes used in reverse osmosis, ultrafiltration/nanofiltration and microfiltration.
In recent years, the public has become increasingly aware of the deteriorating quality and quantity of our nation's and the world's fresh water supply. Pollutants, biological and toxic waste and other contaminants are being introduced into water supplies at an ever increasing rate, making such water supplies unfit for drinking and other necessary uses. For example, medical patients with low immunity we now being requested not to drink tap water, and disease and illnesses linked to poor quality drinking water have increased dramatically in recent years. This problem is especially significa~at outside the United States where water quality has deteriorated to an all time low, with the major source of such contamination primarily being bacterial in nature.
In many areas of the world potable water is not only contaminated but it is also scarce.
In these areas people must rely upon expensive purification systems to remove dissolved solids from sea water or well water.
Reverse osmosis filtration systems are some of the most common solutions for improving water quality. Osmosis is the flow or diffusion that takes place through a semipermeable membrane (as in a living cell) typically separating either a solvent (as water) and a solution or a dilute solution and a concentrated solution. The semipermeable membrane controls the flow of solute from the concentrated solution to the dilute solution thus bringing about conditions for equalizing the concentrations of solute on the two sides of the membrane to form an equilibrium. In reverse osmosis, pressure is deliberately applied to the more concentrated solution causing; the flow of solvent in the opposite direction through the membrane, i.e., into the more dilute solution. In this way the liquid can be separated from solids and dissolved solids, decreasing the concentration of the solids and dissolved solids in the filtered fluid.
The wide spread use of reverse osmosis to produce potable water began in the early 1960's when Loeb and Sourirajan developed thin-skin cellulose acetate membranes for use in reverse osmosis systems. These cellulose acetate membranes provided much higher salt rejection (approaching 95%) and solvent flow than previously known reverse osmosis methods.
Cellulose acetate membranes are also relatively inexpensive and are very tolerant of chlorine which is commonly used to eliminate bacteria in water. Since the 1960's the use of reverse osmosis has grown dramatically in waste water applications and industrial desalinization plants to produce drinking water from brackish and sea waters. More recently cellulose acetate membranes have been incorporated into consumer filtration systems to produce drinking water at the point of use. Matsuura, T., Synthetic Membranes and Membrane Separation Processes, CRC Press, (1994). Although cellulose acetate membranes greatly expanded the utilization of reverse osmosis treatment systems, such systems are still restricted by operational problems.
For example, cellulose acetate membranes biodegrade readily.
Recently, thin film composite polyamide membranes have been developed that offer better performance than cellulose acetate membranes. These composite poIyamide membranes exhibit salt rejection rates greater than 99.5% at pressures much lower than the pressures used for cellulose acetate membrane:.. Additionally, polyamide membranes reject silica, nitrates, and organic materials much betteo than cellulose acetate membranes. Because of the high performance of composite polyamide membranes, these membranes are used in high purity or ultrahigh purity water systems in pharmaceutical and electronics industries.
However, just as cellulose acetate membranes exhibit a limiting characteristic (i.e., biodegradation) so do composite polyamide membranes. Composite polyamide membranes are susceptible to damage firm chlorine.
As the technology for manufacturing composite polyamide and cellulose acetate S membranes has progressed, new fields of filtration, called ullrafiltration (also called nanofiltration) and microfiltration have been created. Membranes based on polysulfone, polycarbonate, polypropylene, polyvinylidene difluoride and nylon have been developed for these applications.
For example, membranes used in hyperfiltration remove particles of 1-10 Angstrom units and include chemical compounds of about 180 to 15,000 molecular weights.
Ultrafiltration filters particles of 30 to 1,100 Angstrom units that includes macromolecules of molecular weight of 10,000 to 2.50,000. Microfiltration which is mainly used to remove bacteria from solutions covers the range of 500 Angstrom to 20,000 Angstroms or 0.05 to 2 microns.
(Lonsdale, H.K. "The Crrowth of Membrane Technology" Journal of Membrane Science, 10, p.80-81 (1982)). Unfortunately, these great strides in filtration have come at a cost, primarily in the form of bacteria contamination of filters and increased back pressures.
Bacteria contained in irdluent water may be arrested by reverse osmosis filters. In such a filter bacteria accumulate on the surface of the semipermeable membranes.
Bacteria multiply every 30-60 minutes. Their growth is logarithmic and a single bacterial cell will result in 16 million bacteria in 24 hours. The explosive growth of bacteria results in fouling of the membrane which reduces the f low of water through the membrane and can adversely affect the filtering properties of the membrane. For example, bacteria build-up typically has an adverse affect on salt rejection in a reverse osmosis membrane. (Wes Byrne, Reverse Osmosis, Chapter 9 - Biological Fouling). Fouled membranes require higher operating pressures which in turn increases operating costs.
In addition to reducing water quality and pressure, bacteria fouled membranes are diffcult to clean. As a result of bacterial growth on the membrane, a gelatinous biofilm is formed on the upstream surface of the membrane which is very difficult to remove, except through use of strong chemical oxidants that damage the membrane. The biofilm protects the bacteria from the normal clearang and sanitizing procedures and leads to a break through of bacteria across the membrane. This phenomena is not completely understood, since the pores of most reverse osmosis and ul.trafiltration membranes are at least 2 to 4 orders of magnitude smaller than the bacterial cells, One possible explanation is that the bacterial cells exist in a dynamic state with continuous'. morphological changes occurring throughout the population.
These bacteria then get more opportunities and time to find their way to an accommodating pathway through the membrane. Typically, bacteria are detected on the downstream side of the membrane in 48 to 72 hours. 'I7ze downstream side of the membrane becomes discolored or black over time as the bacteria colonize on the downstream side of the membrane and form a biofilm that is di~cult to rerrtove. Such biological fouling can also lead to formation of 1 S localized extremes in pH that c;an damage the membrane.
The filter cartridges described in U.S. Patent 5,762,797; Application Serial No.
08/877,080 and Application Serial No. 60/090,966 provide solutions to the problems created by bacteria buildup in reverse osmosis filters. By incorporating antimicrobial agents within various structures within the filter, water filters may be produced that are capable of removing and eliminating practically all r;nicroorganisms that may be present in the influent.
However, these filters, especially those with smaller pore sizes, create substantial back pressures in water delivery sys~:ems. In many countries the water pressure in municipal water lines is less than 60 psi. In such countries 0.1 to 0.45 micron rated filters, such as those described in U.S. Patent 5,762.,797, result in flow rates too low for practical operation. To address this problem the continuation application, Serial No. 08/877,080, taught among other things, the use of a filter cartrid;~e with semipermeable membranes having a nominal pore size of 0.75 microns. Increasing thc; nominal pore size increases the flow of the water through the filter cartridge without increasing back-pressures.
These bacteria then get more opportunities and time to find their way to an accommodating pathway through the membrane. Typically, bacteria are detected on the downstream side of the membrane in 48 to 72 hours. 'I7ze downstream side of the membrane becomes discolored or black over time as the bacteria colonize on the downstream side of the membrane and form a biofilm that is di~cult to rerrtove. Such biological fouling can also lead to formation of 1 S localized extremes in pH that c;an damage the membrane.
The filter cartridges described in U.S. Patent 5,762,797; Application Serial No.
08/877,080 and Application Serial No. 60/090,966 provide solutions to the problems created by bacteria buildup in reverse osmosis filters. By incorporating antimicrobial agents within various structures within the filter, water filters may be produced that are capable of removing and eliminating practically all r;nicroorganisms that may be present in the influent.
However, these filters, especially those with smaller pore sizes, create substantial back pressures in water delivery sys~:ems. In many countries the water pressure in municipal water lines is less than 60 psi. In such countries 0.1 to 0.45 micron rated filters, such as those described in U.S. Patent 5,762.,797, result in flow rates too low for practical operation. To address this problem the continuation application, Serial No. 08/877,080, taught among other things, the use of a filter cartrid;~e with semipermeable membranes having a nominal pore size of 0.75 microns. Increasing thc; nominal pore size increases the flow of the water through the filter cartridge without increasing back-pressures.
Unfortunately, increasing the nominal pore size of a filter also compromises the filter's ability to retain and deactivate bacteria. For example, some bacteria may slip through pores of 0.75 microns. In theory, it is preferable to approach a nominal pore size of 0.1 micron, because as the nominal pore size decre~~ses, the higher the log reduction of bacteria and the better the performance of the filter cartridge as a bactericidal device.
Perhaps the primary factor limiting flow of water through the above described filters is the total surface area of the mernbrane through which water is able to pass or more specifically, the lack of surface area. When a semipermeable membrane is in the form of a flat sheet, as is typically utilized in a microfiltration filter cartridge, the maximum surface area is limited to the circumference of the plastic or activated carbon core over which it is wrapped. One method to increase surface area is to pleat; the filter medium as is done in purely mechanical membrane filters, such as automobile oil filters. In the microfiltration context this solution is difficult to implement.
In short, a need exists fir a reverse osmosis water filter that is capable of retaining and eliminating bacteria and allowi~lg sufficient fluid flow and water pressure to be of practical use in water systems around the world.
OBJECTS OF THE INVENTION
It is the principal object; of this invention to provide a water filter that achieves a high level of separation of water soluble contaminants.
It is also an object of this invention to provide a water filter that resists fouling due to bacterial growth.
It is another object of this invention to provide a microfiltration filter capable of increased fluid flow.
S
It is a fiuther object of this invention to provide a microfiltration filter that may be effectively utilized in low pressure water systems.
SUMMARY OF THE INVENTION
The present invention is~ directed toward an antimicrobial filter cartridge which utilizes a bundle of semipermeable hollow fibers centrally located within a housing.
The housing has a two chambers separated by a barrier through which the hollow fibers extend.
The hollow fibers are enclosed in one chamber and open in the other.
The chamber housing the enclosed hollow fibers also contains a microporous filter medium, such as a melt blown polymer web or a tightly wound yarn, that sun ounds the hollow fibers. This chamber also receives the fluid to be filtered. The barrier between the two chambers forces the water through the microporous filter medium where solid contaminates are removed. The water is also forced through the walls of the semipermeable hollow fibers which work to remove various dissolved solids finm the water.
The water that enters tl;~e hollow fibers flows within the hollow fiber and through the barner where it is then discharged into the other chamber of the housing firm where it flows out of the housing and to its end u.~e:
The various components of the antimicrobial filter, such as the hollow fibers and the microporous filter medium, may be treated with an antimicrobial agent to eliminate any microorganisms, such as bacteria, that may be filtered from the water.
BRIF;F DESCRIPTION OF THE DRAWINGS
The foregoing and other objects will become more readily apparent by referring to the following detailed description rind the appended drawings in which:
FIG. 1 is a cross-sectional view of one embodiment of an antimicrobial filter in accordance with the invention.
FIG. 2 is a cross-sectic~nal_ view of a second emLodirmPnt of an ant;.mic._v.biat filter in accordance with the invention.
DETAILED DESCRIPTION
4 , In the following description, like reference numerals designate like yr corresponding parts throughout the several figures. It is to be also understood that such terms as "front", "rear", "side", "up", and "down" are used for purposes of locating one element relative to another and are not to be construed as limiting terms:' Further, it should be understood that the illustirations are for the purpose of describing preferred embodiments of the invention, and thus are not intended to limit the invention in any manner.
One aspect of the present invention is an improvement upon.the bactericidal filters described in U.S: PatentNo. 5,762;797 (the '797 patent) and U.S. Application 08/877,080 (the '080 application). In general terms, a filter cartridge is piovided.that is similar to the catiridges disclosed ;n the '797 patent arid the '080 application excxpt that the flat semipemaeable membranes utilised in those carrsidges is replaced with hollow fiber membranes. The hollow fiber membranes utilised in this application can be used with or without treatment with an antimicrobial agent, such as Microban~ Additive B, but the use of such an antimicxobial agent is preferred. A description of hollow fiber membranes and their method of manufaatm~e may be found in U.S. Patent No. 5,762,798 to Wenthold et al.
In order to aid in the understanding of this application a brief introduction to hollow fiber membranes is necessary. A microporous hollow fiber is a polymeric tube having an outside diameaer less than or equal to 2 mm and whose wall functions as a semipermeable membrane. Tl~se microporous hollow fibers can be created with controlled porosity starting from as low as 0.05 micron to slightly less than 1 micron using techniques that are familiar to those well versed in the art. See Cabasso, "Hollow Fiber Membranes", Kirk-Othmer Encyclopedia & Chemical Technology, 3rd Ed., John Wiley & Sons, 12:492-517 (1984).
Hollow fiber membranes are made with many types of synthetic polymers such as acrylonitrile, polysulfone, polyethersulfones, aromatic polyamides, polyimides, polyamide-imides, and polyvinylidene fluoride. The preparation of membranes for diverse applications is extensively described in the patent and technical literature, some of the relevant patents being, Klein et al U.S. Patent No. 4,051,300 and Wenthold et al U.S. Patent No.
Perhaps the primary factor limiting flow of water through the above described filters is the total surface area of the mernbrane through which water is able to pass or more specifically, the lack of surface area. When a semipermeable membrane is in the form of a flat sheet, as is typically utilized in a microfiltration filter cartridge, the maximum surface area is limited to the circumference of the plastic or activated carbon core over which it is wrapped. One method to increase surface area is to pleat; the filter medium as is done in purely mechanical membrane filters, such as automobile oil filters. In the microfiltration context this solution is difficult to implement.
In short, a need exists fir a reverse osmosis water filter that is capable of retaining and eliminating bacteria and allowi~lg sufficient fluid flow and water pressure to be of practical use in water systems around the world.
OBJECTS OF THE INVENTION
It is the principal object; of this invention to provide a water filter that achieves a high level of separation of water soluble contaminants.
It is also an object of this invention to provide a water filter that resists fouling due to bacterial growth.
It is another object of this invention to provide a microfiltration filter capable of increased fluid flow.
S
It is a fiuther object of this invention to provide a microfiltration filter that may be effectively utilized in low pressure water systems.
SUMMARY OF THE INVENTION
The present invention is~ directed toward an antimicrobial filter cartridge which utilizes a bundle of semipermeable hollow fibers centrally located within a housing.
The housing has a two chambers separated by a barrier through which the hollow fibers extend.
The hollow fibers are enclosed in one chamber and open in the other.
The chamber housing the enclosed hollow fibers also contains a microporous filter medium, such as a melt blown polymer web or a tightly wound yarn, that sun ounds the hollow fibers. This chamber also receives the fluid to be filtered. The barrier between the two chambers forces the water through the microporous filter medium where solid contaminates are removed. The water is also forced through the walls of the semipermeable hollow fibers which work to remove various dissolved solids finm the water.
The water that enters tl;~e hollow fibers flows within the hollow fiber and through the barner where it is then discharged into the other chamber of the housing firm where it flows out of the housing and to its end u.~e:
The various components of the antimicrobial filter, such as the hollow fibers and the microporous filter medium, may be treated with an antimicrobial agent to eliminate any microorganisms, such as bacteria, that may be filtered from the water.
BRIF;F DESCRIPTION OF THE DRAWINGS
The foregoing and other objects will become more readily apparent by referring to the following detailed description rind the appended drawings in which:
FIG. 1 is a cross-sectional view of one embodiment of an antimicrobial filter in accordance with the invention.
FIG. 2 is a cross-sectic~nal_ view of a second emLodirmPnt of an ant;.mic._v.biat filter in accordance with the invention.
DETAILED DESCRIPTION
4 , In the following description, like reference numerals designate like yr corresponding parts throughout the several figures. It is to be also understood that such terms as "front", "rear", "side", "up", and "down" are used for purposes of locating one element relative to another and are not to be construed as limiting terms:' Further, it should be understood that the illustirations are for the purpose of describing preferred embodiments of the invention, and thus are not intended to limit the invention in any manner.
One aspect of the present invention is an improvement upon.the bactericidal filters described in U.S: PatentNo. 5,762;797 (the '797 patent) and U.S. Application 08/877,080 (the '080 application). In general terms, a filter cartridge is piovided.that is similar to the catiridges disclosed ;n the '797 patent arid the '080 application excxpt that the flat semipemaeable membranes utilised in those carrsidges is replaced with hollow fiber membranes. The hollow fiber membranes utilised in this application can be used with or without treatment with an antimicrobial agent, such as Microban~ Additive B, but the use of such an antimicxobial agent is preferred. A description of hollow fiber membranes and their method of manufaatm~e may be found in U.S. Patent No. 5,762,798 to Wenthold et al.
In order to aid in the understanding of this application a brief introduction to hollow fiber membranes is necessary. A microporous hollow fiber is a polymeric tube having an outside diameaer less than or equal to 2 mm and whose wall functions as a semipermeable membrane. Tl~se microporous hollow fibers can be created with controlled porosity starting from as low as 0.05 micron to slightly less than 1 micron using techniques that are familiar to those well versed in the art. See Cabasso, "Hollow Fiber Membranes", Kirk-Othmer Encyclopedia & Chemical Technology, 3rd Ed., John Wiley & Sons, 12:492-517 (1984).
Hollow fiber membranes are made with many types of synthetic polymers such as acrylonitrile, polysulfone, polyethersulfones, aromatic polyamides, polyimides, polyamide-imides, and polyvinylidene fluoride. The preparation of membranes for diverse applications is extensively described in the patent and technical literature, some of the relevant patents being, Klein et al U.S. Patent No. 4,051,300 and Wenthold et al U.S. Patent No.
5,762,798. Also see "Hollow Fiber Membranes", Kirk-Othmer Encyclopedia of Chemical Technology, 3d Ed., John Wiley & Sons 12:492-517 (1984)s Preferably, the hollow fibers utilized in the invention are treated with an antimicrobial agent. Preferably, the antimicrobial agent is selected from the group consisting, of 2,4,4'-trichloro-2'hydroxy diphenol ether and 5-chloro-2-phenol(2,3-dichlorophenoxy). The antimicrobial agent is present in a concentration from about 500 ppm to about 20,000 ppm by weight, and preferably from about 2,500 ppm to about 20,000 ppm by weight based upon the weight of the polysulfone and polyvinylidene fluoride polymer. The antimicrobial agent is incorporated into hollow fibers by adding it to the "dope" solution used to form the follow fibers. A wide variety of hollow fiber membranes may be made depending on their, applications which include, reverse osmosis, ultrafiltration, microfiltration, etc. Although the concepts of the present invention apply equally to all three of these areas, this discussion is directed primarily to the area of microfiltration.
By using bundles of these microporous hollow fibers as a membrane instead of a flat sheet microporous membrane, it is possible to increase the available filter surface area within a filter cartridge of the same dimension by several orders of magnitude. For example, in the conventional 10 inch filter cacti idge design described in the '797 patent and the '080 application, the surface area of the flat sheet membrane is approximately 0.04 mi. In a filter cartridge of the same basic design using hollow fibers, it is possible to achieve a microporous membrane surface area of between 60 to 160 m2 or more depending on the diameter of the hollow fibers utilized.
Availability of such a large surface area results in higher flow rates, lower back pressures and the ability to use lower pore diameters resulting in higher bacterial log reduction.
'The prP~rt impro~~ement l:: deSlgn ~f 13a~~.terlC:dal ~.ItSi' C
ui'~~°w°, S'ua~, h Fu u~'loSc described in the '797 patent and the '080 application consists of substituting a microporous hollow fiber membrane for a flat sheet microporous membrane. This substitution allows the use of membranes with much finer pore diameters without compromising flow rates or creating unacceptable back pressure.
FIG. 1 illustrates a preferred embodiment of an antimicrobial filter cartridge constructed in accordance with the present invention. The antimicrobial filter cartridge 10 includes a plurality of semipezmeable hollow fibers 12 centrally located within housing 14 which has a first chamber 16 and a second chamber 18 separated by a barrier 20 through which hollow fibers 12 extend.- The second chamber 18 is in fluid communication with the source of the fluid to be filtered through fluid inlet 24. For purposes of this discussiozt water will be used as the fluid to be filtered. The first chamber 16 acts as a temporary repository of filtered water.
I S The semipenneable hollow fibers 12 tnay be made of any of the types of synthetic polymers discussed above including acrylonitrile, polysulfone, polyethersulfones, aroniatic polyamides, polyimides, polyamide-imides, and polyvinylidene fluoride. Preferably the hollow fibers 12 also incorporate an antimicrobial agent. Preferably, the antimicrobial agent used to, treat the hollow fibers, and any other component of the filter, is practically insoluble in the water passing through and over the filter cartridge, and is safe, non-toxic, non-carcinogenic, non-sensitizing to human and animal skin and does not accumulate in the human body when ingested. Generally, therefore, the antimicrobiai is a broad spectrum antirnicrobial agent, i.e., it is equally effective against the majority of harmful bacteria encountered in water. For example, an antimicrobial agent such as 2,4,4'-trichloro-2'-hydroxydiphenol ether, or 5-chloro-2phenol (2,4 dichlorophenoxy) commonly sold under the trademark MICROBAN~B, by Microban Products Co., Huntersville, North Carolina, typically will be used. However, it will be understood various other anixmicrobial agents that are safe non-toxic and substantially insoluble in water can be used in the present invention.
Hollow fibers formed of polyvinylidene fluoride (pvd) containing Microban~ B
have been tested and found to exhibit excellent antimicrobial properties as shown in the test results below.
MICR.OBIOLOGICAL TEST REPORT
Kirby Bauer Test Organism: Syaphylococcus aureus ATCC 6538 Escherichia coli ATCC 25922 Sample Material: PVDF
Sample Size: Variable Growth Medium: Mueller-Hinton Agar Test Conditions: Incubated at 37° ~ 2°C for 18-24 hours Results (Zone Size) Sample Identification S. aureus E. coli 7196-OCP-TP-1 (1.92) Microban in l9mm l2mm dope 7197-OCP-TP-1 (0.98) Microban in l7mm l Omm dope 7198-OCP-TP-1 (0.48) Microban in l4mm 9mm dope Interpretation of Results NZ - No Zone of inl~ubition surrounding the sample NI - No Inhibition of Growth Under the Sample I - Inhibition of Growth Under the Sample (If Observable) mm - Zone of Inhibition Reported in Millimeters The hollow fibers 12 should be arranged such that an open end extends from the barrier 20 into the first chamber 16 while a closed end extends from the barrier 20 into the second chamber 18. Such an ~~rrangement may be accomplished by enclosing one end of a single hollow fiber 12 and extending that end of the hollow fiber 12 into the second chamber 18. A similar arrangement ma.y be accomplished by bending a hollow fiber 12 that has both ends open. This second possit~ility is illustrated in FIG. 1. In FIG. 1 the hollow fibers 12 are long open-ended tubes that ane bent such that the two ends are approximately parallel and approximately equidistant from a midpoint. The hollow fibers 12 must not be bent so as to compromise their structural integrity. The hollow fibers 12 are bundled together by the barrier 20 and placed centrally within housing 14 such that the open end portions of the hollow fibers 12 extend into the first chamber 16.
Preferably the barner 20 is formed of a thermoset or thermoplastic polymer such as polyurethane or an epoxy. Th.e barrier 20 which encloses a portion of the hollow fibers 20 may be manufactured external to the housing. It is anticipated that in most instances the barrier 20 enclosing hollow fibers 12 will be formed in a mold external to the housing so that other elements may be more easily secured through placement within the barrier 20 as will be discussed below.
Continuing with FIG. :l, surrounding the bundle of hollow fibers 12 is a microporous filter medium. In FIG. 1 the ~nicroporous filter medium is a melt-blown polymer web 22.
The polymer may be selected from the group consisting of nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic., polyester, polyethylene and mixtures thereof. In a preferred embodiment polypropylene fibers are impregnated with Microban~ B during extrusion and blown into a continuous web having an effective pore size of 5 microns. The concentration of the antimicrobial agent in the fibers generally is between 50 to 20,000 ppm, preferably between 1000 ppm to 5000 ppm.
The melt blown web 2~; may be held in place by making it of sufficient thickness such that the sides of housing 14 ke;ep its position secure. In fact it is important to surround the hollow fibers 12 and all the empty volume near them with antimicrobial fibers because the objective is to force all bacteri;~ mechanically withheld by the microporous filter medium to come into contact with an antimicrobial surface so that the bacteria may be deactivated.
Alternatively and as illustrated in FIG. I the melt blown web 22 may be secured by setting one end of the web within barrier ZO thereby making the barner 20, the bundle of hollow fibers 12 and the melt blown web 22 a single unit within housing 14.
In operation water enters antimicrobial filter cartridge 10 second chamber 18 through fluid inlet 24 and is prohibited from flowing into the first chamber 16 by the barrier 20. The barner 20 along with the walls of the second chamber 18 force the water into contact with the melt blown web 22 and the semipermeable walls of the hollow fibers 12 where the fluid is filtered and any retained microorganisms, such as bacteria, are eliminated by coming into contact with the antimicrobial agent.
The water that passes through the semipermeable walls of the hollow f hers 12 and into the annular space within each hollow fiber 12 then exits the hollow fiber 12 into the first chamber 16 and is discharged out of fluid outlet 26. The filtering capability of such a filter should meet that of the filters described in the '797 patent and the '080 application while operating at higher flow rates and reduced back pressure.
FIG. 2 illustrates another preferred embodiment of the antimicrobial filter according to the invention that is very similar to FIG. I . However in this embodiment the melt blown web 22 is replaced by a wrapping of yarn 28. The yarn can be made of cotton, nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic, polyester, polyethylene or any mixture thereof. In a preferred embodiment shown in FIG. 2, the yam 28 is 0.60 cotton count (cc) yarn. The yarn 28 contains polypropylene fiber between 0.3 denier per filament (dpf) to 10 dpf, the preferable range based on cost and performance being 1.5 dpf to .
By using bundles of these microporous hollow fibers as a membrane instead of a flat sheet microporous membrane, it is possible to increase the available filter surface area within a filter cartridge of the same dimension by several orders of magnitude. For example, in the conventional 10 inch filter cacti idge design described in the '797 patent and the '080 application, the surface area of the flat sheet membrane is approximately 0.04 mi. In a filter cartridge of the same basic design using hollow fibers, it is possible to achieve a microporous membrane surface area of between 60 to 160 m2 or more depending on the diameter of the hollow fibers utilized.
Availability of such a large surface area results in higher flow rates, lower back pressures and the ability to use lower pore diameters resulting in higher bacterial log reduction.
'The prP~rt impro~~ement l:: deSlgn ~f 13a~~.terlC:dal ~.ItSi' C
ui'~~°w°, S'ua~, h Fu u~'loSc described in the '797 patent and the '080 application consists of substituting a microporous hollow fiber membrane for a flat sheet microporous membrane. This substitution allows the use of membranes with much finer pore diameters without compromising flow rates or creating unacceptable back pressure.
FIG. 1 illustrates a preferred embodiment of an antimicrobial filter cartridge constructed in accordance with the present invention. The antimicrobial filter cartridge 10 includes a plurality of semipezmeable hollow fibers 12 centrally located within housing 14 which has a first chamber 16 and a second chamber 18 separated by a barrier 20 through which hollow fibers 12 extend.- The second chamber 18 is in fluid communication with the source of the fluid to be filtered through fluid inlet 24. For purposes of this discussiozt water will be used as the fluid to be filtered. The first chamber 16 acts as a temporary repository of filtered water.
I S The semipenneable hollow fibers 12 tnay be made of any of the types of synthetic polymers discussed above including acrylonitrile, polysulfone, polyethersulfones, aroniatic polyamides, polyimides, polyamide-imides, and polyvinylidene fluoride. Preferably the hollow fibers 12 also incorporate an antimicrobial agent. Preferably, the antimicrobial agent used to, treat the hollow fibers, and any other component of the filter, is practically insoluble in the water passing through and over the filter cartridge, and is safe, non-toxic, non-carcinogenic, non-sensitizing to human and animal skin and does not accumulate in the human body when ingested. Generally, therefore, the antimicrobiai is a broad spectrum antirnicrobial agent, i.e., it is equally effective against the majority of harmful bacteria encountered in water. For example, an antimicrobial agent such as 2,4,4'-trichloro-2'-hydroxydiphenol ether, or 5-chloro-2phenol (2,4 dichlorophenoxy) commonly sold under the trademark MICROBAN~B, by Microban Products Co., Huntersville, North Carolina, typically will be used. However, it will be understood various other anixmicrobial agents that are safe non-toxic and substantially insoluble in water can be used in the present invention.
Hollow fibers formed of polyvinylidene fluoride (pvd) containing Microban~ B
have been tested and found to exhibit excellent antimicrobial properties as shown in the test results below.
MICR.OBIOLOGICAL TEST REPORT
Kirby Bauer Test Organism: Syaphylococcus aureus ATCC 6538 Escherichia coli ATCC 25922 Sample Material: PVDF
Sample Size: Variable Growth Medium: Mueller-Hinton Agar Test Conditions: Incubated at 37° ~ 2°C for 18-24 hours Results (Zone Size) Sample Identification S. aureus E. coli 7196-OCP-TP-1 (1.92) Microban in l9mm l2mm dope 7197-OCP-TP-1 (0.98) Microban in l7mm l Omm dope 7198-OCP-TP-1 (0.48) Microban in l4mm 9mm dope Interpretation of Results NZ - No Zone of inl~ubition surrounding the sample NI - No Inhibition of Growth Under the Sample I - Inhibition of Growth Under the Sample (If Observable) mm - Zone of Inhibition Reported in Millimeters The hollow fibers 12 should be arranged such that an open end extends from the barrier 20 into the first chamber 16 while a closed end extends from the barrier 20 into the second chamber 18. Such an ~~rrangement may be accomplished by enclosing one end of a single hollow fiber 12 and extending that end of the hollow fiber 12 into the second chamber 18. A similar arrangement ma.y be accomplished by bending a hollow fiber 12 that has both ends open. This second possit~ility is illustrated in FIG. 1. In FIG. 1 the hollow fibers 12 are long open-ended tubes that ane bent such that the two ends are approximately parallel and approximately equidistant from a midpoint. The hollow fibers 12 must not be bent so as to compromise their structural integrity. The hollow fibers 12 are bundled together by the barrier 20 and placed centrally within housing 14 such that the open end portions of the hollow fibers 12 extend into the first chamber 16.
Preferably the barner 20 is formed of a thermoset or thermoplastic polymer such as polyurethane or an epoxy. Th.e barrier 20 which encloses a portion of the hollow fibers 20 may be manufactured external to the housing. It is anticipated that in most instances the barrier 20 enclosing hollow fibers 12 will be formed in a mold external to the housing so that other elements may be more easily secured through placement within the barrier 20 as will be discussed below.
Continuing with FIG. :l, surrounding the bundle of hollow fibers 12 is a microporous filter medium. In FIG. 1 the ~nicroporous filter medium is a melt-blown polymer web 22.
The polymer may be selected from the group consisting of nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic., polyester, polyethylene and mixtures thereof. In a preferred embodiment polypropylene fibers are impregnated with Microban~ B during extrusion and blown into a continuous web having an effective pore size of 5 microns. The concentration of the antimicrobial agent in the fibers generally is between 50 to 20,000 ppm, preferably between 1000 ppm to 5000 ppm.
The melt blown web 2~; may be held in place by making it of sufficient thickness such that the sides of housing 14 ke;ep its position secure. In fact it is important to surround the hollow fibers 12 and all the empty volume near them with antimicrobial fibers because the objective is to force all bacteri;~ mechanically withheld by the microporous filter medium to come into contact with an antimicrobial surface so that the bacteria may be deactivated.
Alternatively and as illustrated in FIG. I the melt blown web 22 may be secured by setting one end of the web within barrier ZO thereby making the barner 20, the bundle of hollow fibers 12 and the melt blown web 22 a single unit within housing 14.
In operation water enters antimicrobial filter cartridge 10 second chamber 18 through fluid inlet 24 and is prohibited from flowing into the first chamber 16 by the barrier 20. The barner 20 along with the walls of the second chamber 18 force the water into contact with the melt blown web 22 and the semipermeable walls of the hollow fibers 12 where the fluid is filtered and any retained microorganisms, such as bacteria, are eliminated by coming into contact with the antimicrobial agent.
The water that passes through the semipermeable walls of the hollow f hers 12 and into the annular space within each hollow fiber 12 then exits the hollow fiber 12 into the first chamber 16 and is discharged out of fluid outlet 26. The filtering capability of such a filter should meet that of the filters described in the '797 patent and the '080 application while operating at higher flow rates and reduced back pressure.
FIG. 2 illustrates another preferred embodiment of the antimicrobial filter according to the invention that is very similar to FIG. I . However in this embodiment the melt blown web 22 is replaced by a wrapping of yarn 28. The yarn can be made of cotton, nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic, polyester, polyethylene or any mixture thereof. In a preferred embodiment shown in FIG. 2, the yam 28 is 0.60 cotton count (cc) yarn. The yarn 28 contains polypropylene fiber between 0.3 denier per filament (dpf) to 10 dpf, the preferable range based on cost and performance being 1.5 dpf to .
6 dpf. The polypropylene fiber is cut into 2 inch staple, then opened and carded and friction spun into a 0.60 cc yarn. The polypropylene fiber is impregnated with an antimicrobial agent, such as Microban~ Additive B during extrusion. The concentration of the antimicrobial agent in the fibers generally is between 50~ to 20,000 ppm, preferably between 1000 ppm to 5000 ppm.
The 0.60 cc yarn is tightly wound around the hollow fibers 12 in a spiral pattern to cover the bundle of hollow fibers 12 completely and to give an effective pore size of 1-5 m. The yam 28 may also be wrapped in a criss-cross pattern as is well described in the '797 patent and the '080 application.
Due to the fragile nature of the hollow fibers 12, it is recommended that the yarn 28 be wrapped around a ridged g~~ide 30 which is set in the barrier 20 and which surrounds and is in very close proximity to th~~ bundle of hollow fibers 12. The guide 30 may simply consist of two or more poles situated ~~t the edge of the bundle of hollow fibers 12 as shown in FIG.
2 or it may be a perforated cylindrical object that completely encloses the bundle of hollow fibers 12.
In an additional embodiment of the antimicrobial filter according to the invention, it is possible to have an activated carbon core working in conjunction with the semipermeable hollow fibers 12. For example, the hollow fibers 12 could be situated within a core of granulated activated carbon which is in turn surrounded by a microporous filter medium.
Likewise the hollow fibers 12 could surround a core of activated carbon. If activated carbon is utilized it is preferable that it be treated with an antimicrobial agent as is thoroughly discussed in the '797 patent arid the '080 application.
The invention has been described in detail, with reference to certain preferred embodiments, in order to enable the reader to practice the invention without undue experimentation. However, a person having ordinary skill in the art will readily recognize that many ofthe components and parameters may be varied or modified to a certain extent without departing from the scope and spirit of the invention. Furthermore, titles, headings, or the like are provided to enhance the reader's comprehension of this document, and should not be read as limiting the scope of the present invention. Accordingly, the intellectual property rights to the invention are defined only by the following claims and reasonable extensions and equivalents thereof.
SUMMARY OF THF: ACHIEVEMENTS OF THE OBJECTS OF THE
INVENTION
From the foregoing, it is readily apparent that I have invented an antimicrobial filter cartridge that achieves a high level of separation of water contaminants while simultaneously resisting fouling due to bacterial growth. Furthermore, the design of the antimicrobial filter cartridge according to the invention provides a microfiltration filter cartridge capable of increased fluid flow and that may be effectively utilized in low pressure water systems.
The 0.60 cc yarn is tightly wound around the hollow fibers 12 in a spiral pattern to cover the bundle of hollow fibers 12 completely and to give an effective pore size of 1-5 m. The yam 28 may also be wrapped in a criss-cross pattern as is well described in the '797 patent and the '080 application.
Due to the fragile nature of the hollow fibers 12, it is recommended that the yarn 28 be wrapped around a ridged g~~ide 30 which is set in the barrier 20 and which surrounds and is in very close proximity to th~~ bundle of hollow fibers 12. The guide 30 may simply consist of two or more poles situated ~~t the edge of the bundle of hollow fibers 12 as shown in FIG.
2 or it may be a perforated cylindrical object that completely encloses the bundle of hollow fibers 12.
In an additional embodiment of the antimicrobial filter according to the invention, it is possible to have an activated carbon core working in conjunction with the semipermeable hollow fibers 12. For example, the hollow fibers 12 could be situated within a core of granulated activated carbon which is in turn surrounded by a microporous filter medium.
Likewise the hollow fibers 12 could surround a core of activated carbon. If activated carbon is utilized it is preferable that it be treated with an antimicrobial agent as is thoroughly discussed in the '797 patent arid the '080 application.
The invention has been described in detail, with reference to certain preferred embodiments, in order to enable the reader to practice the invention without undue experimentation. However, a person having ordinary skill in the art will readily recognize that many ofthe components and parameters may be varied or modified to a certain extent without departing from the scope and spirit of the invention. Furthermore, titles, headings, or the like are provided to enhance the reader's comprehension of this document, and should not be read as limiting the scope of the present invention. Accordingly, the intellectual property rights to the invention are defined only by the following claims and reasonable extensions and equivalents thereof.
SUMMARY OF THF: ACHIEVEMENTS OF THE OBJECTS OF THE
INVENTION
From the foregoing, it is readily apparent that I have invented an antimicrobial filter cartridge that achieves a high level of separation of water contaminants while simultaneously resisting fouling due to bacterial growth. Furthermore, the design of the antimicrobial filter cartridge according to the invention provides a microfiltration filter cartridge capable of increased fluid flow and that may be effectively utilized in low pressure water systems.
Claims (24)
1. An antimicrobial filter cartridge comprising:
a plurality of semi-permeable polymer hollow fibers, said hollow fibers being open at one end incorporating an antimicrobial agent therein, and at least one layer of a microporous filter medium wrapped around said hollow fibers.
a plurality of semi-permeable polymer hollow fibers, said hollow fibers being open at one end incorporating an antimicrobial agent therein, and at least one layer of a microporous filter medium wrapped around said hollow fibers.
2. The antimicrobial filter cartridge of claim 1 wherein said microporous filter medium is a melt blown polymer web formed from the group consisting of nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic, polyester, polyethylene and mixtures thereof.
3. The antimicrobial filter cartridge of claim 1 wherein said microporous filter medium is a yarn wound about said hollow fibers.
4. The antimicrobial filter cartridge of claim 3 wherein said yarn is made from cotton or a polymer selected from the group consisting of nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic, polyester, polyethylene and mixtures thereof.
5. The antimicrobial filter cartridge of claim 2 wherein said melt blown polymer web further comprises an antimicrobial agent incorporated therein.
6. The antimicrobial filter cartridge of claim 3 wherein said yarn is wound in a spiral winding in such manner that each winding turn of said yarn contacts its adjacent turns.
7. The antimicrobial filter cartridge of claim 3 wherein said yarn is wound in a criss-cross pattern.
8. The antimicrobial filter cartridge of claim 3 wherein said yarn further comprises an antimicrobial agent.
9. The antimicrobial filter cartridge of claim 1, wherein said antimicrobial agent is selected from the group consisting of 2,4,4-trichloro-2-hydroxy diphenol ether and 5-chloro-2-phenol(2,4 dichlorophenoxy) compounds.
10. The antimicrobial filter cartridge of claim 1 wherein said hollow fibers have a nominal pore size of from about 0.01 micron to about 1.0 micron.
11. The antimicrobial filter cartridge of claim 1 wherein said hollow fibers have a nominal pore size of from about 0.1 micron to about 0.75 micron.
12. An antimicrobial filter cartridge comprising, activated carbon and a plurality of semi-permeable hollow fibers in close proximity to said activated carbon, said hollow fibers being open at one end and comprising a polymer having an antimicrobial agent incorporated therein; and at least one layer of a. microporous filter medium wrapped around said plurality of hollow fibers.
13. The antimicrobial filter cartridge of claim 12, wherein said antimicrobial agent is selected from the group consisting of 2,4,4-trichloro-2-hydroxy diphenol ether and 5-chloro-2-phenol(2,4 dichlorophenoxy) compounds.
14. The antimicrobial filter cartridge of claim 12 wherein said activated carbon is treated with an antimicrobial agent.
15. The antimicrobial filter cartridge of claim 12 wherein said microporous filter medium is a melt blown polymer web formed from the group consisting of nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic, polyester, polyethylene and mixtures thereof.
16. The antimicrobial filter cartridge of claim 12 wherein said microporous filter medium is a yarn wound about said hollow fibers.
17. The antimicrobial filter cartridge of claim 16 wherein said yarn is made from cotton or a polymer selected from the group consisting of nylon, polypropylene, cellulose acetate, rayon, lyocell, acrylic, polyester, polyethylene and mixtures thereof.
18. The antimicrobial filter cartridge of claim 15 wherein said melt blown polymer web further comprises an antimicrobial agent.
19. The antimicrobial filter cartridge of claim 16 wherein said yarn is wound in a spiral winding such that each winding turn of said yarn contacts its adjacent turns.
20. The antimicrobial filter cartridge of claim 16 wherein said yarn is wound in a criss-cross pattern.
21. The antimicrobial filter cartridge of claim 16 wherein said yarn further comprises an antimicrobial agent.
22. The antimicrobial filter cartridge of claim 12 wherein said hollow fibers have a nominal pore size of from about 0.01 micron to about 1.0 micron.
23. The antimicrobial filter cartridge of claim 12 wherein said hollow fibers have a nominal pore size of from about 0.1 micron to about 0.75 micron.
24. A semi-permeable hollow fiber filter system comprising a plurality of polymer fibers surrounded by a housing, said polymer fibers being generally cylindrical and having an outer wall and an inner wall thereby defining an annular space within each of said polymer fibers, said annular space being in fluid communication with the outside of the housing, said polymer fibers further comprising a non-leaching antimicrobial agent disbursed throughout said polymer fiber.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US1999/018058 WO2001010542A1 (en) | 1999-08-09 | 1999-08-09 | Antimicrobial filter cartridge |
Publications (2)
Publication Number | Publication Date |
---|---|
CA2346750A1 CA2346750A1 (en) | 2001-02-15 |
CA2346750C true CA2346750C (en) | 2003-10-07 |
Family
ID=22273356
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
CA002346750A Expired - Lifetime CA2346750C (en) | 1999-08-09 | 1999-08-09 | Antimicrobial filter cartridge |
Country Status (3)
Country | Link |
---|---|
AU (1) | AU5552099A (en) |
CA (1) | CA2346750C (en) |
WO (1) | WO2001010542A1 (en) |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102010002989A1 (en) * | 2010-03-17 | 2011-09-22 | Sgl Carbon Se | Material composition, its production and use |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4341631A (en) * | 1979-09-07 | 1982-07-27 | Union Carbide Corporation | Ultrafiltration and reverse osmosis device comprising plural carbon tubes bonded together |
US5006267A (en) * | 1989-11-08 | 1991-04-09 | The Dow Chemical Company | Biocidal fluid filters |
US5198110A (en) * | 1990-07-02 | 1993-03-30 | Asahi Medical Co., Ltd. | Bundle of permselective hollow fibers and a fluid separator containing the same |
US5102547A (en) * | 1991-06-21 | 1992-04-07 | Ionics, Incorporated | Anti-fouling semi-permeable membrane system |
EP0537774B1 (en) * | 1991-10-18 | 1998-01-07 | Kuraray Co., Ltd. | Antimicrobial polymerizable composition, the polymer and article obtained from the same |
-
1999
- 1999-08-09 AU AU55520/99A patent/AU5552099A/en not_active Abandoned
- 1999-08-09 WO PCT/US1999/018058 patent/WO2001010542A1/en active Application Filing
- 1999-08-09 CA CA002346750A patent/CA2346750C/en not_active Expired - Lifetime
Also Published As
Publication number | Publication date |
---|---|
WO2001010542A1 (en) | 2001-02-15 |
CA2346750A1 (en) | 2001-02-15 |
AU5552099A (en) | 2001-03-05 |
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Effective date: 20190809 |